Save up to 500.000 € annually with a complete inspection system
In today´s paper, board, and tissue production, web breaks and a range of other substrate defects present a significant issue in all types of paper machines, coaters, and converting operations. Reducing breaks and paper defects is an important objective given the increasing speed and operating complexities of the present production environment.
ISRA´s complete set of camera-based web monitoring and inspection systems covers the whole process chain from pulp to reel. In addition, our systems and software solutions help to optimize the entire production chain – from headbox to the ultimate delivery of the manufactured product to the customers. This complete inspection setup enables manufacturers to significantly reduce costs caused by avoidable web breaks in the slitting and winding process, while accurate defect reports for each cut roll offer 100% production documentation.
Typically, savings of 500.000 €/annum can be realized by implementing the complete inspection suite that consists of a Web Break Monitoring (WBM), Web Inspection System (WIS), Converting Control System (CCS), Unwind Control System (UCS), Paper Master Software and E PROMI Paper Quality Management.
Web Break Monitoring System (WBM)
All installed components in a paper machine are exposed to harsh environments with dirt, moisture, and high temperatures in which optical-electronic devices operate very delicately. On top of that, a reduction in maintenance costs is always a welcome addition.
To withstand these environmental conditions and minimize exposure, ISRA WBM System utilizes a special housing for the high-performance camera for web break analysis that always guarantees perfect image quality. Even the smallest details become visible with the camera so that faults can be automatically detected early in the development process and stopped in time before costly events occur.
Web Inspection System (WIS)
The Web Inspection System (WIS) captures high-resolution defect images over the full web width even at the highest web speeds with high-speed line cameras - or area cameras - and innovative lighting technology. For such a WIS systems, even though paper is mostly monochrome, the use of color cameras in the paper machine provides advantages. The classification gets a significant boost as low contrast defects cannot be detected by black-and-white cameras and would most likely be missed. Plus, It´s now possible to distinguish between an oil and a water drop - a certainly important feature for error source analysis.
Converting Control System
To reduce web breaksand costs in the further processing of tissue products, the Converting Control System (CCS) detects surface defects logged by the inspection system on the Tissue machine. At double-width tissue machines, an additional middle-cut detection, inspecting the quality of the edges along the cut is done, and the production data is stored for later processing and retrieval. The CCS enables synchronization of the defect positions on the different layers. The layer-independent defect position to control the speed of the converting line is then transmitted by the CCS. Thus, web breaks will be drastically reduced in tissue converting lines.
Unwind Control System - Laser Marker
To achieve an exact position synchronization between the defect database of the jumbo-reel, the application of a length code along the edge of the paper web is used. To date, length codes have been applied with conventional inkjet marking systems that cause costs due to regular cleaning, and high consumption of ink.
In addition, possible ink contamination of the substrate can occur, leading to customer complaints. ISRA´s UCS Laser Marker overcomes these limitations by using an absolutely safe and reliable laser-based length code marking system with maintenance and consumables costs that are almost zero. In addition, distances between the individual length marks can be drastically reduced, and laser-based marking systems are suitable for nearly all paper grades.
Paper Quality Management System makes the difference and connects the dots
A WBM or WIS cannot achieve the level of optimization without the software that connects all the bits and pieces of information gathered from sensors and cameras. PAPER MASTER 4.0 is the first browser-based platform for surface analysis to access the data of the ISRA system from anywhere, whether it be directly at the production line, in a meeting room, or on the road, by simply using mobile devices such as a tablet or a smartphone.
PAPER MASTER 4.0 combines all data from the ISRA inspection and web break monitoring systems, the slitter and winder control, with all the software modules, in our paper quality management system on one browser-based platform. A new, modern, and intuitive user interface makes data access even easier.
Automatic surface inspection is a major building block for Industry 4.0
Optical inspection systems, available for all kinds of materials from board to tissue, can make a significant contribution to increasing profits and customer satisfaction. This is not limited to only a single paper machine but, with modern cloud solutions in a network, for an entire worldwide production. The greatest savings potential can be realized from the reduction of the number of web breaks. Even a 20% reduction saves an enormous amount or increases the output of a paper machine.
- Reduce web breaks by at least 50% with the Best performing unified system (WIS / WBM / UCS)
- Detect even the tiniest defects in the µm range at web speeds of up to 2,000 meters per minute.
- Sustainable process stabilisation to reduce your carbon foot print
- Integrated inspection solution from wet to door
- Edge cracks
- Formation defects
- Coated/Uncoated Graphical Papers
- Coated/Uncoated Speciality Papers
- Fluting / Testliner / Top Liner
- Coated Boards
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