1. Paper Quality - New Trends and Specifications
  2. Newsprint Manufacture- Published through AccuRay Corp.
  3. Tissue Manufacture- Published through AccuRay Corp.
  4. Encyclopedia of Papermaking (written but has never been published)

  1. Improving Quality and Process Efficiency at Minimal Cost Using Scientific Principles, Presented at 1999 TAPPI Engineering/Process & Product Quality Conference, Anaheim, California (Coauthor: Yaser A. Ibrahim).
  2. A Practical Look At How To Improve Sheet Formation In the Headbox/Approach Piping Systems, Presented at 1997 TAPPI Papermakers/Engineering Superconference, Nashville, Tennessee (Coauthor: Yaser A. Ibrahim).
  3. Ideal Settings of Headbox Process Variables/From the Open Type to Gap Formers, Presented at NEW ENGLAND TAPPI CONNECTICUT VALLEY PIMA ANNUAL TECHNICAL SEMINAR, March 09, 1994.
  4. New Slice Cleaner "Powerflosser" Eliminates Streaks Caused by Deposits, Presented at TAPPI 1992 Supplier Showcase, March 3, 1992,Georgia World Gongress Center Atlanta, Georgia
  5. The Interference of Stock Contaminants in the Headbox/Approach Piping System, Presented at 1989 TAPPI CONTAMINANT PROBLEMS AND STRATEGIES IN WASTEPAPER RECYCLING SEMINAR, Madison, Wisconsin.
  6. Headbox/Approach Piping-Design and Operation Criteria, Presented at TAPPI VIRGINIA-CAROLINA SECTION winter Meeting, November 18-19, 1988.
  7. How Headbox Design and Operating Criteria Affect Machine Performance and Sheet Structure, PULP & PAPER CANADA 88: 12 (1987) and PIMA/January 1988.
  8. The Interaction of the Headbox Design and Operating Criteria on Machine Performance and the Sheet Structure, Presented at the Institute of Paper Chemistry, Appleton, Wisconsin, October 30, 1987 and at the International Tissue Conference, Columbus, Mississippi, November 11, 1987.
  9. Computerized Control of the Jet/Wire Speed Ratio, Presented at the Annual Meeting of LAKE STATES TAPPI, October 29, 1987.
  10. The Dilemma of Designing and Operating the Forming Board for the Sheet Forming Process, PIMA, November, 1986.
  11. Designing and Operating the Forming Board for Better Sheet Forming, PULP & PAPER CANADA 87:10 (1986).
  12. Compressive Resistance, Strength: What They Mean to the Paper Mill, PULP AND PAPER, April, 1986.
  13. Approach Piping and Headbox Operation as Related to Product Uniformities, "Presented at the Practical Papermaking Seminar, Co-sponsered by PAPYRUS INC. and SOUTHERN PULP AND PAPER" Atlanta, Georgia, February 18 to 21, 1986.
  14. Optimizing the headbox Process Operating Variables for Coated Base Stock Requirements, Presented at OHIO TAPPI, November 21,1985, Chillicothe, Ohio
  15. Retention: A Review of the Fundamental Aspects, PIMA, September, 1985.
  16. Computer Performs Onsite Cleaner System Mass Flow Balance Analysis, PULP AND PAPER, June 1985.
  17. Optimizing the Headbox with a Portable Computer: Part 2, PIMA, June 1985 and SOUTHERN PULP AND PAPER, July 1985.
  18. Computer-Based Optimal Adjustment of Headbox/Slice Flow Dynamics; Presented at Automation 85 Conference, the Georgia World Congress Center, Atlanta, Georgia, May 21, 1985,
  19. Reducing product Variabilities Through Sound Papermaking Concepts; presented at TAPPI Control Conference, April 03, 1985.
  20. Computer Analysis of Headbox/Slice Flow Dynamics, PIMA MAGAZINE, February 1985, SOUTHERN PULP AND PAPER, April 1985 and PULP AND PAPER CANADA, June 1985.
  21. Opportunities to Improve Quality and Increase Productivity with No or Minimum Capital Investment; Presented at the Fall Meeting, 1984 of PIMA Pacific Coast Division.
  22. Approach Piping: Understanding Basis Weight Variations; PIMA,October, 1984.
  23. Practical Aspects of the compressive Forces of Paper, SOUTHERN PULP & PAPER, October 1984.
  24. Getting an Angle on Sheet Formation; PIMA, May 1984.
  25. Some Economic and Quality Significance of Paper Basis Weight and Moisture Cross Machine Uniformity; Presented at Miami University Conference "PAPER QUALITY - KEY TO SUCCESS"; May 1984, Oxford, Ohio.
  26. Paper Quality - New Trends and Specifications; Presented at Miami University Conference "PAPER QUALITY - KEY TO SUCCESS"; May 1984, Oxford, Ohio (Published in Book Form).
  27. Increasing Productivity Via Operating Changes; Presented at the 28th Annual Pulp and Paper Conference; Sponsored by PIMA /WMU / TAPPI; Kalamazoo Valley Section - Michigan, March 22, 1984
  28. How to Obtain Maximum Benefits in Cross Machine Control withNo Capital Investment; PAPER TRADE JOURNAL; March 15, 1984.
  29. Formation and Basis Weight Uniformity Through Headbox Control;TAPPI, Vol. 64, No 11, November 1981.
  30. Headbox Variables and Control; PIMA, September 1981.
  31. Understanding Headbox Operation - An Opportunity for the Papermaker and Computer Control; Presented at 1981 Miami University Symposium, Oxford, Ohio, U.S.A.
  32. Understanding Rewetting Phenomenon in the pressing Operation;PULP AND PAPER CANADA, Vol. 82, No. 2, February 1981.
  33. Computer Control for Multiply Forming; Presented at 1981 C.P.P.A Technical Section.
  34. Sizing With Low Alum Rosin Ratio, INDIAN PULP AND PAPER MAGAZINE (17): 391 (1962).
  35. Presented more than 650 technical reports for problem solving solutions to more than 550 companies around the world.

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.

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