Friday, May 8, 2026
Valmet has strengthened its position in advanced fiberboard production technology with the continued rollout of the Valmet Gap Optimizer. The automated control solution has been developed to improve defibrator performance, increase process efficiency and support energy savings across fiberboard manufacturing operations.
The system has already been installed in more than ten mills across Europe and North America. Installations have included fiberboard mills, paper mills, an insulation board production facility and a soil fertilisation production unit.
The growing adoption of the technology highlights increasing industry demand for smarter and more efficient production systems.
In fiberboard manufacturing, woodchips are mechanically processed into fibres through the use of a defibrator. The quality of these fibres plays a major role in determining the strength, smoothness and overall quality of the finished board product.
As a result, accurate control of the defibrator is considered essential within modern production facilities.
Valmet Gap Optimizer has been designed as an automated system that manages defibrator disc gaps with high speed and precision. Accurate gap control allows mills to achieve more consistent fibre quality while supporting stable production performance.
According to Valmet, mills using the system have experienced improved product quality and increased production capacity.
The technology also helps extend the lifetime of refiner segments and bearings. Maintenance requirements can therefore be reduced.
Energy efficiency remains a major focus for fiberboard manufacturers worldwide. Defibrators consume significant amounts of energy during operation.
Valmet Gap Optimizer offers the possibility of lowering the defibrator’s specific energy consumption. This can lead to meaningful reductions in operating costs.
Several mills have already reported measurable improvements after installation. Reduced production costs have been achieved through lower energy usage and fewer maintenance interventions.
Unexpected downtime has also been minimised. Increased defibrator availability has therefore been experienced by customers.
According to Liam Ahern, Global Product Manager for Mechanical Pulping and Fiberboard at Valmet, the response from customers has been highly positive.
He stated that the company introduced the system approximately two years ago and has since seen increasing interest from fiberboard producers globally.
Ahern explained that the strong results achieved by customers have contributed to the solution’s growing popularity within the industry.
Valmet Gap Optimizer is supplied as a complete OEM solution. The package includes the hydraulic block, mounting plate and cover, hydraulic hoses and fittings, cable assembly and detailed user manuals.
The system has been designed for easier installation and operational reliability.
Several advanced functions are also included:
These features support safer operation and simplified maintenance procedures.
A remote connection capability is also provided. Real-time process support can therefore be delivered through the Valmet Performance Center.
Standard spare parts are included to support ongoing maintenance activities.
One of the key advantages of the Valmet Gap Optimizer is its modular design. The Gap Control Module unit can be integrated into existing control systems without major production disruption.
The system can also be retrofitted into older control panels. This provides mills with a practical option for modernising ageing defibrator control systems.
Control system configurations include a compact local cabinet equipped with a touchscreen interface installed near the refiner.
Ease of replacement has also been considered during system design. Existing outdated systems can therefore be upgraded more efficiently.
Valmet reports that the system has delivered strong financial returns for customers. Faster payback periods and high return on investment have been achieved at several installations.
Improved process stability has also supported more consistent production quality.
The company continues to position the solution as more than simply a piece of equipment. Valmet emphasises long-term customer collaboration and lifecycle support across production operations.
According to Liam Ahern, the company remains focused on helping customers achieve the best possible performance from their production lines throughout the entire operational lifecycle.
The wider fiberboard and wood processing industries continue to invest in automation, process optimisation and energy-efficient technologies. Production facilities are increasingly seeking solutions that improve operational control while reducing overall manufacturing costs.
Valmet Gap Optimizer reflects this broader industry transition towards smarter production systems.
By combining precise defibrator control, reduced energy consumption and improved product quality, the technology supports manufacturers looking to improve competitiveness in a demanding global market.
As demand for higher efficiency and sustainable production grows, automated process control systems are expected to play an even greater role in the future of fiberboard manufacturing.
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Tags: defibrator control system, fiberboard industry, fiberboard production, Valmet, Valmet Gap Optimizer, woodworking and manufacturing, woodworking industry
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