Proven Results

Cutting Bleaching Chemical Costs by $2.5M While Improving Brightness Consistency

June 11, 2026

As pulp flow, kappa, and process conditions shift, bleach plants become increasingly difficult to control, driving variability in brightness and rising chemical costs.

The Solution

Spartan Controls implemented the SpartanPRO™ Kraft Bleaching APC to automatically coordinate reagent addition across bleaching stages based on pulp flow, kappa levels, and final brightness targets.

The solution also strengthened foundational pH and level controls, key drivers of bleaching efficiency. Operators transitioned from manual dosage management to setting target brightness and operating constraints, allowing the APC to continuously optimize chemical usage.

The Value

The APC solution reduced variability and optimized one of the mill’s largest operating costs:
$2.5M per year reduction in bleaching chemical consumption (chlorine dioxide, caustic, peroxide)
20% reduction in final product brightness variability
75% reduction in low‑brightness pulp
Significant reduction in operator workload

The bleach plant APC has remained in continuous operation since deployment, delivering sustained savings and performance improvements.

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Cutting Bleaching Chemical Costs by $2.5M While Improving Brightness Consistency

The Challenge

The Solution

The Value

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