Case Study: RZA Technologies Completes Large-Scale Paper Machine As-Built Data Capture in 72 Hours
- RZA Technologies used five Leica RTC360 laser scanners to scan a quarter-mile-long, three-story paper machine for Sappi North America within a tight timeline.
- The project involved capturing 5,100 high-res full-color scans and creating a comprehensive as-built database of the paper machine, as well as an additional 1,500 scans of surrounding areas of the facility.
- The detail and accuracy of the resulting point cloud data enabled Sappi to ensure that prefabricated parts for the rebuild were a perfect fit once they arrived on site. The rebuild project was completed quickly and seamlessly with no rework required.
- Sappi is now using the 3D as-built database to develop owner’s engineering solutions, plan maintenance and future projects, realizing value beyond the initial project.
Industrial Plant Overview
Sappi is a leading global provider of everyday materials made from wood fiber-based renewable resources. The company produces both raw materials and end-use products such as packaging and specialty papers. Known for its dedication to sustainability and industry innovation, Sappi sets the standard for renewable resource businesses around the world.
Sappi North America, a subsidiary of Sappi Limited, is known for its collaborative customer relationships, world-class talent and assets, and outstanding products and services. The company made the decision to rebuild paper machine number 2 (PM2) to produce paperboard. Components for the rebuild would be engineered and prefabricated globally.
Digitization Challenge
The paper mill stretches over 1/4 mile with a basement, operating level, and mezzanine, and houses three paper machines. Each paper machine is located on the operating level and also comprises multiple levels. To meet demand, the paper mill operates continuously. However, Sappi North America had scheduled a 72-hour shutdown of PM2 for maintenance. As-built documentation on PM2 would need to be collected during this timeframe and made available remotely in a digital format to ensure that all prefabricated machine components would fit precisely with no rework.
High-Value Solution
RZA Technologies, a laser scanning and modeling service provider based in Greensboro, NC, won a competitive bid to capture the as-built documentation on the mill. To capture the as-built data quickly and accurately, RZA employed a 10-person team working in shifts with five Leica RTC360 3D laser scanners operating continuously over the 72-hour shutdown.
Within 20 days after scanning, RZA produced a comprehensive as-built database of the paper machine in Leica TruView, a software for intuitively sharing point cloud data, as well as IMP and E57 scan files. This gave Sappi a full digital representation of the entire paper machine. With the use of Leica scanners, RZA was able to offer a scan accuracy of 2 millimeters.