Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(SEE SECTION 10 AND RULE 13)

OPTICAL TRANSMITTER BASED PULP AND PAPER PRODUCTION SYSTEM AND METHOD THEREOF

PARASON MACHINERY (INDIA) PRIVATE LIMITED
GOLDEN DREAMS, E-27, 4TH FLOOR CHIKALTHANA, MIDC, AURANGABAD, MAHARASHTRA 431006, INDIA

THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED.

FIELD OF THE INVENTION
[001] The present invention relates to a system and method for continuous pulp processing and consistency control in a stock preparation line for paper manufacturing. More specifically, the present invention relates to an optical transmitter based system and method for pulp and paper production, specifically designed for continuous pulp processing and precise consistency control within a stock preparation line.

BACKGROUND OF THE INVENTION
[002] The pulp and paper industry relies on precise control of pulp consistency to ensure high-quality output and operational efficiency in stock preparation lines. Traditional pulp processing systems employ various valve arrangements, to monitor and regulate pulp flow. Further, the traditional manual process for pulp consistency control relied on operators visually inspecting and adjusting pulp flow based on experience. While this method provided flexibility, it often resulted in inconsistencies and higher resource consumption. Standardizing measurement protocols and optimizing manual adjustments can enhance reliability without the high costs of automation. However, these systems often face significant challenges that compromise performance and efficiency
[003] Competitors in the industry offer solutions such as flow, pressure, temperature, moisture, and consistency analyzers to address some of these issues. For instance, systems like those described in CN215518153U utilize chemical dosing and mixing systems integrated with pulp pipelines to improve process control. However, such systems often lack optimized valve designs tailored for optical consistency measurement, failing to address turbulence-induced inaccuracies or maintenance complexities effectively. These limitations result in inconsistent pulp quality, increased operational costs, and reduced system reliability.
[004] The present invention overcomes these challenges by introducing an optical transmitter-based pulp and paper production system with an advanced on off valve design. This system incorporates optimized flow control to minimize turbulence, enhancing the accuracy of optical consistency measurements. An improved sealing mechanism reduces leakage risks, extending system lifespan, while a quick-installation design allows transmitter replacement without full system shutdowns, significantly reducing downtime. Constructed from high-quality, corrosion-resistant materials, the system ensures durability under harsh process conditions. By integrating a custom on off valve, the invention enhances performance, reliability, and maintenance efficiency, offering a robust, automated, and cost-effective solution for industrial pulp and paper applications.

SUMMARY OF THE INVENTION
[005] In an embodiment, the present invention provides a pulp and paper production system (100) is disclosed for continuous pulp consistency monitoring and control. The system includes a pulper (101) that disintegrates fibrous material into pulp. The pulper is driven by a motor (103) and monitored by a level sensor (102). Pulp from the pulper is transferred to a tank (104), which is equipped with a tank motor (105) and a tank level sensor (106). A pump (109) transports pulp from the tank (104) through a main pipeline (110). Downstream of the pipeline, a refiner (107) is positioned to further process the pulp. The system includes at least one installation point (108) formed on the main pipeline (110). Each installation point (108) has a bypass loop that diverts a small portion of pulp stock from the main pipeline (110) for measurement. The bypass loop includes a first nipple (114) connected to the main pipeline to draw pulp into the loop. An ON-OFF valve (111) is placed downstream of the first nipple (114) to regulate or isolate flow through the bypass. A second nipple (115) is located after the ON-OFF valve to guide the pulp to an optical consistency transmitter (112). The optical consistency transmitter (112) is configured to measure the consistency of the diverted pulp and send real-time measurement data to a controller (113). After measurement, the pulp is returned to the main pipeline (110), forming a closed-loop bypass. Each installation point (108) includes the first nipple (114), ON-OFF valve (111), and second nipple (115) arranged in sequence. This setup ensures accurate pulp sampling and measurement without disrupting the main flow in the pipeline. The controller (113) is connected to both the optical consistency transmitter (112) and the ON-OFF valve (111). It receives consistency data and controls the valve accordingly. If the controller detects a failure in a primary sensor (112), it activates a backup sensor (112) at another installation point (108). It also isolates other valves (111) as necessary to ensure uninterrupted monitoring.
[006] In an embodiment, the present invention provides that the ON-OFF valve (111) comprises an advanced sealing mechanism comprising double O-rings or PTFE seals to minimize leakage risks in harsh pulp processing environments, thereby extending the system’s operational lifespan.
[007] In still another embodiment, the present invention provides that the inlet nipple (114) and outlet nipple (115) are constructed from corrosion-resistant materials to maintain laminar flow and ensure representative sampling of pulp consistency without disrupting the main pipeline (110) flow.
[008] In yet another embodiment, the present invention provides that the controller (113) is integrated with a Programmable Logic Controller (PLC) or Distributed Control System (DCS) for real-time monitoring, feedback, and process optimization.
[009] In an embodiment, the present invention provides that the ON-OFF valve (111) is configured to provide precise flow control through automated actuation by the controller (113), minimizing flow disturbances and enhancing the accuracy of consistency measurements by the optical consistency transmitter (112).
[010] In still another embodiment, the present invention provides that the bypass line configuration at each installation point (108) forms a closed loop, allowing the sampled pulp to return to the main pipeline (110) via the outlet nipple (115), preventing pulp loss and pressure imbalances.
[011] In yet another embodiment, the present invention provides that the pulper (101), tank (104), pump (109), and pipeline (110) are constructed from high-quality, corrosion-resistant materials.
[012] In an embodiment, the present invention provides that the transmitter (112) utilizes optical techniques including light scattering or absorption to determine the consistency of the pulp.
[013] In an embodiment, the present invention provides a method for continuously monitoring and controlling pulp consistency in a pulp and paper production system (100) comprises disintegrating fibrous material into pulp using a pulper (101), which is driven by a motor (103) and monitored by a level sensor (102). The disintegrated pulp is transferred into a tank (104) equipped with a tank motor (105) and a tank level sensor (106). The pulp is then pumped from the tank (104) through a main pipeline (110) using a pump (109), and directed toward a refiner (107). At each of at least one installation point (108) along the main pipeline (110), a representative portion of the pulp flow is diverted into a bypass loop via a first nipple (114). The flow of this diverted pulp is controlled using an ON-OFF valve (111) positioned downstream of the first nipple (114). The controlled flow then passes through a second nipple (115) toward an optical consistency transmitter (112), which measures the consistency of the pulp and transmits real-time consistency data to a centralized controller (113). After measurement, the pulp is returned to the main pipeline (110), forming a closed-loop bypass. The controller (113) analyzes the received consistency data and actuates the ON-OFF valve (111) accordingly to regulate sampling. If a failure is detected in the optical consistency transmitter (112) at any installation point (108), the controller (113) automatically activates a backup transmitter (112) located at another installation point (108) and isolates the valve (111) corresponding to the failed transmitter to ensure uninterrupted consistency monitoring.
OBJECTS OF THE INVENTION
[014] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
[015] The primary objective of the present invention is to provide an optical transmitter-based pulp and paper production system that simplifies the installation process of optical consistency transmitters, overcoming the complexities associated with traditional welded coupling and jack assembly configurations.
[016] Another key objective is to enhance maintenance efficiency by incorporating a design that allows for easy access and replacement of optical consistency transmitters without requiring extensive disassembly or system shutdowns, thereby minimizing downtime and associated costs.
[017] Additionally, the invention seeks to improve overall operational efficiency by reducing the complexity of the transmitter assembly, mitigating the challenges posed by conventional setups, such as welded configurations, which contribute to higher operational expenses.
[018] Another object of the present system is to ensure precise consistency measurement while maintaining durability and reliability in demanding industrial environments like pulp and paper manufacturing.
[019] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[020] The present disclosure will now be described with the help of the accompanying drawing, in which:
[021] Figure 1: illustrates a schematic view of the pulp processing system (100);
[022] Figure 2: the illustrated a bypass installation system for the pulp processing system (100);

LIST OF REFERENCE NUMERALS
[023] Reference numeral and references associated with the reference numeral
Numerals Particulars
100 System
101 Pulper
102 Level Sensor
103 Motor
104 Tank
105 Tank motor
106
Tank Level Sensor
107 Refiner
108 Installation Point
109 Pump
110 Pipeline
111 ON-OFF Valve
112 Sensor or QT Sensor or Optical consistency transmitter
113 Controller
114 First 40 NB nipple
115 Second 40NB nipple
DETAILED DESCRIPTION OF INVENTION:
[024] In an embodiment, as illustrated in figure 1, the system (100) is designed for continuous pulp processing and consistency control in a stock preparation line. At the center of this system is a pulper (101), which is responsible for disintegrating raw fibrous material into pulp. The pulper (101) operates under the supervision of a level sensor (102), which monitors the internal pulp level and ensures the operation remains within the desired capacity. A powerful motor (103) drives the pulper (101), enabling thorough fiber separation. Once pulping is complete, the slurry is transferred to an intermediate tank (104), which serves as a buffer reservoir for regulated pulp flow.
[025] Within the tank (104), a dedicated tank motor (105) agitates the contents to maintain pulp uniformity and prevent settling of fibers. The tank’s (104) internal level is continuously monitored by a tank level sensor (106), which helps control the inlet and outlet operations, ensuring stable process flow and preventing overflows or underflows. From the tank (104), the pulp is directed toward a refiner (107), which refines the fiber structure to improve bonding strength and paper quality. This unit is key in tailoring the fiber characteristics to meet production requirements, and its operation depends critically on the consistency of the pulp entering the refiner (107).
[026] The pulp processing system (100) incorporates multiple installation points (108), each equipped with an ON-OFF Valve (111) which include but not limits to ball valve, gate valve, globe valves etc. and a dedicated sensor or Optical Consistency Transmitter (112). In one of the preferred embodiments the ball valve used as said on-off valve (111). In the illustrated figure 1, three such installation arrangements are shown, strategically positioned along a main pipeline (110). Each Installation Point (108) taps into the flow via a bypass connection and includes an on-off valve (111) that allows isolation for maintenance or automatic activation during operational changes. The optical consistency transmitters (112) at each point provide real-time consistency measurements, and each is directly connected to a centralized controller (113). This setup creates a robust multi-point monitoring system, enabling redundancy and enhanced reliability.
[027] In the event that the primary optical consistency transmitter (112) fails, the system logic—governed by the controller (113)—automatically activates a backup transmitter (112) at another Installation Point (108). The corresponding ON-OFF Valve (111) is opened while others are isolated as needed, ensuring uninterrupted pulp consistency measurement and preventing process disruptions. This redundancy enhances system resilience. Furthermore, based on consistency readings from any active sensor (112), the controller (113) dynamically adjusts flow through automated valve actuation to maintain optimal consistency before the pulp enters the refiner (107). This automated valve operation ensures precise control of refining, leading to optimized fiber quality and refining efficiency.
[028] The pulp from the tank (104) is transported using a pump (109), which maintains steady pressure and flow in the pipeline (110). An ON-OFF Valve (111) is strategically placed to control the flow path or isolate parts of the system during maintenance or process changes. If the consistency measured by the optical consistency transmitter (112) deviates from the set point, the controller (113) interprets the sensor signal and adjusts the relevant control elements—such as flow rate or dilution water addition—to restore the desired consistency. This closed-loop control strategy ensures consistent pulp quality throughout the refining stage.
[029] The entire control logic is seamlessly integrated into a PLC (Programmable Logic Controller) or DCS (Distributed Control System), allowing real-time monitoring, feedback, and process optimization. The controller (113) continuously evaluates sensor data from the installation points (108), adjusts valves (111), and communicates with upstream equipment like the pulper (101), pump (109), and tank (104) to maintain flow and consistency balance. In case of sensor failure, deviation alerts are generated, prompting automatic fallback to backup transmitter (112) or notifying operators for intervention. This backup transmitter (112) can be taken from any other transmitter (112) from the multiple transmitters illustrated in figure 1. This level of system integration and automation significantly enhances reliability, minimizes downtime, and ensures high quality, consistent output from the refiner (107) stage.
[030] In essence, the integrated operation of the system (100), including components like the pulper (101), tank (104), refiner (107), and the real-time feedback loop involving the optical consistency transmitter (112) and controller (113), ensures a highly efficient and automated pulp processing line. The modular configuration, enhanced by multiple installation points (108) and precise sensor-driven feedback mechanisms, improves product uniformity, energy efficiency, and overall process control. This setup is ideal for applications requiring tight control over fiber characteristics before entering downstream paper machine operations. This setup is ideal for applications requiring tight control over fiber characteristics before entering downstream paper machine operations.
[031] In an embodiment, as illustrated in figure 1, the system (100) is designed for continuous pulp processing and consistency control in a stock preparation line. However, the configuration is not limited to a fixed setup and can be adapted across various stages of pulp and paper production, depending on operational requirements. The system components—including the pulper (101), tank (104), refiner (107), and the optical consistency transmitter (112)—can be modified or replaced with equivalent equipment to suit different process conditions and scalability.
[032] For example, the pulper (101) may be substituted with alternative disintegration machinery based on the type of raw fiber used, while the refining unit (107) may vary in design to meet specific paper quality standards. Additionally, the ON-OFF Valve (111) configurations—including ball valves, gate valves, or globe valves—can be adjusted depending on process control preferences. The number and positioning of installation points (108) can also be customized to optimize flow regulation and redundancy in diverse pulp processing environments.
[033] Moreover, the system includes a range of sensors (112), including but not limited to consistency sensors, fluid sensors, pressure sensors, and level sensors, to ensure comprehensive monitoring and precise control over process variables.
[034] For example, consistency sensors provide real-time pulp consistency measurements, ensuring uniformity before refining, while fluid sensors monitor flow dynamics, detecting variations in liquid composition and optimizing system operation. Pressure sensors regulate pipeline pressure, preventing process disruptions, and level sensors manage liquid levels in tanks to maintain balance in stock preparation.
[035] This modular and sensor-integrated design enables the system (100) to be reconfigured across different pulp processing units, ensuring flexibility, enhanced automation, and adaptability in diverse industrial environments.

[036] In an embodiment as shown in figure 2, the illustrated diagram represents an elaborated view of a bypass installation system for real-time pulp consistency measurement in the stock flow pipeline (110). The main horizontal pipeline (110) carries the pulp stock from left to right, as indicated by directional arrows. To facilitate online consistency monitoring, an installation point (108) is created on this main pipeline. From this installation point (108), a bypass line is formed using nipples (114) ranging from 20 NB to 60 NB, ensuring compatibility across various system configurations. At least one 30 NB nipple is incorporated to optimize flow control within the bypass loop. The bypass line connects to the ON-OFF valve (111), allowing operators or an automated system to regulate or isolate the flow into the bypass loop as needed.. Downstream of the ON-OFF valve (111), the bypass line includes a QT Sensor (112) via an outlet nipple (115), which functions as an optical consistency transmitter (112). This sensor (112) continuously measures the consistency of the pulp using optical techniques such as light absorption or scattering, and provides real-time data to a central controller (113). The sensor (112) is strategically positioned to receive a representative flow sample from the pipeline (110) while ensuring minimal disruption. After passing through the sensor (112), the sample flow re-enters the main pipeline (110), maintaining a closed loop. This arrangement ensures that pulp consistency is monitored accurately and efficiently, with the bypass system allowing for sensor maintenance without interrupting the main process flow. The modular nature of this setup allows for multiple installation points (108), each with its own ON-OFF valve (111) and sensor (112), to be deployed along the pipeline (110) for redundancy, precision, and robust process control. In the diagram, at least two nipples are used to form a bypass loop from the main pipeline (110) to the QT Sensor (112) and back, enabling continuous pulp consistency measurement. The first nipple (114) acts as the inlet connection allowing a portion of the pulp stock to be diverted from the main flow at the installation point (108) into the on off valve (111). This controlled diversion feeds the pulp into the sensor circuit. After the stock passes through the QT Sensor (112), which functions as an optical consistency transmitter—it must return to the main pipeline to maintain system continuity. This is accomplished via the second nipple (115), which acts as the outlet connection back into the pipeline. Together, the two nipples (114,115) create a closed-loop bypass system, ensuring that real-time sampling occurs without interrupting the main flow. Additionally, the use of the valve (111) allows for isolation of the sensor for maintenance or operational changes, enhancing both safety and reliability of the system.
[037] Further, in the present invention, the optical transmitter (112)-based pulp and paper production system (100), achieves enhanced performance, reliability, and maintenance efficiency through a combination of advanced components and the valve (111) integrated into its multiple installation points (108). The system addresses critical challenges in traditional pulp processing systems, including inaccurate measurements due to flow disturbances, leakage, maintenance complexity, and limited process control.
[038] Furthermore, the system (100) incorporates the on-off valve (111) at each installation point (108) along the main pipeline (110). These valves (111) are designed to ensure smooth, consistent flow with minimal turbulence, significantly improving the accuracy of pulp consistency measurements by the optical consistency transmitters (112). By reducing flow disturbances, the system ensures that optical measurements, based on principles such as light scattering or absorption, are precise, leading to reliable data relayed to the controller (113) for real-time process adjustments. This enhances the overall control of pulp quality entering the Refiner (107), optimizing fiber characteristics for downstream paper production.
[039] Furthermore, the valve (111) design at the installation points (108) features an improved sealing mechanism that minimizes leakage risks. This is useful in harsh pulp processing environments where seal degradation is common. By using high quality, corrosion-resistant materials, the valves (111) extend the system’s lifespan, reducing the frequency of maintenance interventions and associated costs. The robust sealing ensures continuous operation without interruptions caused by leaks, contributing to the system’s reliability and efficiency. Particularly, the ON-OFF valve (111) in the optical transmitter-based pulp and paper production system (100) is a custom-designed ball valve optimized for precise flow control and minimal turbulence within the bypass line at each Installation Point (108). The valve features a streamlined, full-bore internal geometry with smooth, corrosion-resistant surfaces (e.g., polished stainless steel or PTFE-lined) to ensure laminar flow, reducing turbulence and enhancing the accuracy of pulp consistency measurements by the optical consistency Transmitter (112). Its advanced sealing mechanism, utilizing double O-rings or PTFE seals, prevents leakage in harsh pulp processing environments, extending system lifespan. The valve (111) operates via automated actuation controlled by the centralized Controller (113), which opens or closes the valve to regulate or isolate flow into the bypass loop for real-time sampling or maintenance. In case of a primary transmitter (112) failure, the controller (113) activates the ON-OFF valve (111) at a backup Installation Point (108), ensuring uninterrupted monitoring without system shutdown. This design minimizes flow disturbances, supports quick maintenance access, and enhances system reliability.
[040] The bypass line configuration in the optical transmitter-based pulp and paper production system (100) ensures representative sampling of pulp consistency with minimal disruption to the main pipeline (110) flow,. At each Installation Point (108), a nipple (114) diverts a controlled portion of pulp into a bypass loop, with its at least 10 mm nominal bore size designed to match the main pipeline’s flow dynamics, preventing pressure drops or disturbances. The ON-OFF valve (111), regulated by the controller (113), precisely controls the sample flow, while smooth, corrosion-resistant nipples (114, 115) maintain laminar flow to the QT Sensor (112), ensuring accurate optical consistency measurements via light scattering or absorption. After measurement, the pulp returns to the pipeline (110) via the outlet nipple (115), forming a closed loop that avoids pulp loss or pressure imbalances. This configuration, with automated valve actuation and modular design, supports maintenance without interrupting the main flow, enhancing operational efficiency and pulp quality control for the refiner (107).

[041] Moreover, the system (100) is designed for maintenance efficiency, allowing optical consistency transmitters (112) to be replaced without requiring full system shutdowns. Each installation point (108) includes an ON-OFF Valve (111) that can isolate the bypass line for maintenance while other Installation Points (108) remain operational. In the event of a primary transmitter (112) failure, the controller (113) automatically activates a backup transmitter (112) at another installation point (108), ensuring uninterrupted consistency measurement. This redundancy and quick-installation design significantly reduce downtime, enhancing operational continuity and cost-effectiveness.
[042] The system’s components, including the custom b ON-OFF Valve (111) which includes ball valves and optical consistency transmitters (112), are constructed from high-quality, corrosion-resistant materials tailored to withstand harsh process fluid conditions in pulp and paper production. The pulper (101), tank (104), pump (109), and pipeline (110) are similarly designed for durability, ensuring long-term performance under continuous operation. This durability minimizes wear and corrosion, further reducing maintenance needs and extending the system’s operational life.
[043] The integration of the ON-OFF Valves (111) at the installation points (108) simplifies maintenance procedures. The ability to isolate individual installation points (108) using ON-OFF Valves (111) allows for targeted servicing without affecting the entire system [100]. Additionally, the controller (113), integrated with a PLC or DCS, continuously monitors sensor data and generates deviation alerts in case of transmitter (112) failure, prompting automatic fall back to a backup unit or operator intervention. This automation reduces maintenance complexity, minimizes downtime, and ensures consistent output quality from the refiner (107).

[044] The proposed invention has the following technical effects:
[045] Improved Signal Transmission Efficiency: The precise alignment and positioning of the optical transmitter with or within the valve minimize signal loss, enhancing the quality and accuracy of consistency measurements in the pulp processing system.
[046] Minimized downtime during installation: The design enables rapid and seamless integration of the optical transmitter into existing pipelines without extensive modifications, significantly reducing system downtime during installation.
[047] Enhanced protection from environmental factors: The on off valves including ball valve provides a robust enclosure, safeguarding the optical transmitter from dust, moisture, vibration, and high-pressure conditions, thereby maintaining consistent performance in harsh industrial environments.
[048] Increased system reliability and longevity: By optimizing the installation process and providing a stable mounting structure, the design reduces mechanical stress and wear, resulting in a more reliable and durable system with an extended operational lifespan.
[049] Simplified maintenance and replacement: The modular configuration of the valve allows easy access to the optical transmitter, streamlining maintenance and replacement procedures without requiring full system shutdowns, thus improving operational efficiency.
[050] Better flow control and reduced interference: In systems involving fluid dynamics, the valve optimizes flow control, minimizing turbulence and vibration-induced signal distortions, which enhances the accuracy of optical consistency measurements.
[051] Cost savings over time: The design’s reduced maintenance requirements, enhanced efficiency, and prolonged equipment lifespan lead to significant long-term cost savings, despite potentially higher initial investment.
[052] Reduced sensor requirements and improved data correlation: The optimized design reduces the number of sensors needed by improving measurement accuracy and enhances data correlation across process variables, enabling more effective process control and monitoring.
[053] These technical effects collectively contribute to a more efficient, reliable, and cost-effective pulp and paper production system, addressing the limitations of traditional optical consistency transmitter installations.
[054] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of the any other element, integer or step, or group of elements, integers or steps.
[055] The use of the expression “at least” or “at least one” suggested the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or result.
[056] Any discussion of documents, acts, materials, devices, articles, or the like that has been included in this specifications is solely for the purpose of providing a context for the disclosure, it is not to be taken as an admission that any or all of these matters from a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
[057] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiment, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the forgoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
Dated this 25th day of June 2025
Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent

, Claims:CLAIMS
We claim;
1. A pulp and paper production system (100) for continuous pulp consistency monitoring and control, comprising:
a pulper (101) configured to disintegrate fibrous material into pulp, the pulper (101) driven by a motor (103) and monitored by a level sensor (102);
a tank (104) receiving pulp from the pulper (101), the tank (104) equipped with a tank motor (105) and a tank level sensor (106);
a pump (109) configured to transport pulp from the tank (104) through a main pipeline (110);
a refiner (107) positioned downstream of the main pipeline (110);
at least one installation point (108) formed on the main pipeline (110), each installation point comprising:
a bypass loop configured to divert a representative portion of pulp stock from the main pipeline (110) for measurement, the bypass loop comprising:
     a first nipple (114) connected to the main pipeline (110) and configured to divert pulp stock into the bypass loop;
    an ON-OFF valve (111) positioned downstream of the first 40 NB nipple (114), the ON-OFF valve (111) being configured to regulate or isolate flow through the bypass loop based on control signals;
     a second nipple (115) positioned downstream of the ON-OFF valve (111) and configured to direct the diverted pulp to an optical consistency transmitter (112);
     the optical consistency transmitter (112), positioned in the bypass loop and configured to measure the consistency of the diverted pulp and transmit real-time measurement data;
  wherein the measured pulp is returned to the main pipeline (110), forming a closed-loop bypass arrangement;
wherein each installation point (108) comprises said first nipple (114), ON-OFF valve (111), and second nipple (115) arranged in sequence to enable accurate, non-intrusive pulp sampling and measurement without interrupting the main pipeline flow;
a controller (113) operatively connected to the optical consistency transmitter (112) and valve (111), configured to receive real-time consistency data and actuate the valve (111);
wherein the controller (113) automatically activates a backup sensor (112) at another installation point (108) upon detecting a failure in a primary sensor (112), and isolates other valves (111) as needed to maintain continuous monitoring.
2. The system (100) as claimed in claim 1, wherein the ON-OFF valve (111) comprises an advanced sealing mechanism comprising double O-rings or PTFE seals to minimize leakage risks in harsh pulp processing environments, extending the system’s operational lifespan.

3. The system (100) as claimed in claim 1, wherein the inlet nipple (114) and outlet nipple (115) are constructed from corrosion-resistant materials to maintain laminar flow and ensure representative sampling of pulp consistency without disrupting the main pipeline (110) flow.
4. The system (100) as claimed in claim 1, wherein the controller (113) is integrated with a Programmable Logic Controller (PLC) or Distributed Control System (DCS) for real-time monitoring, feedback, and process optimization.
5. The system (100) as claimed in claim 1, wherein the ON-OFF valve (111) is configured to provide precise flow control through automated actuation by the controller (113), minimizing flow disturbances and enhancing the accuracy of consistency measurements by the optical consistency transmitter (112).
6. The system (100) as claimed in claim 1, wherein the bypass line configuration at each installation point (108) forms a closed loop, allowing the sampled pulp to return to the main pipeline (110) via the outlet nipple (115), preventing pulp loss and pressure imbalances.
7. The system (100) as claimed in claim 1, wherein the pulper (101), tank (104), pump (109), and pipeline (110) are constructed from high-quality, corrosion-resistant materials.
8. The system (100) as claimed in claim 1, wherein the transmitter (112) utilizes optical techniques including light scattering or absorption to determine the consistency of the pulp.
9. A method for continuously monitoring and controlling pulp consistency in a pulp and paper production system (100), the method comprising:
disintegrating fibrous material into pulp using a pulper (101) driven by a motor (103) and monitored by a level sensor (102);
transferring the disintegrated pulp into a tank (104) equipped with a tank motor (105) and a tank level sensor (106);
pumping the pulp from the tank (104) through a main pipeline (110) using a pump (109);
directing the pulp from the main pipeline (110) toward a refiner (107);
at each of at least one installation point (108) along the main pipeline (110), performing the steps of:
   diverting a representative portion of the pulp flow from the main pipeline (110) into a bypass loop via a first nipple (114);
   controlling the flow of the diverted pulp using an ON-OFF valve (111) positioned downstream of the first nipple (114);
   directing the controlled flow of the diverted pulp through a second nipple (115) toward an optical consistency transmitter (112);
   measuring the consistency of the diverted pulp using the optical consistency transmitter (112) and transmitting real-time consistency data to a centralized controller (113);
   returning the measured pulp to the main pipeline (110), thereby completing a closed-loop flow path;
analyzing the consistency data at the controller (113) and actuating the ON-OFF valve (111) based on the measurement results to regulate sampling;
detecting any failure of the optical consistency transmitter (112) at an installation point (108);
upon detecting a failure, automatically activating a backup optical consistency transmitter (112) at another installation point (108) and isolating the valve (111) associated with the failed sensor to maintain uninterrupted consistency monitoring.

Dated this 25th day of June 2025
Shailendra Om Khojare,
IN/PA-4041
Applicants Patent Agent