Scientific Paper Making Practice With No Or Minimum Capital Investment

PAPYRUS INC. was founded in 1982 by Mr. Ahmed A. Ibrahim, scientist and professional engineer (P.Eng.). Mr. Ibrahim's career spans a distinguished time frame of more than 50 years of industrial experience in the pulp andpaper industry which includes:

  • Specialty Technical Services
  • Paper Quality Optimization
  • Engineering Design
  • Product Development
  • Process Optimization and Control
  • Training

It’s mission to the pulp and paper industry is to apply scientific principles for solving serious papermaking problems and translating our knowledge to the practical level at the operating floor.


How long does it take to analyze problems pertaining to a specific section of the headbox/approach piping, Press or dryer ?

There are two approaches to conduct the analysis; either In-House or at the Mill- Site.
The In-House approach is done at PAPYRUS main headquarters once we receive the information based on the checklist provided (assuming the questions answered are complete and accurate).

The duration of the analysis including writing the report is one and half weeks.

For Mill – Site analysis in USA and Canada, the duration of the analysis is two weeks. One week at mill site and one week at PAPYRUS main office for time spent doing the calculations and writing the technical report.

For the one week at mill site, we leave Columbus, Ohio Monday at the earliest flight available and depart the mill site on Friday at a convenient time to arrive in Columbus, Ohio no later than 8.00 pm.

In some cases, due to poor flight connections and /or lengthy travel time, we leave Columbus, Ohio on Sunday instead of Monday.

For overseas visits due to the lengthy travel time, the duration of the analysis is two and half weeks.

How do you conduct the analysis?

Depending on the kind of design criteria of a section to be analyzed, we will email you our easy to follow checklist which is self-explanatory. This is to be filled out by the papermill process engineer.

Our checklist is classified into three categories:

  • Operating Criteria.
  • Design Criteria.
  • Other Measurements.

These measurements are to be taken while the machine is shut down.

Once the checklist is completed, and the proper measurements are sent back to us, we will conduct the calculations utilizing our PAPYRUS Exclusive Computer Programs.

These complex calculations are translated back to you so that you may implement the necessary solutions easily, quickly and accurately at the operating floor.

Our analysis in some cases can unravel any hidden Problem areas that have gone unnoticed.

How can I obtain the checklist?

Our checklists are custom-made to cover any design criteria generally available in the paper industry. For example if the analysis is done in the headbox/approach piping systems, we have to know in advance what kind it is (open, air padded, or hydraulic). We also need to know if the machine is Flat Fourdrinier, Gap Former, Multi-Formers and who is the manufacturer.

In order to gain access to our checklist, we require an up-front down payment of 20% once you have committed to our services. This amount will be deducted from the overall cost for our analysis.

We will then immediately email you our checklist.

Following identifying the problem areas, how do you rate the success of a remedial solution?

We operate on a "Show and Tell" basis. This means how far the system is departing from PAPYRUS ideal conditions, the mill will see results.

If the system is running at an ideal condition, there will be no results. But we can assure you that in over three decades that we have been performing our services, these ideal conditions have never been met especially in the headbox/approach piping systems.

Why did you select the headbox/approach piping systems as always operating with less then ideal conditions?

This is a statement which PAPYRUS has been preaching since its inception.

Take for example, the calculation to define the jet speed in relationship to the wire speed which is currently performed at the main frame computers and DCS systems. While it is well understood that this is a powerful variable which has a major influence in sheet formation development and its strength properties, the equations in the current industry practice are considered mediocre and are taken off the shelf and not adapted to the specific design and application.

This state of inaccuracy has left the machine operator in a state of alarming confusion. As a result, a paper machine making the same grade may run with many different process settings according to the interpretations and preferences of the current Operator instead of a scientifically-based analysis. The result is like a car out of tune. The car runs but ultimately it gives poor gas mileage.

Do you have anything to support evidence of the above statement?

Of course we do. In our list of problem areas, you will find a strong connection between what the mill is struggling with on a daily basis to solve the typical problems associated with the headbox operation. This is an area where PAPYRUS always makes substantial contribution. The sheet formation sample in the problem areas category illustrates the dramatic improvement when the headbox process settings are applied based on PAPYRUS calculation.

What do you mean by scientifically – based analysis?

Our analysis is based on complex scientific equations, high level research materials done by universities and research institutions. Our role is to combine this knowledge along with our experience and apply them successfully.

The bottom line is: If you believe in science then you have to believe in this methodology.


  • Professional Engineer
  • Former TAPPI Papermaking Committee
  • C.P.P.A. (Canadian Pulp and Paper Association)
  • Former C.P.P.A Training and Education Committee
  • I.A.S.P.M. (International Association of Scientific Papermakers)
  • Formerly member of Columbus, Ohio, Chamber of Commerce


Ahmed Ibrahim

Papyrus Inc.

Westerville, OH 43082

Dear Ahmed,

Congratulations for your nomination and subsequent Bronze Key Award. The Bronze Key Award is designed to recognize outstanding performance and achievement in "finding a better way." Your work on the # 4 headbox operating procedure is an example of an increase in business as a result of new approaches, ideas, and concepts. These aspects capture the essence of the Key To Finding A Better Way Program.

With this in mind, I would like to express my sincere appreciation for your contribution. Efforts such as these help to ensure the continued success of James River.

In Addition, I have enclosed your Bronze Key lapel pin in recognition of your hard work.


Dave Hulit
Vice President, Resident Manager


  1. A Method for operably adjusting a leading forming board strip. (U.S.A. and Canada).
  2. Forming board structure having an adjustable leading forming board strip (U.S.A. and Canada).
  3. Removing objectionable streaks from the headbox slice lip due to material accumulation (U.S.A. and Canada).
  4. Floc and streak prevention in papermaking (Pending).


  1. Calculating in an elaborate format the flow velocities in the approach piping, the manifold header, the manifold header distributor tubes and the headbox proper and compare the velocities of the operating flow rates and PAPYRUS design flows with the ideal velocities.
  2. Calculating the acceleration ratio between the flow velocity in the manifold distributor tubes and the manifold header and compare the results with ideal condition.
  3. Calculating the manifold header distribution performance and compare the result with industry standards.


  1. Optimizing foil blades angle at the Fourdrinier Table as a function of product basis weight, furnish constituents, wire speed, instantaneous mat consistency during drainage, foil blade spacings and foil blade design.
  2. Optimizing Dandy roll operation.


  1. Calculating cleaners material balance and their efficiency.


  1. Determining sheet dryness after each press nip without grab samples or moisture sensors.
  2. Conducting water material balance around any press nip.
  3. Detecting sheet rewetting problem which might be a cause of sheet breaks, holes in the sheet and picking at press rolls.
  4. Characterizing stock quality.
  5. Examining different options for machine rebuild for the highest dryness after each nip.
  6. Conducting "What If Scenarios" on the effect of a multitude of process variables on sheet dewatering at press nips.


  1. Calculating dwell time at the felt suction boxes and compare the results with ideal conditions.
  2. Calculating the exit felt moisture ratio after the felts suction boxes.
  3. Detecting if sheet crushing might occur at a press nip.
  4. Calculating the air flow requirement at the felts suction boxes and compare the results with the vacuum pumps capacities.
  5. Calculating the felts operating permeabilities to anticipate the duration of a given felt file.
  6. Calculating the ideal showering system flows and comparing the results with the operating conditions.
  7. Calculating the drainage rate at the suction boxes.
  8. Conducting "What If Scenarios" on the effect of a multitude of process variables on the performance of a Felt Conditioning System.

Purchase Agreement

The prices represent 20% of the total cost for our full in-house services. All downloadable purchases are non-refundable. You have access to one download per purchase for a period of 24 hours.

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