Gas Detection Solutions for the Paper and Packaging Industry

In the paper and packaging industry, safe production is always the top priority. Raw materials such as wood, straw, reeds, rags, bamboo, and waste newspapers can easily generate biogas, hydrogen sulfide, and other harmful gases during storage and processing. These gases not only threaten workers’ health but may also trigger explosions or environmental pollution. During pulp manufacturing, high-temperature and high-pressure cooking separates cellulose while discharging black liquor containing lignin and volatile organic acids. This black liquor has a strong odor and is highly polluting. Therefore, real-time monitoring of gas concentrations in the production environment has become an industry standard, helping enterprises prevent risks and ensure compliance.

Nexisense, as a professional brand in the field of gas detection, provides a series of reliable solutions to help paper enterprises address these challenges. From fixed online monitoring to portable inspection devices, our products focus on practicality and stability to ensure efficient operation in complex industrial environments. Below, we explore the applications and advantages of these solutions in depth.

Gas Risk Analysis in Paper Production

Paper production involves multiple processes, each of which may release different gases. First, raw material storage areas are major sources of biogas and hydrogen sulfide. These gases originate from organic decomposition, and excessive concentrations can lead to oxygen deficiency or poisoning accidents. Second, chlorine and chlorine dioxide are widely used in cooking and bleaching processes. Chlorine is a highly toxic asphyxiating gas; short-term exposure can cause respiratory damage and even be life-threatening. Chlorine dioxide is used for bleaching, but its instability may result in leakage. In addition, turpentine, as a by-product, is a flammable and explosive gas that can ignite upon contact with a fire source.

According to industry data, gas-related incidents account for a significant proportion of accidents in the paper industry. For example, a large paper mill once suffered a chlorine leak that led to production shutdown and substantial economic losses. This not only affected production efficiency but also resulted in environmental penalties. Although the packaging industry is relatively less hazardous, printing and gluing processes may release volatile organic compounds (VOCs), which are harmful to health when accumulated over time. Therefore, a comprehensive gas monitoring system is essential to prevent these risks. Through real-time data, enterprises can intervene early, optimize ventilation systems, and reduce pollutant emissions.

Application of Nexisense Online Gas Detectors

The Nexisense SGA-500 series online gas concentration detector is an ideal choice for paper enterprises. This series adopts original imported sensor chips and undergoes strict calibration to ensure accuracy and durability. Installation is simple; it requires only a 24V power supply and can be put into use without additional reagents or complex operations. When the target gas concentration reaches the preset threshold, the instrument automatically alarms and notifies relevant personnel for timely handling.

In paper workshops, this detector is particularly suitable for monitoring chlorine, chlorine dioxide, and turpentine. The chlorine detection module features high sensitivity and can capture ppm-level changes to prevent escalation. Turpentine monitoring focuses on flammability and integrates lower explosive limit (LEL) alarm functions to ensure safety. For black liquor treatment areas, hydrogen sulfide and biogas sensors track concentration changes in real time, helping enterprises comply with national environmental standards such as GB 16297-1996 Integrated Emission Standard of Air Pollutants.

In practical cases, after a packaging plant introduced the SGA-500, gas leakage incidents decreased by 40%, and production efficiency improved significantly. The instrument supports remote data transmission, allowing the central control room to monitor multiple points and achieve intelligent management.

Core Technologies and Advantages of the Detector

The core of the SGA-500 series lies in its sensor technology. Using electrochemical or infrared sensors, it operates stably in harsh environments with strong anti-interference capability. The enclosure features explosion-proof design and IP65 protection rating, suitable for humid and dusty paper environments. The response time is less than 30 seconds, ensuring rapid reaction to leaks.

Compared with other brands, Nexisense emphasizes user-friendliness. No professional training is required for operators to get started. In terms of maintenance, sensor lifespan reaches 2–3 years, reducing replacement costs. It supports Modbus or 4-20mA communication protocols, facilitating integration with existing SCADA systems. This enhances monitoring efficiency and supports enterprise digital transformation.

Enhancing System Integration with Alarm Controllers

To achieve more comprehensive management, the Nexisense SGA-500 series can be used with the SGA-800 series alarm controller. The controller supplies power to detectors and centrally processes signals. It is available in split-type and bus-type configurations; the former suits small workshops, while the latter supports large-scale monitoring with up to 64 monitoring points.

The controller’s advantage lies in linkage functionality. When the detector alarms, it can automatically activate fans, shut off valves, or trigger audible and visual alarms, enabling zoned control. For example, if hydrogen sulfide exceeds limits in the raw material storage area, the controller immediately activates ventilation to prevent gas spread. Central control room personnel can view real-time data on the LCD screen, reducing manual inspections and saving labor.

On packaging production lines, the controller can connect with PLC systems to optimize processes. Practical applications show that such integrated solutions can shorten response time to within 10 seconds, significantly reducing risks.

Installation and Maintenance Recommendations for Controllers

During installation, select the type based on the number of monitoring points. Split-type wiring is simple and low-cost; bus-type offers stable signals and strong scalability. For maintenance, calibrate quarterly to ensure accuracy. Nexisense provides remote diagnostic services to help enterprises resolve issues quickly.

Role of Portable Detectors in Inspection

In addition to fixed monitoring, paper workshops require flexible inspection tools. The Nexisense SGA-600 series portable gas concentration detector is designed for this purpose. It is compact, lightweight, and operable with one hand, ready to use upon startup. Sampling methods include diffusion, pump suction, and probe type to adapt to various scenarios.

Diffusion type suits open areas, pump suction is used for confined spaces, and probe type facilitates in-depth detection. The instrument responds quickly, displays real-time concentration, and alarms automatically at preset levels. Inspectors can carry it to check digesters, black liquor pools, and other high-risk zones to ensure full coverage.

A paper mill reported that after adopting the SGA-600, inspection efficiency increased by 30%, and hazard detection rates improved significantly. Battery life reaches up to 8 hours and supports data storage for subsequent analysis.

Practical Tips for Portable Instruments

During use, it is recommended to wear the detector near the breathing zone to avoid misjudgment. Conduct regular bump tests to ensure sensor effectiveness. With APP integration, data can be uploaded to the cloud for team sharing.

Overall Strategy for Implementing Gas Detection Solutions

When implementing gas detection solutions in paper and packaging enterprises, first conduct a risk assessment to identify key monitoring points such as raw material areas, production workshops, and waste liquid treatment zones. Then select appropriate Nexisense product combinations: fixed detectors covering major areas, portable devices for dynamic inspections, and controllers for centralized management.

Training is critical. Enterprises should organize employees to learn gas knowledge and equipment operation. Conduct regular system audits to ensure compliance. In the long run, such investments not only prevent accidents but also enhance corporate image and attract more partners.

Frequently Asked Questions (FAQ)

1. How to choose the appropriate sensor type for paper industry gas detectors? Sensor selection should target specific gas characteristics: chlorine and chlorine dioxide require high-sensitivity electrochemical sensors capable of precise response within 0.01–10 ppm to avoid cross-interference; turpentine and other combustible gases are recommended to use catalytic combustion or infrared sensors covering 0–100%LEL to ensure explosion risk warning; hydrogen sulfide and biogas prefer electrochemical or semiconductor types suitable for humid and dusty environments. The Nexisense SGA-500 series optimizes sensor combinations for common paper industry gases and supports anti-interference calibration. It is recommended to conduct on-site risk assessment, considering humidity (often >80%), temperature fluctuations, and interfering gases such as VOCs, and select products with IP65 or higher protection to ensure long-term stability.

2. What are the key considerations for installation position and height of online detectors? Install near potential leakage sources such as digesters, bleaching pipeline joints, above black liquor tanks, or downwind of raw material storage areas, avoiding dead zones. Height is generally set at 1.2–1.8 meters (breathing zone); heavier gases like chlorine may be installed lower (0.5–1 meter), while lighter gases like turpentine may be higher. Keep away from strong vibration sources, direct sunlight, high-temperature exhaust outlets, and strong electromagnetic interference. Nexisense SGA-500 supports wall-mounted or pipeline installation; reserve maintenance space for quarterly inspection and zero calibration.

3. What about battery life, charging method, and actual endurance of portable detectors during inspection? The Nexisense SGA-600 series uses high-capacity lithium batteries, offering 10–12 hours in diffusion mode and about 8 hours in pump mode. It supports USB fast charging or dedicated charging docks, requiring 4–6 hours for full charge. It is recommended to recharge daily after use and avoid battery below 20%. It includes low-battery warning and stores the latest 1000 records even after power loss. Replaceable backup batteries support hot swapping for long shifts.

4. How does the alarm controller achieve linkage control with other equipment? What are typical scenarios? The SGA-800 controller uses relay outputs (NO/NC) and 4-20mA/RS485/Modbus protocols to link with fans, solenoid valves, audible/visual alarms, or PLCs. At level-1 alarm (e.g., chlorine 0.5 ppm), local ventilation starts; at level-2 (e.g., 1 ppm), gas source valves shut off and full alarms activate. Typical scenarios include hydrogen sulfide exceeding limits in black liquor pools triggering ventilation acceleration, or chlorine leakage shutting down bleaching pumps. Supports zoning, graded alarms, and customizable delays (5–30 seconds). Expandable beyond 64 points.

5. How to integrate the gas detection system with existing SCADA or ERP systems? Nexisense devices support Modbus RTU/TCP and 4-20mA protocols. Through gateways or OPC servers, they connect to SCADA systems for real-time curves, historical trends, and alarm logs. Data can further integrate with ERP for reporting, compliance audits, or predictive maintenance. IT departments should configure network isolation and encryption for data security. Many enterprises incorporate gas monitoring into digital workshops to improve response speed and traceability.

6. What are protection and maintenance requirements in high-humidity and dusty environments? Choose IP65 or higher protection. Nexisense enclosures use engineering plastic or stainless steel, resistant to acid and alkali corrosion. Maintenance includes monthly cleaning of sensor filters, quarterly bump testing and zero/span calibration (using standard gas or fresh air). Sensor lifespan is 2–3 years. Check sealing rings in humid environments to prevent condensation ingress. Maintain logs and adjust calibration cycles according to pollution levels to maintain ±5% accuracy.

7. How to properly use Nexisense detectors for emergency response and post-incident analysis? First, use SGA-600 portable units to quickly scan leakage points and define hazard zones (chlorine >0.5 ppm requires evacuation), while activating fixed SGA-500 linkage ventilation/shutdown. Wear positive-pressure respirators in high concentration areas. Afterward, download logs including peak values, duration, and trigger points, and analyze causes such as valve aging or operational errors. Nexisense supports USB/Bluetooth export for reporting and improvement measures.

8. How to evaluate ROI after introducing Nexisense gas detection solutions? Compare initial purchase cost (detectors + controllers + installation about 60% of total investment) with potential benefits: reduced shutdown losses (single chlorine leak may cause hundreds of thousands to millions in loss), avoided environmental fines, lower injury medical expenses, and improved efficiency (optimized ventilation saving 10–20% energy). ROI is typically achieved within 1–2 years. Many mills report accident reduction of 30–50% and inspection efficiency improvement above 25%. Calculate payback period based on historical accident data and local standards, considering annual sensor replacement cost of 10–15% of total investment.

Conclusion

The gas risks faced by the paper and packaging industry cannot be ignored, but through Nexisense’s comprehensive solutions, enterprises can effectively manage these challenges. From SGA-500 online detection to SGA-600 portable inspection and SGA-800 controller integration, a closed-loop system ensures safety and environmental compliance. Implementing these solutions not only improves operational efficiency but also drives sustainable development. Enterprises are advised to consult professional teams to customize the most suitable monitoring strategy and move toward a safer future.