A major lightweight paper producer boosts quality and flexibility with De Iuliis C&A’s advanced headbox technology.
In a strategic move to enhance product quality and production efficiency, a prominent paper manufacturer in North Africa has successfully completed the installation and commissioning of the Flexi Flow headbox.
Specialized in the production of lightweight papers ranging from 32 to 70 grams per square meter, the mill faced the challenge of maintaining consistent sheet quality while managing frequent grade changes and a wide operating range. The implementation of Flexi Flow has proven to be a decisive turning point, delivering improved control, stability, and performance.
Flex Flow is the latest evolution in DJM’s headboxes, designed specifically for producers seeking extreme versatility without compromising on precision or process control. This installation marks a key reference for the company in the North African region, confirming its ability to meet the unique demands of international markets with customized engineering solutions.
What makes Flexi Flow stand out is its ability to efficiently handle wide basis weight ranges while maintaining excellent cross-directional profiles, formation uniformity, and edge consistency. The headbox allows easy integration into both new machines and existing lines as part of revamping projects.
One of the core advantages of the Flexi Flow system lies in its dedicated on-board PLC. Unlike conventional passive headboxes, this unit operates control over all process variables—including:
- Flow rate and pressure management
- Slice opening
- Internal rolls speed
The PLC allows precise fine-tuning of these parameters in real-time and supports fast transitions between operating conditions—an essential feature for mills producing a wide array of paper grades.
Furthermore, the system is fully integrated with the customer’s DCS (Distributed Control System), enabling remote supervision, diagnostics, and process optimization from the plant’s central control room or even from remote technical centers. This feature enhances both responsiveness and reliability, especially in facilities aiming for Industry 4.0-level process management.
Proven Results on Lightweight Paper Grades
The installation included full commissioning services, training sessions for plant operators and technicians, and a comprehensive performance test phase. From the very first days of operation, the customer reported:
- Improved sheet profile uniformity
- Greater jet stability and fiber distribution
- Reduced waste and trim loss during changeovers
- Faster adaptation to different basis weights
As a result, the mill is now able to operate with greater consistency, higher overall efficiency, and better quality assurance, ultimately strengthening its position in regional and export markets.
Why FLEXI FLOW?
The name says it all. Flexi Flow is the perfect balance between operational flexibility and precise flow control, engineered to handle a wide range of basis weights while maintaining superior cross-directional profiles. It’s built for production environments where frequent grade changes, high efficiency, and process adaptability are essential.
FLEXI FLOW advantages:
- Fast and reliable adjustments, even under variable operating conditions
- Compact and modular design for easy maintenance
- Optimized jet distribution ensuring profile stability and sheet consistency
- Suitable for both new machines and rebuilds, bringing innovation even to existing lines
Flexi Flow is the result of years of customer-focused design, in order to achieve the customers demands. As with every De Iuliis C&A project, precision engineering and customization are at the core of our work.
With Flexi Flow, we aim to provide more than just a component—we deliver a true competitive advantage to paper and board producers operating in global markets.
