Every procurement team is told to dual-source. Every technical team knows that a second source means a second set of process settings, a second validation cycle and a second failure mode. Both are right.
The real cost of a second source
Switching between pulps is not free. Each switch costs:
- Validation time — typically 2–4 weeks from sample to full production.
- Line time — a trial run consumes production capacity.
- Scrap — the first hours of a trial usually produce off-spec material.
- Operator attention — a familiar pulp needs less supervision than a new one.
For a large converting line running continuously, those costs are manageable. For a smaller line running two shifts, they can exceed the value of the supply security gained.
When dual sourcing genuinely pays
- Single-region supply. If both suppliers ship from the same port or the same region, you have two suppliers and one risk.
- Grades with tight availability. Absorbent grades with specific debonding systems are often produced on a small number of machines.
- Long ocean transit. A single supplier plus a four-week transit time is a fragile chain regardless of how reliable the mill is.
How to structure it
The most workable model is a primary supplier at 70–80% of volume and a qualified secondary at 20–30%, with the secondary running continuously rather than only in emergencies. A secondary that has not run for a year is not a qualified secondary — it is an untested material.
Run both grades on a fixed rotation so operators stay familiar with both, and keep the process settings for each documented and posted at the line.
The honest trade-off
Dual sourcing buys continuity and costs efficiency. The right number of sources depends on how much downtime your line can absorb — and that is a business question, not a procurement one.