Integrated Analytics for Pulp Mill Optimization

Business Need

Pulp manufacturing operations face challenges in effectively monitoring and optimizing production due to fragmented data across shop-floor systems, MES, SAP, and manual logs. This lack of integration limits real-time visibility and makes it difficult to align operational performance with business targets.

Traditional approaches rely on delayed and disconnected reporting, preventing operators from reacting quickly to process deviations and making it difficult for leadership to track production efficiency, cost per ton, and resource utilization against financial goals. Additionally, the absence of unified analytics restricts the ability to identify inefficiencies in chemical usage, energy consumption, and production yield, impacting overall cost optimization and sustainability efforts.

To address these challenges, the objective was to:

▸Establish real-time visibility into shop-floor operations
▸Align operational data with strategic business KPIs and targets
▸Enable data-driven optimization of cost, yield, and resource utilization

Solution

The Techylla team developed an Integrated Analytics Ecosystem for Pulp Mill Optimization and implemented the following key initiatives:

▸Built a dual-layer data architecture (Hot & Cold paths) combining real-time (Grafana + InfluxDB) and strategic analytics (Power BI)
▸Enabled real-time shop-floor monitoring by integrating sensor and PLC data into a time-series database for instant visibility
▸Developed interactive Grafana dashboards to track production, yield, inventory levels, and cost per ton
▸Implemented Power BI analytics layer to monitor KPIs, forecasts vs AOP targets, and variance analysis
▸Integrated data from MES, SAP, and manual logs to create a unified performance view
▸Enabled data-driven decision-making for optimizing cost, yield, and resource utilization