How DS Smith, Belgium Improved Corrugator Control & Saved Energy with Baelz Controls
10-20%
Fuel Saved
↑↑↑
Reaction Time
0
Steam Traps
DS Smith’s corrugator line in Ghent (Belgium) benchmarked poorly on energy consumption versus other plants & also faced runnability issues on certain board compositions. An audit pointed to the steam distribution set-up as the root cause.
The implementation of Baelz 356 Control Valves in place of traditional control valves as per end Customer has resulted in approximately 10-20% steam savings, Faster Reaction Time & Temperature Adjustment, Reduction of Waster & better Drying Quality.
The Challenge
The line combined equipment from multiple OEMs & struggled to maintain stable temperatures across sections. That led to higher boiler fuel use, difficulties when switching between light-weight/coated papers, & increased warp/waste—all symptoms of a steam & condensate regime that lacked responsive control.
DS Smith implemented Baelz control 2-way valves (Baelz 356), the Baelz 6596 industrial controller, & Baelz WinBas control-supervision software on the corrugator. The Profiler control units deliver fast reaction time & temperature adjustment, enabling quick changeovers between extreme board mixes & tighter process control—with short installation time & minimal operational interference.
The Solution
The Results
Flexible, plant-wide process control on the corrugator line.
Better temperature control tuned to board composition; improved control of warp & waste; ability to run complex/light-weight/coated papers.
Energy saving on boiler fuel consumption: 10–20% can be expected, along with boiler pressure reduction.
Reliable, maintenance-free components, modular design, turnkey supply, & online supervision capability for the Corrugator Steam system; standard protocols ease connection to planning systems.
Why It Matters
By replacing legacy control approaches with precise valve control & closed-loop supervision, DS Smith gained faster thermal response & uniform heat transfer across heating systems—exactly what corrugators need for quality & throughput. The result is a repeatable way of saving energy while running a broader portfolio of papers with confidence.
Takeaway
If your line shows high fuel per ton, temperature swings, or board-change headaches, upgrading the steam equipment that governs steam & condensate flow is one of the fastest levers on OPEX & quality. DS Smith’s experience shows that modern controls can unlock both efficiency & runnability—with short installation time & proven ROI.
principle during technology selection.
Location: Belgium
Baelz Technology: Baelz 356 control valves, Baelz 6596 controller, Baelz WinBas supervision.
Industry: Corrugated board production
Company: DS Smith (Ghent)