Web Break Monitoring, Web Inspection and Converting Control optimize production efficiency
Save up to 500.000 € p.a. with a complete inspection system
In today´s tissue production, web breaks and a range of other substrate defects present significant challenges in all types of tissue machines, converting and layering operations. Reducing breaks and surface defects is an important objective, given the increasing speed and operating complexities of present tissue production environments.
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 optimize efficiency in the entire production chain – from tissue formation 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. Additionally, accurate defect reports generated for each cut roll offer 100% production documentation.
Web Break Monitoring System (WBM) and Web Inspection System (WIS)
All installed components in a tissue 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.
In addition, the Web Inspection System (WIS) captures high-resolution defect images over the entire web width, even at the highest web speeds, with high-speed line cameras - or area cameras - and innovative lighting technology. For such a WIS system, even though tissue or paper is mostly monochrome, using 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, they would most likely be missed. Plus, color cameras make it now possible to distinguish between an oil and a water drop - certainly an important feature for error source analysis.
Converting Control System
To reduce web breaks and costs in downstream processing of tissue products, the Converting Control System (CCS) detects surface defects recorded by the inspection system on the Tissue machine. At double-width tissue machines, an additional middle-cut detection feature inspects the quality of the edges along the cut, 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 (UCS)
The flexible Unwind Control System accurately assigns defects and precisely synchronizes the defect database for each roll using a code marking applied to the web edge. This ensures that defects can be clearly assigned by location on the sheet in the next production stage, regardless of paper losses incurred in the process.
The UCS can be integrated at various points in the process, such as the reeler, the offline coating, calenders, or winder.
Paper Quality Management System makes the difference and connects the dots
A WBM, WIS, or converting system 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 remotely access the data of the ISRA system, 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.
- 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
- Process efficiency and product optimization by production analytics
- Web break monitoring and web inspection
- Web converting control
- Unwind control (UCS) for accurate defect assignment
- Paper quality management (Yield management, Production analytics, Product data optimization)
- Edge cracks
- Formation defects
- Coated Boards
- Coated/Uncoated Graphical Papers
- Coated/Uncoated Speciality Papers
- Fluting / Testliner / Top Liner
Course dates Paper Master
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Brochure: PAPER MASTER
Breaking the Limits of Automatic Surface Inspection
PAPER MASTER: The New Standard for Paper
State-of-the-art technology along the whole process chain
Webinar: Web break monitoring and web inspection
Learn how to optimize your production results and reduce web breaks by at least 50%.
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