Failure Mode & Effects Analysis for Pulp and Paper Equipment

extreme moisture and process chemical exposure accelerate corrosion and bearing degradation while continuous operation limits access windows. In this environment, equipment failures cause paper machine downtime at $15K–$80K per hour, broke generation, and off-spec product. Our systematic FMEA and criticality analysis program specifically targets paper machine rolls and bearings, refiners, stock pumps, recovery boiler fans, chip conveyors, and dryer section drives — the assets where early detection has the greatest impact on machine efficiency (uptime × speed × quality) and broke percentage. We also account for continuous 24/7 production and heavy water usage, adapting our measurement approach to maintain data quality despite these operating conditions.

Yes. Pulp & Paper facilities must comply with EPA effluent guidelines, OSHA combustible dust standards, and boiler/pressure vessel codes. Our systematic FMEA and criticality analysis program generates the condition documentation needed for epa discharge compliance tied to recovery boiler and effluent system reliability; combustible dust program for wood handling areas. Beyond compliance, the condition data drives measurable improvements in machine efficiency (uptime × speed × quality) and broke percentage by converting unplanned failures into scheduled repairs. Most pulp & paper clients see meaningful reductions in paper machine downtime at $15k–$80k per hour within the first 12 months of program implementation.