Effectively solving tissue production and converting problems using event capturing camera systems
by Martin Rempel, Scott Delzer, Kari Hilden, Papertech Inc. - Papertech Inc.
Martin Rempel Scott Delzer Kari Hilden
Papertech Inc. Papertech Inc. Papertech Inc.
Hamburg, Germany Greenville, WI, USA Vancouver, Canada
Increasing demands for operator safety, faster production speeds and enhanced product quality make it imperative to have visibility of all your production processes. High resolution cameras and comprehensive event capturing software not only deliver full visibility, they provide you with the opportunity to address issues at their root source, allowing you to maximize product quality and machine efficiency without jeopardizing operator safety.
Full visibility into all production processes is fundamental to the overall success of any tissue operation and yet most operators are not able to answer a resounding “yes” to the following questions.
- Can you safely see inside your tissue machine and converting line?
- Do you have an immediate means of visually capturing an unwanted event in your process to find its root cause?
- Do you have a means of viewing video from the past 24 hours (or more) of process?
These questions can be answered with a “yes” if you have installed a high speed and high resolution event capturing camera system that is fully integrated into the process of operating your machine.
Simple visibility can be provided through any surveillance system. However, full visibility, with automatic event analysis and continuous troubleshooting, together with accurate same piece of paper synchronisation benefits, can only be achieved through advanced event capturing and web inspection systems, such as Papertech’s WebVision®Digital & WebInspector® solutions. The motivators that warrant an investment in such solutions are:
- The need for efficient high quality production
- Excessive process interruptions – Do you experience frequent web breaks? Would solving the root cause of the break improve your bottom line? Web break footage can be acquired by an event capturing system through strategically located cameras – each synchronised to ensure rapid root cause analysis.
- Product quality problems – Have you experienced issues in your converting operation as a result of an unacceptable number of product defects in the finished reel? An advanced event capturing system with web inspection capabilities can map and classify defects. Together with additional critically located cameras, the system can often show the defects’ root causes.
- Eliminating converting bottlenecks
- Operate with knowledge of incoming product quality – If you could make an advanced decision on how to run your machine based on the quality of the incoming product, would you save a significant amount of time and money? Would you be able to increase your quality output by running reels of lesser quality product as middle plies on a multi-ply re-winder? These efficiencies can be achieved through accurate reel quality maps – provided by a web inspection system. Additionally, converting lines can employ a single camera from an event capturing system to map incoming product quality to assist in accepting or rejecting product.
- Excessive process interruptions – Are your process engineers presented with increased challenges and production stoppages due to abnormalities in complex converting sequences?A typical re-winder may experience process interruptions due to faulty transfers, improper web tensioning, poor web quality, embossing, laminating, perforating, log formation, bounce and improper core insertion. An event capturing system is the only solution for capturing these events for slow motion playback and root-cause analysis.
- Ensuring a high quality end product – Can you ensure your end product meets your customer’s minimum requirements? Without knowledge of incoming product quality and the ability to measure quality parameters, the end product is often packaged in the “good faith” that it meets customer quality requirements. However, top tier converters have started rejecting product based on base sheet flaws and monitoring other quality factors using event capturing systems.
These are just a few examples of how event capturing systems can meet the needs of tissue producers and converters.
Your event capturing solution investment will typically provide the quickest payback and provide the largest return on investment under the following scenarios.
1. Rapid and efficient start up of a new tissue/converting machine
Visibility and proof of commissioning problems will ensure your new machine is up and running as fast as possible. The return-on-investment is achieved by being able to rapidly find out where breaks are occurring and why, as well as finding the sources of quality issues that result in breaks in the converting lines.
2. Improving the performance of an existing machine
Rebuilding or re-purposing an existing machine for a change in product output and quality poses similar challenges as commissioning a new machine. Also any machine that is production-limited can often benefit from an event capturing solution that provides the ability to resolve unwanted process interruptions. For an example return on investment see Figure 7. Also Figure 8 shows another results summary example on the tissue mill reported results.
3. Conforming to new safety and operator training regulations – machine guarding
Many operators are faced with decreased or often completely restricted visibility of their machines as a result of newly implemented safety guarding measures. An event capturing solution can not only restore operator-machine visibility, but can also enhance it to levels otherwise unattainable.
High speed camera technology for both event capturing and defect analysis has a clear return on investment for both tissue machines and converting lines. Proof of this acceptance is the rapid growth in system installations by large tissue producers such as Georgia-Pacific, Kimberly Clark, Procter and Gamble and SCA – each having heavily invested in event capturing technology.
Web inspection defect detection reel map page showing defects that have been detected, their location in the reel, and a close up image of highlighted defect
High speed event capturing camera system log burst captured!
Web inspection shows a reel map with a diagonal defect row starting at 150,000 feet and ending at 230,000 feet alerting the operators to a nick in the moving doctor blade.
High speed event capturing camera system software page with multiple tissue machine images synchronized to the same piece of paper allowing rapid diagnosis of the root cause of the problem.
Figure 7, shows a tissue mill reported result after installing a 5 camera system on an existing machine:
Figure 8, shows a tissue mill reported actual results following project performance summary review: