Minimization of Trim Loss During Reel Cutting at Paper Mill by Using Different Optimization Algorithms

Trim loss is one of the major issues in the paper industry and occurs during the cutting of master and stocked reels to fulfill the ordered demands of reels with smaller widths. The trims (paper waste) produced during this reel cutting need to be reprocessed and follow a heavy chemical process that causes a significant amount of effluent discharge to the water surface which is hazardous as per environmental concern. Hence, this work aims to reduce the trim loss problem by using the flexible width master reels and stocked over-product and usable leftover reels. The minimization is performed with a linear single objective optimization problem with consideration of different operational and technological constraints. Three different solution approaches named simplex method, particle swarm optimization, and genetic algorithm have been proposed to optimize this trim loss problem employed for solving a real-world industrial problem. Again, the obtained solutions are analyzed in contrast with some reported results to prove the validity of the model and check the efficiency of the algorithms. The optimized result produces minimization in trim production due to which a lesser reproduction required that depletes the chemical use and tends to economic saving and reduction in environmental pollution.