Better housekeeping for paper machines.

There has been definitely some improvement in the microbiological control of paper machines since late 1970's (when IM started his work for it). As a very short review, two issues have been highlighted because their positive effect on the hygiene and driveability of machines: application of oxidative agents as biocides and biofilm research. Rapid killing of microbes in strategic sites of processes with compounds like peracetic acid, chlorine dioxide and ozone have given very promising results when the overall load of microbes inside machines shall be dropped. Better understanding of the features of biofilms - essential changes of bacterial metabolism when they attach on surfaces from flowing water and start to release more and more living cells and spores back to the process  - also help to focus attention on them.

Poor interests to invest in better analytical control of microbial activities, in opposite, is surprising, however. Why do the mills not benefit the obvious progress of such control methods like ON LINE luminometry, rapid PMEU incubations etc.? Is it a question of lacking knowledge, lacking interest or the status of old-fashioned analytical methods, not suited to rapid QC/HACCP of paper and board processes? Is microbiology regarded as the unknown living creature on the surface of "Solaris" in the novel of S.Lem (the most excellent film by Andrei Tarkovsky recommended!)

IM has been relatively frustrated for this situation but tries to think optimistic: some small-scale simulations are already running today, and more and more people with technical background have been interested to know about tools to estimate and forecast microbiological events inside their machines. Happy to hear that they understand that with costs of only a couple machine rolls they could have improved microbiological control which can lead to remarkable spare of money when preventing unexpected machine stops or claims of poor product quality by customers.  

The new beginning of P&P industry in Africa?

IM follows frequently the bright blog written by Jim Thompson (http://www.nipimpressions.com/).

His last post discusses about the dark future of Finnish P&P. In opposite, he gives an optimistic forecast: the promising region for the manufacture of pulp and paper could be Africa! After reading his points of view - short but comprehensive - I must agree. Everything could begin once more on this huge continent if only social and political confusions can be won there.

Sitting and thinking - what else? What about a new way to construct paper and board machines? To take into account not only technical issues, but also all chances to have machines which were easier to control and keep clean/safe than these old ones, we are still driving?

There are a lot of relatively simple solutions which can improve the hygiene of raw materials as well as keep wet end area, white water circulation, pulp towers and broke systems cleaner. These ideas were discussed during the professional career of IM and very many wise men (and women) agreed. It has been the question of reconstruction costs which has prevented the realisation of the progress in paper machine development towards cleaner production and processes.

But: what about starting everything once more? To build up machines with clever ON LINE process control and alarm systems? Machines which were easier to clean during production? Machines which even have self-cleaning constructions?

Ozzy Osbourne sings: " I'm a Dreamer" - but what we are lacking just now are the dreams, aren't we?  

Where are the novel ideas?

Where are the novel ideas?

This is actually not my question tonigth. Just to start.. 

There are a lot of them! But are they received?

I will understand it very clearly. My wife is working for young people as a "grand  lady" in Jyväskylä "School Nursery", Central Finland, today (in English: what to do with over 700 youngsters?).

She also has got novel ideas.

But what is the "Black Hole" where all our activities - yours and ours - will be drown?

Novel ideas will promote paper industry to be more economical. 

Where are yours and mine?

On the Threshold of a Dream: Application of rapid mb methods in paper industry

It seems that certain interest in novel, both rapid OFF LINE and automatized ON LINE  methods for the control of paper machine microbiology has arisen at least in Finland. The benefits of fast activities against spoilage of raw materials, biofilm and slime problems in processes as well as immediate corrections of biocide problems is understood in many mills.

What has prevent the progress of microbiological control in the mills until now?

First of all: lack of knowledge (ref. the picture above, drawn by my son in his early years). Bacteria, moulds and yeasts are something frightening for the majority of paper mill personnel. This opinion is false: learning basic facts of microbial ecology, environmental ecology and biotechnology helps to understand the activities of microbes. This kind of knowledge is served every year on trainig courses, intended in to present microbiology to laymen of paper industry.

Another claim: " We shall wash our machines several times per year - we then clean both chemical and microbiological problems away". False again: microbiological problems very often hide inside the process and lead frequently to acute problems which force to stop the production and clean the machine - and in worsest cases, lead to severe faults of products. 

We do not think that visiting our doctor a couple of times per year covers us against infectious diseases all the year, do we? Absolutely not - why then we thrust that infrequent boil-outs could prevent our machines against their "diseases"?

"Where we can catch information of novel control methods? We are not microbiologists?"

A good supply of paper industry microbiology is available nowadays, not only in scientific journals (J.Appl.Environ.Microbiology and J.IndMicrobiol.Biotech.  may be the best sources of P&P microbiology today),  but also on courses, blogs (like this and www.biotechtouch.blogspot.com) and elsewhere in Internet.

Focusing certain activity to be familiar with P&P microbiology isn't too hard task for those persons who are responsible for the technical and quality issues of paper and board production. It is definitely worth to do and to reserve time for it.

Back to the title of this post: great british rock group "The Moody Blues" published and album with the same title years ago. Progressive rock with jazz features (near to the heart of IM) then grew to a respective form of music all over the world on 1960's-1970's. I hope that we are now similarly stepping into a new era of control methods for paper industry microbiology today.

How to present novel mb methods to paper industry?

Novel methods of microbiology have been a most interesting topic for IM for decades. Beginning from 1970's, the value of ATPAssay and RR Test have been obvious, and both were adopted to paper industry on 1980's-1990's.

The increase of economical problems in paper industry are also very obvious today. IM has red articles and blogs about the reasons for this situation in this small, northern country with extensive forests: is it the problem of wood supply (= high Russian taxes for export and decreased activity by Finns themselves to sell their wood to the mills), the overcapacity of fine paper (other P&P products have no problems?) or both?

Back to the subject of my blog (after a short political survey, in which IM really has no expertice):

Paper companies are calling for tools to improve driveability of the machines, to catch better process control systems andto have lower number of product disqualification. Microbiological problems are still huge among all types of paper and board production, and QC methods like ON LINE ATP, BIOTOUCH Concept etc. could help significantly to lower the number of annual hours and days when the machines are stopped because microbiological problems.

But: how can we microbiologist publish these ideas? It seems that people, working for P&P industry, are more and more busy. How can we create a channel to deliver information about new methods to them?

Web-based marketing seems to be one challenging alternative to traditional paper articles, fairs etc. KK-Net (as an example) is doing a pioneer work to activate contacts between P&P industry and research institutes. This can be the way in future what we should follow. 

One must remember: Microbes are active day and night, no matter we may not are!

Petroleum vs. paper industry microbiology - an exciting analogy.

IM has noticed an most interesting review by Lewis R. Brown in SIM News September/October 2007 (SIM = Society of Industrial Microbiology). The author presents us various topics of petroleum microbiology which can significantly help this industrial branch to locate new deposits, to increase production rates, to eliminate corrosion caused by H2S and to have new tools for the bioremediation of oil spills.

What especially has waken IM up was the obvious analogy between petroleum and paper industry microbiology: similar reasons have caused a lag period of the benefication of microbiology. Here are some lines from the beginning of this review article:

" It must be remembered that it was not until the 1940's that a U.S. oil company hired a full-time microbiologist, thus most of the research on petroleum microbiology was conducted in university laboratories. Consequently, potential uses of microbes in the industry were based on laboratory experiments, not field demonstrations, and were viewed with certain amount of scepticism. Also, it must be remembered that microbiology as a science was less than a hundred years old at that time and therefore people in other disciplines, e.g., geology and petroleum engineering, had little or no understanding of microbiology...".

Sounds very familiar to a microbiologist, working for  paper industry. A lot should to be done to publish the multitude of  issues of microbiology which could help paper industry to minimize microbiological problems, to secure product quality and to have benefits served by biotechnological products like enzymes in the manufacture of pulps, papers and boards. 

An ideal biocide - is there any?

What should an ideal biocide be like?

* effective against a variety of microbial species
* effective in different process environments (temperature, pH, RO potential, solid concentrations etc.)
* both fast and conserving type of action
* not harmful for employers of paper machine
* not harmful for paper machine
* not harmful for products of the paper machine
* not harmful for environment
* (something else?)

As far as IM knows, no such ideal biocide has been developed yet. "Tailored" biocide products shall therefore be combined to fight against raw material contamination, microbial activity in large process water and pulp systems, fiofilm producers...

The rapid development of fast-acting oxidative agents (chlorine-and bromine-based compounds, PAA, ClO2 and even O3) is very promising, but they have relatively limited success as storing agents. Their broad-spectrum influence on even bacterial spores should be taken into account
when planning biocide programs, which also should contain compounds to prevent biodegradation during storage periods and formation of biofilms on wet surfaces of the machine.

In some cases, activity of alternative biocides against certain hazardous bacteria are also worth to evaluate.