Ensuring thermal uniformity, surface quality and operational continuity is the main challenge in web drying and finishing processes. In industrial production lines, even minimal temperature variations can compromise substrate flatness, coating adhesion and final color rendering.
SCR power controllers from CD Automation are designed to ensure precise management of electrical energy in critical applications: from web dryers to ink drying tunnels, up to the thermal regulation of IR lamps. Thanks to accurate power modulation, our systems instantly adapt to variations in line speed and material grammage, maintaining constant quality standards across the entire width of the substrate.
Choosing our solutions means choosing a partner with consolidated experience in continuous processes, capable of guiding the entire sector towards greater energy efficiency, a drastic reduction of waste and full monitoring of electrical parameters.
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Energy efficiency and integration with cogeneration systems
In the paper sector, characterized by high continuous energy consumption, integration with cogeneration systems (CHP – Combined Heat and Power) represents a strategic lever to improve overall plant efficiency. CD Automation SCR controllers enable dynamic and modulating management of electrical loads, facilitating adaptation to the variable energy profiles typical of cogeneration plants. This allows maximizing self-consumption of produced energy and reducing dependence on the grid.
In parallel, techniques such as Demand Side Management (DSM) and peak shaving allow reduction of power peaks and optimization of electrical load distribution in drying and coating processes. The integration between SCR control and advanced energy management logic enables stabilization of overall consumption and improvement of the operational efficiency of the entire plant.
Optimization of electrical consumption and reduction of losses
In addition to cogeneration, energy efficiency in paper production lines is based on a combination of strategies including load balancing, power factor correction and modulating control of electrical power. The use of SCR controllers allows precise energy management, avoiding over-delivery and reducing unnecessary consumption in drying, coating and industrial heating processes.
Integration with energy monitoring systems and energy KPIs also makes it possible to analyze consumption by zone or process, supporting continuous optimization and predictive maintenance activities. In this context, intelligent power regulation becomes a key element to reduce losses, improve internal grid stability and increase overall plant energy efficiency.
Role of power units in thermal and energy control in the paper industry
Power units are introduced in this context as key elements for optimizing energy consumption in paper and printing lines. Used for precise control of electric heating, particularly in drying systems, IR lamps and continuous coating processes, they enable stable and modulating energy regulation, essential to ensure thermal uniformity, surface quality and operational continuity even in high-speed production and in the presence of variable energy profiles.
Role of power units in thermal and energy control in the paper industry
Power units are introduced in this context as key elements for optimizing energy consumption in paper and printing lines. Used for precise control of electric heating, particularly in drying systems, IR lamps and continuous coating processes, they enable stable and modulating energy regulation, essential to ensure thermal uniformity, surface quality and operational continuity even in high-speed production and in the presence of variable energy profiles.
Drying and humidity control (Web dryers and tissue)
In paper, cardboard and tissueproduction processes, thermal load constantly varies depending on speed, grammage and humidity. SCR controllers allow fine modulation of power on resistors or IR lamps, ensuring cross-direction stability and reducing mechanical stresses on the sheet.
Ink drying and coating polymerization (IR & UV)
In printing lines (gravure, flexo) and continuous coating, IR and UV lamps require an immediate dynamic response. Phase angle firing of CD Automation SCRs avoids flicker, prevents thermal shocks to lamps and ensures uniform ink fixing even at high speeds.
Heated cylinders and finishing (rollers and calenders)
For finishing, smoothing and lamination processes, heated rollers must maintain constant temperature across the full width. Our systems quickly compensate for line speed variations, ensuring surface uniformity and dimensional stability of the final product.
Sustainable packaging and thermoforming
In the biopackaging and molded fiber sector, thermal control is critical for structural stability. The use of SCR units for power regulation enables precise and constant heat modulation, helping reduce waste and deformation during forming and drying phases of eco-compatible cellulose materials.
Gluing phase management and auxiliary systems
From corrugated cardboard production to converting systems, adhesive viscosity depends on the thermal stability of tanks and distributors. SCRs precisely manage these resistive loads, optimizing setting times and joint quality.
Integration for Industry 4.0 and smart diagnostics
All solutions are designed for full integration with PLC/SCADA via the main fieldbuses. Advanced diagnostics (Heater Break, short circuit) enable preventive maintenance, drastically reducing unplanned plant downtime.
REVO power units: SCR for every production need
To respond to the different complexities of drying and finishing systems, CD Automation has developed the REVO family, a modular SCR range designed to solve typical critical issues in the paper sector, such as management of high-power single-phase loads and synchronization of complex multizone systems.
All models integrate native communication protocols to interact with existing automation systems, turning thermal control into a strategic asset for consumption monitoring and predictive maintenance.
REVO C
REVO C is a high-performance SCR power controller designed for precise control of electric heating in industrial applications.Available from 30A up to over 2000A and configurable for single-phase, two-phase or three-phase control, it is suitable for a wide range of resistive loads and industrial drying systems.
Main features
- Wide range of firing modes (burst, single cycle, phase angle).
- Advanced diagnostics and precise voltage, current and power measurements.
- Integration with the main industrial fieldbuses.
- Stable control even in the presence of rapid load variations.
In the paper and printing sector it is used in web dryers, ink drying systems and coating lines where precise thermal control is required.
REVO PN
REVO PN is a power unit designed for applications with numerous heating zones, typical of paper drying and converting linesa. It can manage from 4 up to 24 power channels for independent control of different thermal zones.
Main features
- Multizone control of heating elements and IR lamps
- Synchronized switching management to reduce power peaks.
- Integration with PLC and industrial supervision systems.
- Diagnostics for heater break and zone monitoring.
It is particularly suitable for web dryers, IR tunnels and multizone drying systems in paper and printing production lines.
REVO PC
REVO PC is a multichannel power controller designed for applications with numerous heating zones and for efficient management of energy loads in industrial plants.
Main features
- Management of up to 24 outputs for controlling external solid state relays.
- Reduction of instantaneous power peaks.
- Synchronized switching with Dynamic Burst Firing logic.
- Integration with main industrial fieldbuses.
In the paper and coating sector it is used for multizone drying lines, adhesive reactors and high-power drying systems, where it is necessary to control numerous heating elements while keeping energy consumption stable.
REVO S
The REVO S from CD Automation are compact and reliable solid-state relays, designed for the control of single-phase, two-phase and three-phase electrical loads up to 800 A. Ideal for industrial thermal applications, they ensure fast and precise switching thanks to Burst Firing technology. They integrate advanced diagnostic functions, such as Heater Break alarm, and internal fuses that simplify wiring. With SSR or analog inputs, the REVO S offer versatility, operational safety and easy integration into existing systems.
CD Automation solutions comparison: find the most suitable model
REVO C
Single / two / three-phase SCR controller
30A-2100A
Modbus, Profinet, EtherCAT, Ethernet/IP
Web dryers, paper and cardboard drying systems, coating lines, ink drying
Advanced power control, high configurability and full integration with industrial automation systems
REVO PC
Multichannel controller for SSR
Up to 24 zones via REVO S
Profinet, Modbus TCP, EtherNet/IP
Drying lines with many heating elements, adhesive reactors, multizone heating
Intelligent management of power peaks and centralized control of multiple heating zones systems
CD Automation solutions comparison: find the most suitable model
Model: REVO C
Type: Single / two / three-phase SCR controller
Current range: 30A to 2100A
Supported protocols: Modbus, Profinet, EtherCAT, Ethernet/IP
Typical applications: Web dryers, paper and cardboard drying systems, coating lines, ink drying
Why choose it: Advanced power control, high configurability and full integration with industrial automation systems
Model: REVO PN
Type: Multizone SCR system
Current range: Up to 25A per zone
Supported protocols: Profinet, Modbus TCP, EtherNet/IP
Typical applications: IR drying tunnels, multizone drying in paper lines, continuous coating systems
Why choose it: Advanced power control, high configurability and full integration with industrial automation systems
Model: REVO PC
Type: Multichannel controller for SSR
Current range: Up to 24 zones via REVO S
Supported protocols: Modbus RTU, Profibus, Profinet
Typical applications: Drying lines with many heating elements, adhesive reactors, multizone heating
Why choose it: Intelligent management of power peaks and centralized control of multiple heating zones systems
Frequently asked questions about power controllers for the paper industry
Here you will find answers to the most common questions about electric heating control in paper production lines, coating systems and industrial printing processes
Which is the most suitable controller for web dryers in paper lines?
REVO C is often the most widely used solution thanks to its ability to precisely control power on industrial resistors or IR lamps. Configuration flexibility allows easy adaptation to line speed variations and process thermal load.
How are multiple drying zones managed in paper lines?
REVO PN systems allow independent control of multiple heating zones, ensuring thermal uniformity across the entire sheet width and improving drying process stability.
How are power peaks reduced in industrial drying systems?
REVO PC allows management of numerous heating elements by distributing switching events over time. This reduces power peaks on the electrical grid and improves plant energy efficiency.
Can SCR controllers improve final product quality?
Yes. Precise electrical power control ensures uniform temperatures in drying and coating systems, reducing surface defects, humidity variations and production waste.
Can CD Automation controllers integrate into paper line automation systems?
Yes. The devices support major industrial communication protocols such as Modbus, Profinet, EtherCAT and Ethernet/IP, facilitating integration with PLCs and supervision systems.
Which firing mode is most suitable for drying systems and IR lamps?
For standard resistive loads, zero crossing is often used, reducing grid disturbances.
For IR lamps or applications requiring faster response, phase angle or burst firing modes are used depending on process dynamics.
Can SCR controllers help reduce energy consumption in paper lines?
Yes. Precise power control allows only the energy required by the process to be delivered, reducing waste and improving overall plant efficiency.
Do SCR controllers work with cogeneration systems in paper mills?
Yes. SCR controllers integrate with cogeneration (CHP) systems, optimizing self-consumption and adapting to variable paper line loads.
How to improve energy efficiency in paper lines with SCR controllers?
SCR controllers enable precise power control, reduce consumption peaks and optimize energy in drying, coating and industrial heating processes.
