“We begin with a comprehensive process audit, capturing thermal balances, kW profiles, chemical dosing rates, and bottleneck analysis across pulp, paper machine, and recovery boiler sections,” says Mr. Vinit Garg, MD, Vizen Solutions

“We begin with a comprehensive process audit, capturing thermal balances, kW profiles, chemical dosing rates, and bottleneck analysis across pulp, paper machine, and recovery boiler sections,” says Mr. Vinit Garg, MD, Vizen Solutions

Key Points of The Interview:
 “By employing model-based predictive control within our Honeywell-based DCS platforms, we adjust steam-to-dryer load ratios in real time, yielding a 3–5% improvement in drying efficiency”
“Our AI-IoT modules optimize step-grate feed rates and oxygen trim, driving 30% lower GHG emissions and 4–5% higher boiler efficiency”
“Automation drives paper mills toward proactive efficiency, achieving 10–15% steam reduction, up to 12% chemical savings, and boosting profitability”

The Pulp and Paper Times
In an exclusive Interview with The Pulp and Paper Times, Mr. Vinit Garg, Managing Director of Vizen Solutions, shares insights on the growing role of automation and energy efficiency in modern paper manufacturing. Founded over a decade ago, Vizen Solutions has emerged as a trusted provider of end-to-end industrial automation, instrumentation, and energy-efficiency solutions for power, pulp, and paper plants. Here is the full interview:

Q: Please give us a brief introduction to Vizen Solutions

Vizen Solutions offers end-to-end industrial automation, instrumentation, and energy-efficiency solutions for power , pulp and paper plants. Established over a decade ago and backed by CPRI approval and ISO 9001:2015 certification. In pulp and paper, we deliver DCS/PCC/MCC/HT/LT panels, VFDs, field instruments (pressure, flow, temperature, level), and complete cable/lighting/bus-duct systems. To date, we have executed 500+  projects across India and overseas. Our objective is to ensure reliable operations and measurable energy savings for every paper mill partner.

Q: How has automation become important for paper mills in terms of profitability and productivity?

Automation fundamentally shifts mills from reactive to proactive control. By implementing DCS-driven loop optimization—with redundant controllers, fast history logging, and customized reporting—clients consistently achieve 10–15% steam reduction and up to 12% chemical savings . For example, deploying Coriolis flow meters for furnish dosing and magnetic flow meters for white-water recovery stabilizes fiber consistency within ±0.1%, reducing off-spec production by up to ₹2 lakhs per month. VFD-equipped motors, rated up to 710 kW, maintain precise speeds under variable load, cutting motor draw by 20–25%. SCADA dashboards provide real-time kW, kVAR, PF, and THD data, enabling immediate corrective action. Together, these gains translate to higher throughput, lower energy bills, and improved mill profitability.

Q: How has AI-IoT benefited the pulp and paper industry?

Integrating AI-IoT begins with installing smart field instruments—pressure, temperature, level, and analyzers—that stream data to on-site edge servers. Our edge units run basic anomaly detection, flagging deviations such as abnormal vibration in blower motors or sudden steam-pressure fluctuations. In one recent installation, the system detected an impending failure in a pulp chopper gearbox two weeks in advance, allowing scheduled maintenance that prevented eight hours of unplanned downtime. By employing model-based predictive control within our Honeywell-based DCS platforms, we adjust steam-to-dryer load ratios in real time, yielding a 3–5% improvement in drying efficiency. On RDF boilers, our AI-IoT modules optimize step-grate feed rates and oxygen trim, driving 30% lower GHG emissions and 4–5% higher boiler efficiency. Those savings directly support both regulatory compliance and cost reduction.

Q: How has Vizen scaled up its expertise in handling automation projects that require high accuracy and customer satisfaction?

Our multi-tiered quality framework includes:
1. Standardized Engineering Templates: We maintain pre-built PLC/DCS function libraries for pulp washing, stock prep, and wet-end control.
2. Factory Acceptance Testing (FAT): All panels—HT, LT, PCC, MCC, VFD, and DCS—undergo FAT with worst-case I/O simulation and loop-response verification to ±0.5% accuracy.
3.On-Site Verification: During site acceptance, we use redundant controllers and dual-mode simulation to confirm each control loop matches the FAT performance before cutover.
4.Post-Commission Audits: Six months after commissioning, we review energy savings versus targets (e.g., 10–12% steam savings) and production KPIs to ensure client expectations are met.

This rigorous approach has reduced commissioning timelines by 25% and delivered first-pass acceptance at clients like Silvertoan Paper, KK Duplex, Maruti Paper, Genus Paper, Meenu Paper and Nikita Paper, ensuring consistent, high-quality outcomes.

Q: How does Vizen study and analyze the entire lifecycle and value chain of a client's business to provide effective solutions?

We begin with a comprehensive process audit, capturing thermal balances, kW profiles, chemical dosing rates, and bottleneck analysis across pulp, paper machine, and recovery boiler sections. During site visits, our engineers document equipment ratings—such as VFD size up to 710 kW, HT switchgear parameters, and field-device calibration history. We then use Control Builder and Enhanced Bulk Builder tools to simulate control strategies under 20+ load-change scenarios, verifying loop-response times in a virtual environment. Next, we produce an Automation Strategy Report that details capital and operating expense trade-offs—e.g., the payback period for switching from an analog feedwater loop to a digital DCS loop, estimated at 9–12 months based on steam savings of 10%. This lifecycle approach ensures that every recommendation aligns with the client's production targets and financial goals.

Q: What is Vizen Solution unique selling point (USP) in automation?

Our USP lies in single-point accountability and technical comprehensiveness:
1. Proprietary Function Libraries: Pre-built modules for pulp handling, liquor concentration loops, and paper machine headbox control reduce engineering time by 40%.
2.CPRI & ISO 9001:2015 Certification: Ensures consistent quality across EPC contracts—we have delivered 500+ projects nationwide within budget and schedule parameters .
3. Redundant Architectures: All DCS installations feature redundant controllers, redundant power supplies, and redundant communications, guaranteeing >99.5% uptime.
4.End-to-End Support: From design to commissioning—our 100+ skilled engineers, backed by pan-India offices, offer transparent pricing and anytime assistance, cutting MTTR by 35%.

Q: What products does Vizen Solutions offer to paper mills?

Our pulp and paper portfolio includes:
1. HT & LT Panels: Designed  of complex HT System & LT system with OLTC with CPRI-approved, low-defect, in-house-tested assemblies.
2. PCC & MCC Panels: Equipped with electrolytic-grade copper busbars, IP42/IP52/IP54 enclosures, and DCS-compatible intelligent starters. Up to 2000 kW VFD modules for refiners, pumps, and calendars.
3. DCS / PLC System: Powered by Honeywell
4. Field Instruments: Pressure transmitters, differential pressure/level transmitters, magnetic/mass flowmeters, on-off/control valves, and thermocouples/RTDs, all pre-calibrated to ±0.25% accuracy.
5. VFD Panels: Rating from 0.4 kW to 2000 kW—CPRI-approved and zero-defect tested.
6. Cabling & Bus Ducts: Field cabling with trays, AC lighting, and bus ducts customized as per plant layout.

This full suite is backed by 100% in-house testing and delivered with detailed FAT documentation.

Q: Tell us about your after-sales services, which are a crucial part of automation solutions.

Thank you for emphasizing support. Our after-sales framework includes:
1. 24×7 Remote & On-Site Assistance: We maintain critical spares stock at our Faridabad and Chennai warehouses, ensuring 24-hour spare delivery to major centers.
2. Preventive Maintenance Programs: Scheduled monthly thermographic imaging, quarterly vibration analysis, and annual loop-tuning audits, each logged in our client portal with KPI comparisons (e.g., steam savings, downtime hours).
3. Operator & Technician Training: We conduct hands-on workshops—covering HMI navigation, PLC ladder logic diagnostics, and DCS historian reporting. Training includes mock-failure drills to hone troubleshooting under real conditions.
4. Performance Audits: Biannual assessments compare baseline KPIs (e.g., kWh/ton, chemical consumption) against current performance. Clients typically register 25–30% lower breakdown costs within the first year.

Below is a snapshot of the key projects that stand as milestones in our journey of transforming operations for our client 

•  Star Paper Mill- UAE 
•  Silvertoan Paper - Muzaffarnagar India  
•  Nikita Paper Limited - Muzaffarnagar India 
•  Maruti Paper Shamli 
•  PSB Paper 
•  Genus Paper Mill 
•  Bindal Papers 
•  M/s Thermofab (Aroma-Craft) 
•  M/s Silverton Muzaffarnagar 
•  Mohit Paper Pvt Ltd 
•  M/s Thermofab (Dev-Prayag) 
•  M/s Omshree Paper 
•  M/s Bindlas Duplex 
•  M/s Anand Duplex Ltd 
•  Janki Newsprint 
•  Pakka Limited 
•  Devpriya Products
•  Kibos Packaging & Paper- Kenya 
•  Kuantam Paper - India 
•  Khanna Paper - India 
•  KR Pulp & Papers - India 
•  Naini Papers Ltd - India 
•  Century Pulp And Paper - India 
•  Sheryans Industries Ltd - India 
•  KK Duplex - India 
•  Shree Hari Om Paper - Hyderabad India 
•  Mohit Papers(P.) Ltd                                   • Shree Vishnu Vishal Paper Mill Pvt Limited - Moradabad India 
• Ashoka Paper - Ghaziabad India 
•  Garg Duplex & Paper Mills Pvt Ltd - Muzaffarnagar India  
•  Meenu Paper Pvt Limited - Muzaffarnagar India 
•  Varda Exports LLP  
•  Pinax Paper - India    
• Devpriya  Industries

Web Title: “We begin with a comprehensive process audit, capturing thermal balances, kW profiles, chemical dosing rates, and bottleneck analysis across pulp, paper machine, and recovery boiler sections,” says Mr. Vinit Garg, MD, Vizen Solutions