Expert Interview: Joe Waite, VP of Air Handling & Material Handling Products
Host: Jen Little, Director of Commercial Operations
The pulp and paper industry remains one of the most essential manufacturing sectors supporting everyday life. Even in a digital world, people rely on paper products constantly; from packaging and shipping materials to tissue, hygiene products, and specialty papers. Behind these products is a complex industrial process that depends on reliable equipment, efficient air-handling systems, and durable material-handling systems.
In this episode of Powering the Process, host Jen Little sits down with Joe Waite, Vice President of Air Handling and Material Handling Products at ProcessBarron, to explore how pulp and paper mills operate, the industry’s biggest challenges, and how engineered industrial solutions help facilities maximize uptime and efficiency.
Why Pulp & Paper Still Matters
Despite the rise of digital communication, pulp and paper remain indispensable. The industry has evolved from traditional printing grades to high‑demand products such as:
- Containerboard and corrugated packaging
- Shipping labels for major e‑commerce companies
- Tissue, hygiene, and incontinence products
- Paper towels and household paper goods
E‑commerce growth and consumer packaging needs continue to drive strong demand, making pulp and paper one of the most resilient manufacturing sectors.
How ProcessBarron Supports Pulp & Paper Mills
ProcessBarron has served the pulp and paper industry for decades, providing engineered solutions across the most critical areas of mill operations. Pulp and paper facilities function like small cities, with multiple interconnected systems that must operate reliably around the clock.
Air Handling Systems
- Induced draft (ID) fans
- Combustion air systems
- Flue gas evacuation
- Mechanical dust collectors
- Airflow optimization
Material Handling Systems
- Wood yard conveyors
- Chutes and reclaimers
- Ash handling systems
- Drag chain conveyors
- Lime kiln material handling
Environmental & Recovery Systems
- Precipitators
- Baghouse support
- Scrubber integration
- Emissions control equipment
ProcessBarron’s strength lies in delivering integrated solutions across multiple systems, helping mills improve reliability, reduce downtime, and extend equipment life.
Major Efficiency Upgrade: Eliminating a Costly Fan Erosion Problem
One of the most impactful improvements ProcessBarron delivered involved a large power boiler at a pulp and paper mill experiencing severe fan erosion. Excess particulate was bypassing the dust collection system and causing significant wear on a high‑horsepower ID fan. The mill was forced into multiple unplanned outages each year, resulting in substantial production losses.
After conducting a detailed system survey, ProcessBarron upgraded the mechanical dust collector to reduce particulate carryover. The improvement dramatically extended fan life, eliminated repeated outages, and paid for itself within the first year. The mill has since operated for multiple years without fan‑related downtime. This project demonstrates how targeted engineering upgrades can deliver major operational and financial benefits.
Understanding Particulate and Erosion
Pulp and paper mills process wood that naturally contains sand, silica, dirt, and other abrasive materials. During combustion, millions of particles travel through the boiler and into downstream equipment. Larger particles cause significant erosion, especially in high‑velocity airflow systems.
Mechanical dust collectors play a critical role in removing these larger particles before they reach fans, ductwork, and pollution control equipment. When dust collectors become overloaded or clogged, particulate bypass increases, accelerating wear and reducing equipment life.Effective particulate management is essential for maintaining reliability and preventing costly failures.
Common Operational Challenges in Pulp & Paper Manufacturing
Pulp and paper mills face several recurring challenges due to the abrasive nature of the process and the complexity of mill operations.
1. Erosion in Power & Recovery Boilers
High particulate loads cause wear on fans, ductwork, and flue gas systems.
2. Ash Handling Issues
Older pneumatic systems often lead to plugging, erosion, and even secondary fires.
3. Wood Yard Equipment Wear
Reclaimers, conveyors, and chutes experience constant abrasion from wood chips and bark.
4. Lime Kiln and Caustic Area Maintenance
Chemical exposure and material handling demands create ongoing maintenance needs.
ProcessBarron provides engineered solutions and maintenance support across all these areas to help mills maintain safe, reliable operations.
Preventive Maintenance: The Foundation of Mill Reliability
Preventive maintenance is one of the most important factors in reducing downtime and extending equipment life. Mills that invest in regular inspections and proactive repairs consistently experience fewer outages and lower long‑term costs.
ProcessBarron supports mills with preventive maintenance programs across:
- Power and recovery boilers
- Wood yards
- Lime kilns
- Material handling systems
- Air handling equipment
A strong PM program ensures equipment performs reliably throughout each operating cycle.
Environmental Compliance and Emissions Control
Environmental regulations require pulp and paper mills to maintain strict emissions standards. Reliable air-handling and pollution-control equipment are essential for staying in compliance and avoiding fines or shutdowns.
ProcessBarron helps mills improve environmental performance by:
- Optimizing combustion airflow
- Enhancing flue gas evacuation
- Maintaining dust collectors, precipitators, and baghouses
- Supporting opacity and emissions control systems
These improvements help mills operate cleanly, safely, and efficiently.
Advice for the Next Generation of Industrial Professionals
For engineers and sales professionals entering the industry, success comes from curiosity, continuous learning, and hands‑on experience. Understanding mill operations, studying equipment, and learning from seasoned experts builds the foundation for a strong career in industrial manufacturing.
ProcessBarron encourages new professionals to explore multiple departments, engineering, estimating, design, and field work, to gain a comprehensive understanding of how industrial systems work together.
Why Reliable Equipment Keeps Pulp & Paper Mills Running
Pulp and paper production depends on durable equipment, efficient airflow systems, and reliable material handling. Engineered solutions help mills:
- Improve uptime
- Reduce maintenance costs
- Extend equipment life
- Enhance environmental compliance
- Support continuous, 24/7 operation
As the industry continues evolving, partnering with experienced industrial solution providers ensures mills remain productive, sustainable, and competitive.
Contact a ProcessBarron sales representative near you.