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Introducing Blueprint Paper Mill – Our Reference Implementation

· 4 min read
Georgios Rousopoulos
Solution Architect

We're excited to introduce Blueprint Paper Mill, a fictitious mid-sized pulp and paper production facility that serves as the reference implementation for Cyzag Blueprint throughout our documentation, tutorials, and demonstrations.

Why Create a Reference Facility?​

When explaining how operator rounds and asset condition monitoring work, abstract examples like "Pump P-101" and "Motor M-204" can feel disconnected from reality. We wanted to provide a consistent, realistic industrial context that helps you understand how Cyzag Blueprint applies to your own operations—regardless of your industry.

Blueprint Paper Mill gives us that context.

About Blueprint Paper Mill​

Blueprint Paper Mill is a sustainability-focused facility that produces recycled paper products. The mill operates 24/7 across three shifts and is undergoing a digital transformation to improve operational reliability, safety, and equipment performance.

Facility Layout​

The mill consists of four main production units:

  • Unit A – Pulping: Converting raw wood chips into pulp through continuous cooking
  • Unit B – Screening & Cleaning: Removing contaminants and preparing clean pulp
  • Unit C – Paper Machine Line: Forming, pressing, and drying paper from pulp
  • Unit D – Utilities: Providing steam, compressed air, cooling water, and electrical power

Key Equipment​

We've populated the mill with realistic equipment that faces common operational challenges:

Digester D-101 (Unit A – Pulping)

  • Continuous digester for cooking softwood chips
  • Normal operating pressure: 5.2–5.8 bar
  • Monitored daily during morning shift rounds

Feed Pump P-404 (Unit A – Pulping)

  • High-pressure centrifugal pump feeding the digester
  • Bearing vibration alert threshold: >6.0 mm/s
  • Example of equipment that requires vibration monitoring

Dryer Can DC-12 (Unit C – Paper Machine Line)

  • Steam-heated drying cylinder in the first dryer section
  • Surface temperature range: 85–95 °C
  • Inspected every 2 hours during production

Steam Boiler B-01 (Unit D – Utilities)

  • High-pressure steam generation for process steam
  • Steam pressure range: 40–45 bar
  • Critical utility requiring daily monitoring

And several more assets across all four units.

Operational Challenges​

Before implementing Cyzag Blueprint, Blueprint Paper Mill faced typical industrial challenges:

Paper-Based Rounds: Operators used clipboards and paper checklists, leading to lost data, illegible handwriting, and delayed visibility for supervisors.

Inconsistent Data Capture: Different operators recorded readings differently, with no standardized units or normal operating ranges.

Connectivity Issues: Basement areas, equipment rooms, and outdoor locations often had poor or no cellular coverage, making real-time data entry impossible.

Delayed Issue Detection: By the time supervisors reviewed paper rounds (often hours later), abnormal conditions had worsened or equipment had failed.

Shift Handover Gaps: Information was lost during shift changes, with verbal handovers missing details and written notes being incomplete.

How Blueprint Paper Mill Uses Cyzag Blueprint​

Throughout our documentation, you'll see realistic scenarios demonstrating how Blueprint Paper Mill:

  • Completes daily operator rounds in Units A and D, capturing 30+ readings across 6 assets
  • Handles abnormal conditions like high digester pressure (6.1 bar vs. 5.8 bar limit) and elevated pump vibration (7.2 mm/s)
  • Operates offline in basement areas with zero connectivity, syncing data automatically when returning to ground level
  • Manages shift handovers with digital records, ensuring incoming shifts have complete context
  • Tracks equipment trends over days and weeks to identify degradation before failure

Realistic Data Throughout​

Every example in our documentation uses consistent, realistic data:

  • Specific assets (Digester D-101, not just "a digester")
  • Normal operating ranges (5.2–5.8 bar, not just "normal pressure")
  • Real readings and observations (168 °C, 7.2 mm/s, "audible knocking sound")
  • Named operators (John Smith, Sarah Johnson, Mike Chen)
  • Structured round templates ("Morning Shift - Pulping & Utilities")

This consistency helps you visualize how Cyzag Blueprint would work in your facility, with your equipment, and your operations—regardless of whether you're in pulp & paper, chemical processing, food & beverage, or any other process industry.

Explore Blueprint Paper Mill​

Ready to see Blueprint Paper Mill in action? Start with:

A Note on Fictitious Data​

Blueprint Paper Mill is entirely fictitious. All assets, readings, operator names, and scenarios are created for demonstration purposes. However, they're based on real paper mill operations and common industrial challenges.

Use Blueprint Paper Mill as a reference to understand how Cyzag Blueprint applies to your own facility. The principles—structured data capture, offline operation, trend analysis, and shift handovers—translate directly to any industrial environment.

Have questions about how Blueprint Paper Mill examples apply to your industry? Reach out at hello@cyzag.co or explore our documentation to see more realistic scenarios in action.