Paper Technology International 2024 - Journal - Page 16
PAPERTECHNOLOGYINTERNATIONAL
Figure 2: Overview of the defect count and defect classes
But big data and industry 4.0 are not limited to the
production as another example is the use of Big Data analytics in
forestry operations to evaluate the growth and volume of harvestable
trees for wood supply. Big Data analytics will become widely popular
in all phases of the paper and board value chain during the next ten
years.
Recyclability is becoming more of a key requirement for
昀氀exible and rigid consumer packaging products. When entering
recycling streams many traditional waterproo昀椀ng and oil/greaseproo昀椀ng barrier coatings are hard to remove economically and can
lead to such packs being sent to land昀椀ll. This is also the case when
talking about the migration from plastics or undissolved ink particles
into the pulp of recycled 昀椀bre. This creates a signi昀椀cant potential
for new ways to reuse this recycled material for new products, such
as recyclable barriers. And of course, one of the biggest drivers
disrupting the current market situation as well the future market is
the need to signi昀椀cantly reduce energy costs and at the same time a
dramatic reduction of your ecological footprint.
Keeping these driving forces in mind, ISRA VISION has
developed a complete set of camera-based web monitoring and
inspection systems covering the entire process chain from pulp to
reel. In addition, our systems and connected software solutions
help to optimize the entire production chain – from headbox to the
ultimate delivery of the manufactured product to the customers –
being the go-to production analytics hub with the paper mill.
Inspection system
Optical systems can help companies on their way to a
production increase in a sustainable way. Inspection systems are
specialized not only to 昀椀nd all kind of surface defects but also to
classify each defect using the latest AI-based classi昀椀cation methods
like deep learning and neural networks. Having this information
available for the next production or 昀椀nishing steps, gets the mill
operation closer to a full circular quality inspection system – helping
to avoid surprises as all defects can be tracked down to their origin
and in what process step they were created. In addition, operators
will learn more about how inspection and extracting de昀椀ned sections
of produced products in any processing or treatment step will not
only reduce waste and lower the carbon footprint, but will also
increase the pro昀椀t at any step within the value-added chain.
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Connecting optical quality data in all the different production
stages is done in three steps:
•
Inspect the material to collect quality data
•
Distinguish what is of relevance for quality grading
•
Correlate this information with other data and of course
hand it over with the product further down the process
chain.
Surface quality data and classi昀椀cation
Optical Inspection Systems are a known tool to not only
昀椀nd process disturbances and gather information about the quality
of the raw or input material but also to get immediate feedback of
the produced quality. Inspection Systems are nowadays located
in all production steps so that relevant production speci昀椀c defects
are recognized. After the recognition or detection of a defect the
next step is the correct classi昀椀cation of this defect. Today arti昀椀cial
intelligence methods automatically assign the detected defects
to individual classes. The usual time-consuming, and error-prone
training of the classi昀椀er by the operator is eliminated. This is a
milestone in defect classi昀椀cation and already surpassed what
humans can achieve regarding speed, consistency and quality.
The system operator can now concentrate on their main task: the
Production of Paper.
Process Control
A key driver for using optical inspection and monitoring
systems is process control. Connecting Information (quality and
process) from different lines in the mill-wide system allows gathering
of status of components as well as the most important quality data.
This can be displayed together with the production data and gives
an operator or plant manager easy access to the respective system
status data of the individual components like the ISRA VISION web
inspection and web break monitoring system. Users can thus see
possible causes for emerging problems and prevent faults through
targeted intervention or predictive maintenance.
Tracking of quality Data
Optical inspection systems, available for all kinds of
materials from board to tissue, make a signi昀椀cant contribution to
increasing pro昀椀ts and customer satisfaction. All this not only for one
single paper machine in one selected mill, but with modern cloud
solutions in a network for the entire, worldwide production. A reject
