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Powering the Process℠ is a podcast for engineers, plant managers, and operations leaders focused on industrial systems, plant optimization, and manufacturing efficiency. Hosted by ProcessBarron experts, each episode delivers practical insights on material handling, air and gas systems, industrial equipment, and reducing downtime.
Jen Little:
This podcast is brought to you by ProcessBarron. Handle everything better. Welcome to Powering the Process, the podcast focused on the real work behind industrial manufacturing. Each week, your host, Jen Little, digs into the systems, equipment, and strategies that keep plants running efficiently. From everyday operational challenges to emerging engineering solutions, we’re here to share practical insights that help you keep your process moving.
Let’s get started.
Welcome to Powering the Process, the show where we uncover the industries that shape our everyday lives. Today, we’re diving into a sector you may not think about very often—but you use its products every day: pulp and paper.
From the packaging that protects your deliveries to the paper products in your home and office, this industry is everywhere. Behind the scenes, keeping these massive mills running efficiently is no small task. That’s where ProcessBarron comes in, with expertise in air handling, material handling, and environmental systems to help pulp and paper operations stay productive, sustainable, and reliable—even in the toughest conditions.
We have Joe Waite with us today. He’s been with the company for nearly 22 years and is the Vice President of Air Handling and Material Handling Products. Joe, thank you so much for being here.
Joe Waite:
Glad to be here.
Jen:
A lot of people think about the digital age and assume paper use has declined because everything is electronic now. But they don’t always think about the products they use every day that come from pulp and paper mills—paper you write on, magazines, tissue products, packaging. The digital age hasn’t changed the need for many of these items.
When you think about and touch these products in your home or office, consider where they come from and the processes used to make them—and how ProcessBarron fits into that picture.
Joe:
Nicely said.
Jen:
Pulp and paper has historically been one of the biggest industries we serve. Is that still true?
Joe:
Yes. When the company started in 1981, our biggest customers were in pulp and paper, cement, steel, lime, and a little bit of power. Even today, most of the work we do is in pulp and paper. These mills are unique—they’re basically cities unto themselves. There are many smaller “mills within the mill” working together to produce products like paper towels and cups.
There was a time when printing paper dominated, but that’s shifted. Many plants have revamped operations to produce containerboard. Think about how many shipping boxes you see on front porches every day—that demand has replaced much of the printing paper market. And products like diapers, tissue, and other hygiene products will always be needed.
Jen:
I remember visiting a paper mill in South Carolina where one paper machine runs 24/7 printing shipping labels for a major delivery company. That really puts into perspective how much we rely on this industry.
We often don’t think about where these everyday items come from.
Joe:
Exactly.
Jen:
What’s the most common challenge paper mills face today?
Joe:
From our perspective, we work primarily in power and recovery, wood yards, and caustic areas. Mills process wood—a commodity product—and that process causes heavy erosion and wear on equipment. We repair and replace conveyors, air systems, and equipment that constantly deteriorates due to the harsh operating environment.
A lot of our work centers on power boilers, recovery boilers, lime kilns, and wood yards. These areas require significant ongoing maintenance.
Jen:
Can you share an example of a major efficiency improvement?
Joe:
Sure. At a paper mill in Georgia, a large wood-fired power boiler had an ID fan requiring 3,000–4,000 horsepower to operate. Every six months, the boiler had to be taken offline due to severe erosion damage—costing millions in downtime.
After surveying the system, we discovered excessive particulate was bypassing the mechanical dust collector and destroying the fan. We upgraded the dust collector, and the project paid for itself within one year. The fan has now operated for five to six years without downtime.
Jen:
We talk about particulate often. Can you explain how tiny particles can damage such massive equipment?
Joe:
Power boilers burn wood fuel that often contains dirt and silica from harvesting and handling. During combustion, fine particulate travels through the furnace and into the gas stream. Mechanical dust collectors remove larger particles—typically 10–15 microns and above—to protect the fan. Without proper filtration, millions of particles sandblast the fan, causing severe erosion.
Jen:
So it’s essentially sandblasting metal continuously.
Joe:
Exactly.
Jen:
What’s the most common problem we’re asked to solve?
Joe:
High-erosion areas around power boilers, ash handling, wood yards, and lime kilns. Many mills still use older pneumatic conveying systems, which can cause erosion and even secondary fires. We often upgrade these systems and provide maintenance solutions.
Jen:
Preventive maintenance plays a big role in equipment longevity. Have you seen maintenance cycles change over the years?
Joe:
Yes. Downtime costs millions, so plants often push equipment longer between shutdowns. But strong preventive maintenance programs directly reduce downtime. Mills that invest in maintenance consistently perform better.
Jen:
Let’s talk environmental regulations. How does ProcessBarron help mills stay compliant?
Joe:
If you see a white plume from a stack, it’s usually steam. Darker emissions indicate potential issues. Mills use continuous emissions monitoring systems (CEMS), and non-compliance can result in fines or shutdowns. We help maintain and upgrade pollution control equipment—precipitators, baghouses, scrubbers—to reduce emissions and improve efficiency.
Jen:
Facilities are often near communities, so staying compliant is critical.
Joe:
Absolutely. We help improve combustion efficiency, flue gas evacuation, and downstream equipment to reduce emissions before they reach the stack.
Jen:
For young engineers or sales professionals interested in this industry, what advice would you give?
Joe:
Come in with an open mind and be a sponge. Learn from experienced professionals, research the plants you visit, and understand your products deeply. Working in multiple departments—engineering, design, estimating—builds a strong foundation. The key is to go to bed a little smarter than when you woke up.
Jen:
Great advice. As we wrap up our pulp and paper episode, thank you again to Joe Waite for joining us today.
Joe:
Thank you.