Paper Mills Get a Smart Makeover With AI

AI is transforming US paper mills, cutting chemical use and boosting efficiency while giving early adopters a powerful competitive edge

5 Mar 2025

Artificial intelligence is beginning to reshape operations in US paper mills, as producers deploy software to improve efficiency, reduce chemical use and manage rising environmental pressures.

Mills across regions including the southeastern US and the Midwest are adopting AI-based control systems that analyse production data in real time. The technology adjusts chemical dosing and machine speeds during the manufacturing process, aiming to improve output while lowering operating costs.

One of the systems gaining traction has been developed by ProcessMiner in partnership with water treatment and chemical supplier Solenis. The platform collects live data from mill equipment and applies machine-learning models to refine operating settings during production.

Early results suggest notable savings. At one mill in the US southeast, chemical consumption fell by about 25 per cent within months of adopting the system. Other sites report increases in production efficiency and throughput without additional labour or major capital investment.

“This isn’t just automation,” said a Solenis executive. “It’s predictive control that learns and adapts faster than any human can.”

The shift comes as the paper industry faces growing scrutiny over water use and emissions. Mills rely heavily on chemicals during pulping and processing, and regulators and customers are increasingly pressing companies to reduce waste and environmental impact.

AI-based control tools can help by adjusting inputs more precisely than manual processes, limiting excess chemical discharge and improving resource efficiency. For some producers, the technology has also become a way to strengthen margins in an industry often defined by tight cost controls.

However, adoption has not been uniform. Older mills frequently operate with legacy control systems that can complicate integration, while operators must adapt to a production environment where software increasingly guides decisions.

Industry groups say uptake is likely to expand as companies modernise facilities and seek operational savings. If early trials continue to deliver cost reductions and environmental gains, AI could become a standard feature in mill control rooms over the coming decade.