Papeterie Le Bourray and ISRA VISION's 20-Year Journey Toward Excellence in Tissue Production
Papeterie Le Bourray and ISRA VISION's 20-Year Journey Toward Excellence in Tissue Production In the intricate dance of paper production, particularly in the demanding field of tissue paper, the specter of paper breakage stands as a costly and disruptive challenge. Such issues demand a perfect symphony of speed, precision, and an uninterrupted flow of reliable data to achieve flawless production—where not a single sheet goes to waste. With the robust inspection system pioneered by ISRA VISION, Papeterie Le Bourray has the capability to maintain optimal paper quality, even at maximum production speeds. In the picturesque Sarthe region of France, Papeterie Le Bourray, a paper mill with a heritage extending over 150 years, continuously pursues excellence and perfection. Crafting bespoke colored tissue and innovative cellulose tissue, Le Bourray’s legacy of pioneering innovation has been greatly enhanced through its transformative partnership with ISRA VISION. The deployment of ISRA VISION’s systems in 2006 at Le Bourray’s facilities has been signaled the start of a significant evolution. This year marks an exciting milestone as the systems in PM3 and PM4 areset to be updated, celebrating 19 years of reliable and robust performance.
In the picturesque Sarthe region of France, Papeterie Le Bourray, a paper mill with a heritage extending over 150 years, continuously pursues excellence and perfection. Crafting bespoke colored tissue and innovative cellulose tissue, Le Bourray’s legacy of pioneering innovation has been greatly enhanced through its transformative partnership with ISRA VISION. The deployment of ISRA VISION’s systems in 2006 at Le Bourray’s facilities has been signaled the start of a significant evolution. This year marks an exciting milestone as the systems in PM3 and PM4 are set to be updated, celebrating 19 years of reliable and robust performance.
LE BOURRAY’S QUEST FOR PERFECTION
Founded in 1844 and located near Le Mans, France, Le Bourray stands as a historic beacon inthe papermaking industry. Known for pioneering the world's first recycled tissue paper and leadingin bespoke color solutions, Le Bourray exports its high-quality products to 41 countries. Innovationis at the heart of their operations, allowing them to produce 29,000 tonnes of tissue annually, ranging across a vibrant spectrum of 250 colors tailored for various applications, from tableware to specialty uses.
Despite its historic roots and innovative strides, Le Bourray faced significant challenges in maintaining the exceptional quality of its products. The necessity to detect even the minutest of defects in their tissue papers, such as holes and stains, prompted the need for a sophisticated solution that could enhance quality control without compromising production efficiency.
TWO DECADES OF COLLABORATIVE EXCELLENCE
The collaboration began with earnest discussions in 2004, focusing on integrating a system tailored to meet the rigorous demands of tissue production. Le Bourray was looking for a defect detection system to optimize the quality of their paper products. At the outset of the project, they initiated contact with ISRA VISION to ensure the best possible implementation and outcomes. From the very beginning of the co-operation, ISRA VISION provided Le Bourray with outstanding support at every stage of the project, including sales, project initiation, installation and commissioning.
In 2006, when the PAPER MASTER systems were first installed on the PM1, PM3, and PM4 production lines at Le Bourray, they became more than just machinery; they served as the mill’s vigilant eyes, adept at detecting the slightest imperfections in real time. The systems have not only delivered unparalleled reliability but have also successfully adapted to the varying demands of inspecting both white and colored tissues.
François Bourdin, Managing Director of Papeterie Le Bourray.: “We have primarily gained in quality and speed of intervention for our operators. Also in case of customer complaints, we are able to review the production history to identify and qualify the detected problem.”
Renowned for engineering systems that elevate product quality across diverse industries, ISRA VISION not only provided equipment but also a promise to safeguard Le Bourray's reputation through advanced defect detection. ISRA VISION inspection systems, celebrated for their robustness, are ideally suited to thrive in the demanding environments of paper production characterized by high humidity, temperature variations, and dust. The continuous monitoring offered by these systems is an invaluable tool for operators, enabling immediate alerts in the event of any defects. This capability allows operators to quickly assess and respond to issues, deciding whether to halt the machine or continue production, thereby enhancing the diagnostic process and significantly advancing process analysis. This proactive approach in anticipating and resolving production challenges underscores ISRA VISION's role in improving operational responsiveness and maintaining high-quality standards at Le Bourray.
CUTTING-EDGE INSPECTION SYSTEM
This partnership included cutting-edge web inspection sytem that revolutionized Le Bourray's operational capabilities. The Web Inspection System (WIS) from ISRA VISION conducts a 100% inspection of every tissue sheet produced on the line. Equipped with the industry’s fastest highresolution cameras and advanced image processing technology, it detects and classifies even the smallest defects at speeds exceeding 3,000 meters per minute. This capability has been instrumental in maintaining Le Bourray's commitment to high-quality outputs, ensuring that each product meets their stringent standards.
Additionally, the robust inspection capabilities of the WIS set a solid foundation that could be effectively coupled with technologies like the Web Break Monitoring (WBM) System. WBM, bolstered by the unique IntelliCam technology, monitors the production process for web breaks and other critical disturbances. These ruggedized cameras provide real-time, crystal-clear images that allow for quick diagnostic and corrective actions, reducing web breaks by up to 50%. This reduction not only minimizes downtime but also enhances overall productivity and efficiency on the production floor.
Johnny GAIGNON, Automation Manager of Papeterie Le Bourray: “The machine operators use the system. It is well-regarded internally. We understand that it needs to continue evolving to achieve new performance targets that we defined together (Paper Master M4 WIS replaced in 2024 and Paper Master M3 WIS replacement planned in 2025)."
STRATEGIC IMPACT AND LASTING BENEFITS
This blend of technological innovation and operational enhancement provided by ISRA VISION’s PAPER MASTER systems not only underscores the narrative of a successful partnership but also highlights the tangible benefits of integrating advanced machine vision technology into traditional papermaking practices. The integration of the systems revolutionized Le Bourray's production processes by providing real-time, reliable defect detection, which significantly reduced scrap rates and improved the overall quality of the tissue paper. The once elusive defects were now clearly visible on the inspectors' screens, allowing for immediate adjustments. The ability to quickly respond to and diagnose defects has led to a dramatic decrease in customer complaints and an increase in production efficiency.
The economic impact of these systems is also noteworthy. By implementing the complete inspection suite from ISRA VISION, Le Bourray has realized significant cost savings— they don’t measure precisely their cost saving but it could go up to 500,000 euros annually for some paper machines—stemming from reduced defects and improved efficiency during the slitting and winding processes.
Le Bourray: “With the support of ISRA VISION, we created a classification system that meets our requirements. As the tool is very user-friendly, we have gradually refined this classification over time.”
Over the years, the partnership has deepened, underscored by the system’s reliability and the continuous support from ISRA VISION. The systems, having been operational for over 18 years, are not just tools but pillars of Le Bourray’s commitment to quality. This long-term reliability is rare in the rapidly evolving technological landscape and speaks volumes about ISRA VISION’s commitment to their partners. Quantifying the success, Le Bourray noted an improvement in operational responsiveness and a reduction in downtime, directly attributable to the advanced capabilities of the ISRA VISION systems. This not only bolstered their reputation among global paper converters but also solidified their position as a leader in quality tissue production.
A FLOURISHING COLLABORATION
Celebrating a partnership that has spanned two decades, both Le Bourray and ISRA VISION keep exploring future enhancements. The systems on PM3 and PM4 continue to deliver exceptional performance, with plans for ongoing updates (system in PM4 already replaced in december 2024, PM3 will follow in the end of 2025), highlighting that the journey of innovation is far from complete.
As the partnership moves into its third decade, plans to expand the system to accommodate the INFINITY recycled tissues and KALEIDO colored tissues are underway. Reflecting on the enduring relationship, Le Bourray appreciates ISRA VISION's solution-oriented approach and proactive support. ISRA VISION reciprocates this sentiment, highlighting the successful adaptation of their systems to the challenging environment of tissue production, a testament to their commitment to customer-centric innovation.
And the last words from Le Bourray, “We have had a long-standing partnership of 20 years with ISRA VISION. We value their solution-oriented approach, support, and collaboration.”
About ISRA VISION
ISRA VISION is a leading provider of technologies for industrial image processing (machine vision). As part of the Atlas Copco Group, a global leading provider of sustainable productivity solutions, we offer an extensive range of solutions for surface inspection, robot guidance and automated metrology. With around 1,200 employees, we supply customers in 16 markets and in a wide range of industries. Headquartered in Darmstadt, Germany, we deliver value to our customers through a global organization under the ISRA VISION, Perceptron and QUISS brands.
