Valmet has introduced Valmet IQ Virtual Sensor, a new software solution designed to provide paper and board producers with real-time visibility into key end-product strength properties that have traditionally been measured only in the laboratory.
The technology delivers continuous quality predictions, enabling mills to maintain consistent standards, reduce fiber and starch consumption, lower energy demand, and improve overall production efficiency.
The system generates minute-by-minute predictions of key parameters such as tensile and tear strength, burst, and SCT (Short-span Compression Test), using data already available in the mill. Through continuous learning based on laboratory feedback, the solution enables proactive process optimization, reduces waste, and helps prevent quality deviations.
“To avoid rejected batches, operators often maintain large safety margins, increasing the use of costly raw materials and raising production costs,” said Timo Aro, Business Manager, Quality Management System, Automation Solutions at Valmet. “With Valmet IQ Virtual Sensor, there is no longer any need to wait for laboratory results to understand how process adjustments will affect final product quality.”
The solution also includes a built-in “what if” simulator that allows operators to test process adjustments and view predicted impacts before applying changes to real production, reducing operational uncertainty and enabling more efficient resource management.
Valmet IQ Virtual Sensor operates without the need for additional sensors or production downtime. All calculations are performed locally, without cloud dependency, ensuring secure data handling and fast response times.
Integrated with Valmet DNA and Valmet DNAe systems, the software allows operators to view predicted strength properties alongside other quality data from line scanners, improving decision-making speed and production performance.
The new solution becomes part of the Valmet IQ Quality Management Systems family and can be used either as a standalone application or in combination with the Valmet IQ Quality Control System (QCS), providing an integrated overview of quality across the entire paper machine.
Looking ahead, the system can be further enhanced with automated closed-loop controls through Valmet Advanced Process Controls (APC), paving the way for even more advanced levels of process optimization, quality performance, and production profitability.