Uniform wood chips remain one of the most important factors influencing production efficiency in modern pulp manufacturing. Chip consistency directly affects pulp yield, cooking performance and raw material consumption. Although mills cannot eliminate every variation in incoming timber, equipment performance throughout its lifecycle can significantly improve production stability.
Valmet continues to support pulp producers with technologies and services designed to optimise chip production from the first installation through long-term maintenance and modernisation. The company’s lifecycle approach helps mills achieve greater operational efficiency while extending equipment life.
Wood chips are produced through several processing stages. These include raw material storage, log handling, debarking, chipping, screening and the removal of oversized particles and fines before the chips enter the pulping process.
Among these stages, the chipper remains the most influential machine. Its operating geometry determines the quality of the final product. Factors such as knife angles, infeed design, chipping speed and the number of knives all contribute to producing uniform chips.
Valmet has accumulated more than two centuries of combined expertise through the heritage of Carthage, Camura, Murray, Rauma and Demuth chippers. More than 2,200 heavy-duty chippers have been supplied globally. Its current portfolio includes disc, drum and compact chippers designed for different wood species and production requirements.
According to Timo Vastamaa, Senior Engineer for Chipping at Valmet, equipment condition is critical because every component inside a chipper experiences wear during operation. Proper maintenance therefore plays an essential role in maintaining consistent chip production.
The company has also introduced continuous product improvements. One example is the Valmet Chipper Thrust Bearing. It was developed to maintain minimal knife clearance throughout operation. Better knife positioning helps reduce oversized chips, fines and pin chips while improving chip consistency.
Raw material characteristics continue to change across global markets. Smaller log diameters, inconsistent timber availability and increasing fibre costs have created new operational challenges. These developments have increased the importance of adaptable processing equipment.
Valmet addresses these challenges through equipment upgrades that improve both productivity and chip quality. Existing machines can often be modernised without major structural modifications.
Several upgrade options are available. New disc designs incorporate additional knives. Bearing systems can be improved. Wear components may also be replaced with enhanced alternatives. Additional equipment, including chip post-processors, can further improve production performance.
The company’s patented Chipping Speed Control technology also supports operational consistency. The system regulates disc rotation speed to stabilise chip length despite seasonal changes in wood characteristics, including frozen or dry timber.
More than 300 chippers currently form part of Valmet’s global installed base. Service expertise is also provided for equipment manufactured by other suppliers. This broad experience enables maintenance solutions to be tailored for various machine types regardless of age or original manufacturer.
Routine servicing remains essential throughout the equipment lifecycle. Knife replacement, grinding, wear plate renewal and alignment inspections should be completed regularly. Stable operating conditions are thereby maintained, while equipment lifespan is extended.
Wear components receive particular attention because deterioration directly affects chip quality. Excessive wear inside the infeed spout alters feed geometry, reducing uniformity. Similarly, inconsistent knife clearance increases the generation of fines and pin chips.
Alongside equipment upgrades, Valmet offers a comprehensive service portfolio designed to improve mill performance. These services include inspections, wear part management, maintenance planning, operator training and performance monitoring.
Annual audits of wood handling systems are recommended. During these assessments, wear, bottlenecks, alignment issues and opportunities for improvement are identified. Corrective measures can then be implemented before production is affected.
Long-term collaboration forms another important part of Valmet’s strategy. Tailored service agreements help mills transition from reactive repairs to proactive lifecycle management. Spare parts, maintenance planning and process optimisation are integrated within these programmes.
One specialised offering is the Chip Quality Agreement, known as ChipQ. This performance-based agreement focuses specifically on improving chip quality while reducing wood losses. Financial risk is shared between Valmet and its customers, encouraging measurable operational improvements.
Even relatively small reductions in wood consumption can deliver substantial financial benefits. According to Valmet, savings of only half a percent in raw material usage may generate significant cost reductions for pulp producers.
Digital technologies are becoming increasingly important in equipment lifecycle management. Online monitoring systems provide continuous information that supports predictive maintenance and faster operational decisions.
Modern chip quality measurement tools allow mills to identify process variations almost immediately. Although monitoring systems do not solve issues automatically, they provide valuable operational insights that support timely intervention.
Automation solutions supplied by Valmet include online chip moisture measurement, condition monitoring and chipper diagnostics. Mechanical behaviour, vibration levels and motor loads are continuously monitored. Maintenance teams can therefore be alerted before serious failures occur.
At newer greenfield pulp facilities, advanced chip analysers, automatic sampling systems and particle size analysers are increasingly installed as standard equipment. Production data collected by these systems is used to optimise both chipping and cooking operations while supporting autonomous mill development.
Through ongoing technology development, equipment upgrades and lifecycle services, Valmet continues to help pulp manufacturers improve operational reliability, enhance wood utilisation and strengthen long-term production efficiency.
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