See Revere Control Systems’ top tips for success in the paper industry, from managing tight timelines to meeting rigorous safety and environmental standards.
Revere’s clients in the paper industry are everywhere—from Amazon packages on your doorstep to the bucket holding your KFC chicken. But while the products are commonplace, the process behind producing these items is anything but that, with strict schedules, high standards, and the need for reliable partners to make it all happen. For Revere Control Systems, helping paper mills achieve these standards is part of their core expertise.
Revere’s work covers all aspects of paper mill operations, supporting mill managers with crucial automation and control solutions. Revere’s automation systems manage everything from woodyard operations to chemical controls, sheet brake systems, and recovery boilers. They also implement and maintain emissions controls to keep the mill compliant with environmental standards. By integrating these controls and ensuring the reliability of each process, Revere enables the mill’s core operations to perform efficiently and stay on target.
With years of hands-on experience, Revere has become a trusted name in paper applications and this article offers Revere’s unique perspective on how you can prepare yourself to succeed as a partner in the paper industry.
1. Know Your Client
When you’re working in the paper sector, success comes down to three things: on-time delivery, staying on budget, and meeting performance goals. But of these, meeting the deadline is by far the most important. Every hour of downtime represents a direct financial loss in this industry, with mills increasingly expected to produce more with less. Projects must be precisely executed to avoid unplanned outages; “They give you the timeline, not the other way around,” says one Revere engineer. These plants set strict outage periods and partners have to meet, or even exceed them. As another Revere engineer puts it, “If you mess up on the budget, they’ll eventually forgive you. If the finished product isn’t exactly as expected, they’ll also eventually let that go. But if you lead a plant to unplanned outage time? You’ll never hear from them again.” Getting to know a client’s needs goes beyond just timelines. It also means understanding the nuances of both the industry and each individual company you work with. For Revere, this involves spending plenty of face-to-face time at each clients’ facility, learning the ins and outs of their operations and their staff early on in the project development process. Revere’s team also includes former industry insiders, which brings an even deeper level of knowledge to each project. This on-the-ground experience that Revere brings to the table allows them to offer insights and suggestions for each project, while also taking into account each individual mill’s operating standards.
2. Do Your Homework
A paper project’s success often depends on setting realistic expectations from the very start, so Revere begins each project with meticulous scoping and a clear project justification, ensuring alignment between mill objectives and automation solutions. In the paper industry, funding typically follows a front-end loading (FEL) process, where each stage is assessed to estimate costs, identify risks, and determine expected returns. For instance, projects that reduce chemical input costs by improving efficiency are often prioritized because they lower the dollar-per-ton cost of production. For each project, someone at the mill has already determined that it will deliver a specific return on investment, often in the form of reduced energy costs or lower material use per ton of paper produced. Revere’s role is to provide insights into these justifications to help clients secure funding and design solutions that align with these goals. The Revere Project Engagement Model demonstrates the extensive planning and detail required at each stage of a project. From FEL 1 (Discovery) to FEL 3 (Design) and finally Execution, Revere ensures every phase is fully scoped, risks are mitigated, and deliverables are clearly defined.
This structured approach allows Revere to handle the complexity of paper mill automation projects efficiently. The chart visualizes how deliberate and systematic planning is embedded into every step of their process, ensuring that no detail is overlooked.
Preparation also means laying as much groundwork as possible to avoid unplanned downtime during the critical outage phase. Tasks like network design, equipment testing, and safety reviews are often completed long before the plant shutdown begins. Revere’s team dedicates significant time to pre-outage work and participates in go/no-go (IPOP) meetings to identify risks and refine timelines.
“When the outage begins, the clock starts ticking,” a Revere expert explains. “Any misstep during this phase can have ripple effects on the entire project.” The “Revere Project Engagement Model” reinforces that success in the paper industry doesn’t happen by chance—it’s the result of thorough preparation, technical expertise, and a systematic approach that leaves nothing to guesswork.
3. Take Responsibility
In the paper industry, there’s no room for excuses. Revere’s role in these projects often positions them as the “closer,” meaning that automation work and instrument controls are typically the final step before the mill can start up again. Any delays earlier in the process—such as issues with mechanical installations or equipment delivery—can directly impact Revere’s timeline, adding pressure to meet the original deadline despite setbacks beyond their control.
As the Revere team says, “Our leg of the project is always the last thing left to do before a plant can start back up.” This position demands radical accountability, requiring Revere to be adaptable and ready to take responsibility for managing any delays or unexpected issues that come up. Their commitment to full accountability—ensuring that projects finish on time regardless of the circumstances—has earned them the trust of their clients. In this field, success means stepping up, owning the entire process, and delivering results, no matter what.
4. Be Honest
In an industry with tight margins and exacting time frames, overpromising can quickly end a working relationship. “People who overpromise and can’t deliver don’t last in this industry,” a Revere group leader says. Transparency is essential in setting realistic expectations and building trust. When potential delays or limitations come up, Revere’s team addresses them openly, knowing it’s better to be upfront than to fall short later. By keeping communication open and clear, Revere reassures clients that they can depend on honest feedback and realistic plans, helping to avoid costly surprises and building mutual candid communication.
5. Do It All
For paper mills, working with multiple vendors can create risk and potentially lead to costly delays, miscommunications, and project setbacks. Revere’s one-stop, turnkey approach addresses these issues by delivering a complete solution that includes engineering, equipment procurement, production, installation, commissioning, and startup. By covering every aspect of the project, Revere simplifies the process of budgeting and scheduling. Managing a paper mill’s operations requires expertise in process control, systems integration, and instrumentation. Revere’s technical depth spans the entire mill, from woodyard operations to finishing lines, as shown in their Mill-Wide Experience graphic below.
Revere leads projects in each of the major areas of the mill shown in the graphic above, and it is this expertise across the board that has enabled them to become such a vital extension of a paper mill’s own team.
6. Stay Aligned: Safety, Results, and Reliability
If you aim to serve an industry effectively, you must commit to staying abreast of what matters most to the players in the space. Safety, key performance metrics (KPIs), and reliability are at the core of this field. Safety is non-negotiable; mill managers are accountable for their teams’ wellbeing and rely on partners who share the same commitment. Revere’s A+ safety rating reflects its dedication to rigorous protocols that prioritize worker protection.
Also important are the KPIs that measure success, including metrics like quality tons per day and adherence to environmental standards. The paper industry is increasingly focused on reducing its environmental footprint through emissions control and water management, and Revere’s solutions support mills in achieving these sustainability goals without compromising productivity.
Finally, reliability has surfaced as an increasing priority for mills, as downtime directly impacts production and profitability. Many paper mills now have dedicated reliability teams focused on maintaining machine uptime through improvements in electrical systems, vibration control, and precision maintenance. Revere strives to stay in step with such industry priorities, doubling down on helping mills reduce disruptions, extend equipment life, and increase production output. As new initiatives continue to arise, like the shift from white paper to brown paper, Revere will continue to tailor its offering towards the direction that the industry is going, as should anyone looking to succeed in the space.
7. Expect to Work Hard
The paper industry demands commitment, resilience, and a willingness to go above and beyond. As one Revere engineer puts it, “No matter who you work for…they’re hard. They get on you. They mean business… but the biggest joy of the whole thing is whenever they come back and give you another PO.” Working in this industry often means putting in 15- or 16-hour days during the toughest times, but for Revere, the reward is in seeing clients return with the next project, because they can recognize quality work.
In this no-excuses industry, Revere Control Systems brings dedication, precision, transparency, and a results-driven approach to each project. By delivering turnkey solutions that meet the paper industry’s rigorous standards for safety, efficiency, and sustainability, Revere stands out as a partner mills can depend on.
Key Takeaways
- On-Time Delivery: Meeting tight project deadlines is non-negotiable in the paper industry—every hour of downtime represents direct financial loss.
- Preparation is Key: Revere’s structured planning, including meticulous pre-outage work, ensures projects are scoped properly and risks are minimized before execution.
- Mill-Wide Expertise:
- Brown Stock: Woodyards, digesters, and washing systems.
- Bleach Stock: Bleaching processes, washing, and ClO₂ generator controls.
- Recovery: Lime kilns, boilers, evaporators, and causticizing systems.
- Utilities: Power boilers, generators, steam systems, and air controls.
- Water Treatment: Cooling systems, clarifying, and aeration processes.
- Paper Machine: Stock preparation, forming, and drying stages.
- Finishing: Winder controls, wrapping, roll handling, and safety systems.
- Radical Accountability: As the “closer” on many projects, Revere takes full ownership of delivering results, even when earlier phases face delays.
- Safety is Everything: Revere prioritizes rigorous safety protocols to protect workers and ensure project success.
If you’re ready to elevate your mill’s performance with reliable, end-to-end automation solutions, Revere Control Systems is here to help. Reach out to learn how we can help your operations and keep production rolling smoothly—no excuses, no downtime.