COMPLETE TISSUE PRODUCTION IMPROVEMENT SYSTEM Improving Tissue & Converting Machine Efficiency by detecting Defects, reducing Web Breaks and creating Value Don t miss what you can t see! Reduce web breaks Increase yield Stabilize your process Escalate your quality level Minimize manufacturing costs Maximize profit Total Machine Efficiency Improvement (TME) Key Capabilities Slow the converter for specific defects to prevent breaks & alleviate production bottleneck at converting (Unwind Control) Classification: Position, frequency & severity of defects created by the tissue machine (100 % Tissue Inspection) Determine where the defects originate (100 % Tissue Inspection with Web Break Monitor) Identify root cause of sheet breaks (Web Break Monitor) Web Break Monitoring (WBM) 105 124 112 122 122 172 101 Decrease sheet breaks. Improve machine efficiency 86 95 89 85 94 WBM recording for precise root cause analysis Reduce defects being sent to converting Reduce sheet breaks on tissue machine Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Unwind Control System (UCS) Eliminate sheet breaks at converting. Increased efficiency. Web Inspection System (WIS) Significant reduction of defects on the tissue machine 100 % Inspection: High resolution images & specific classified defects Low total cost of ownership & installation no cleaning issues with lighting & consistent image quality 100 % Inspection, defect mapping & defect classification at the tissue machine transferred to converting Database storage of all reel data Data transfer to UCS to automatically slow converter for pre-classified slow down type defects Consistent Image Excellence at ~ 5,750 fpm TME ~ 2.5 % improvement value > $ 900K USD 12 months
Title: Tissue & Converting Machine Efficiency Improvement System Pete Angle, ISRA Abstract: A significant opportunity in tissue production is to increase machine speeds and reduce downtime due to sheet breaks and improve production efficiency in converting. The solution is comprised of 3 parts and each part alone provides a limited value to improve tissue production capability. The sum of the parts results in a compelling and synergistic approach to considerably improve and benchmark a mill s performance. The three components of the system are integrated into a single solution. The solution drives the implementation of each system component within the mill for improved total machine efficiency. Having only one component of the solution reduces the value and significance of the other components, allowing the possibility of not realizing the full value of the complete solution. The solution s value is improving tissue machine and tissue converting efficiency, including off machine tissue quality. The full system accurately communicates, across the tissue mill production, transferring knowledge of how specific process adjustments improve quality with objective and quantifiable data. The complete tissue production improvement system cultivates corporate understanding of where investments and resources can be directed for final product quality and overall equipment efficiency. Outline: The key capabilities of the system: Slow the converter for specific defects to prevent breaks at converting (Unwind Control) o The Unwind Control System allows the operator to slow the converter speed as a defect that could cause a break enters the machine. The converter operator will select the reels and view a combined reel map of the reels at the converter. He can view the defect images and add or delete slow down defects. The Web Inspection System can pre-classify defects as slow down defects. The unwind will automatically slow down for these defects, after they pass, the Operator can speed up the machine. The marking system on the tissue machine and part of the Tissue Inspection System enables the reels to be synchronized so that the reel maps match. The synch marks applied during inspection are read at unwind of the reels at converting. The Operator selects reel numbers from the PC terminal and reviews the defects. As the reels unwind, the next slow down defect image and its location is displayed. To reduce the number of defects that have to be reviewed by the Operator, a filter can be applied to show only the defects of interest. The conversion process will quickly conclude with higher certainty which defects can be ignored and which ones should be slow down defects. This knowledge can then be transferred to the Tissue Inspection
System to classify slow down defects accurately as they are detected on the tissue machine. Classification of defects created by the tissue machine (Tissue Inspection) o The Tissue Inspection System on the tissue machine will detect and classify defects and creating a reel map showing the location of each. Repeating defects can be immediately alarmed and eliminated/fixed at their source. Accurate classification provides full understanding of the types of defects that are occurring and allows objective feedback as the process is changed. Specific defect types can be closely monitored and reduced. Process upsets are immediately recognized and action can be taken quickly. Trends can be monitored and preventative measures can be implemented to reduce defects. Simultaneously, the Tissue Inspection System will use an edge marker to apply a synchronization mark on the edge of the sheet to match and synchronize the reel maps and control the converter to slow down at the appropriate time. The Tissue Inspection System is located near the reel on the tissue machine and provides a high resolution image and automatic classification of each defect. Determine where the defects originate (Tissue Inspection with Web Break Monitor) o The Web Break Monitoring System is integrated with the Tissue Inspection System as part of the complete solution system. The Tissue Inspection System triggers the upstream Web Break Monitoring cameras to record video when a large defect is detected or when a specific defect type requires analysis of where it is originating on the machine. The Web Break Monitor will show where specific defects originate or where they are born on the machine so they can be quickly and easily corrected. Determine root cause of sheet breaks (Web Break Monitor) o Defects that cause sheet breaks do not reach the Tissue Inspection System, so the Web Break Monitor also records video whenever there is a sheet break. The video will show the cause and the location in the sheet where the break started. Knowing the cause of sheet breaks results in action/fixes to reduce further breaks. The Web Break Monitor cameras are positioned at critical and strategic positions along the tissue machine to continuously monitor these points. Integration with the Tissue Inspection System with its accurate classification and high resolution imaging capability identifies the defect with certainty. The end result, when combined with Web Inspection, is an easier ability to reduce defects at their source quicker by knowing what the defect is and where it came from on the machine.
Case Study I: IntelliCam Test Report Holes o In general, TM had 50-70% more holes vs. ZZZZ MP1 where our team conducted tests o Holes were concentrated in the 50 cm from the edge: On the half sheet view, no repeated holes were detected in the center of the sheet. However, especially the area within 10 cm of the edge had many pinholes and larger holes o ~30-40 % of the holes were also detected on the Yankee cylinder, before the creping blade Chemical / pigment spots o Continuous chemical or pigment spots were detected at the pressure roll and at the creping blade o Normally these spots are coagulated spots of fillers bound with chemicals (retention aid, etc.). TM does not use filler in the furnish though, for that reason our team recommended analyzing the chemical composition of the spots in the lab and correcting the issue as the spots could stick to the cylinder, causing breaks. Image quality and results of future system o The purpose of the test was to show the smallest possible details IntelliCam could detect on a fast machine. From the images we could even see fiber clumps in the sheet and 1 mm holes Results & recommendations: o The amount of holes on the product from the machine is rather high: a 2 camera WIS system recommended actions, lowering the amount of repeated holes and showing all run ability defects as a map. On a similar machine, over 50% reduction in the number of holes was achieved. o 5-camera WBM system recommended actions to reduce breaks. Standard break reduction is greater than 50% giving project ROI of less than 3 months. Recommended positions: 4 x pressure roll, 2 x creping blade, 1 x reeler
Pinholes: image 1 Edge Crack: image 2
Pinhole Burst: image 3 Repeating Holes: image 4
Chemical / pigment splash: image 5 Chemical / pigment splash after creping: image 6
IntelliCam: one camera for - WIS, WBM, and UCS HD + 2048 x 1088 pixels Light type: Strobe LED synchronized with camera exposure at frame rate Material AISI316, 20x20x30cm, weight 8 kg Single housing for camera and lights Strobe light lifetime up to 25 years Vortex cooling and thermo-insulation Industrial wiper/washer or air/brush Housing: Compact stainless steel housing built to accommodate digital camera, strobe LED light unit with dry brush or wet wiping self-cleaning technology to ensure superior imaging in the harshest environments. The all in one design allows for lower installation cost and smaller form factor for optimized positioning ad viewing of the critical locations of the tissue machine. Housing specs: - Dimensions & weight: Rugged and compact housing 10 Kg (22 lbs) Harsh Environment Protection: IP65 with AISI316 Stainless steel housing Insulation & heat resistance: Up to 70 C ambient temperature w/optional vortex cooling to 120 C. Cleaning: air purge with brush wiper or water jet washer with wind screen wiper. Wiper/washer designed for extreme locations and wiper lifetime is up to 12 months of continuous operation. Cleaning frequency every 3-60 minutes depending on location Mounting bracket: 2-piece stainless steel mounting bracket Connections: Air only or air and water for water washing. Cabling LAN Cat 6e or Cat 7 to for image transfer and one power cable (48 VDC).
Case Study II: Total Machine Efficiency Improvement A mill reported a Total Machine Efficiency (TME) improvement of ~ 2% as a direct result of their latest PaperMaster Tissue System implementation. Based on their QCS report below and monthly average production yield, we calculate the TME savings translates to ~ $ 900,000.00 USD/first year PaperMaster Tissue in service. Total # of Break Events (Former to Reel)
Minutes/Break Events (Excluding Threading Time)
Speaker Information: Pete Angle I have a background in sales with a concentration in vision and camera systems, industrial equipment, process automation, and systems integration. The bulk of my professional sales career, 20 years, has been in camera and vision system technologies for industrial applications. As a Paper Account Manager for ISRA VISION, I promote and sell PAPERMASTER Process Improvement Systems for the Paper, Pulp, and Tissue Industry of North America. Before coming onboard with ISRA, I was the European Sales Manager for 20/20 Hindsight and worked with food and beverage, pharmaceutical and medical devices, beauty care, baby care, and other global consumer products manufacturers. In the industrial equipment market, I was a Sales Engineer for Carotek Inc. representing their Mechanical Products, Systems Integration, and Mechanical Integration Divisions. My start in camera system technologies began as a Key Account Manager for ECS. He has managed key accounts and developed new partnerships in tissue, packaging, pulp, paper, and converting industries. I encourage the sharing of knowledge and experience to develop effective and valuable partnerships to meet and exceed the customer s goals.
Complete Tissue Production Improvement System Improving Tissue & Converting Machine Efficiency by Detecting Defects, Reducing Breaks, and Creating Value 1
Total Machine Efficiency Improvement (TME) Increasing converting machine throughput by reducing sheet breaks at converting with unwind control system (UCS) Reducing defects on the tissue machine with web inspection system (WIS) Improving tissue machine performance by reducing sheet breaks with web break monitoring (WBM)
Key Capabilities Slow the converter for specific defects to prevent breaks and alleviate production bottleneck at converting (Unwind Control) Classification, position, frequency, and severity of defects created by the tissue machine (100% Tissue Inspection) Determine where the defects originate (100% Tissue Inspection with Web Break Monitor) Identify root cause of sheet breaks (Web Break Monitor)
Unwind Control System (UCS) Increasing converting efficiency by reducing sheet breaks at converting 100% Inspection, Defect Mapping, & Defect Classification at the tissue machine transfered to converting and Database storage of all reel data Transfer of data to unwind control system to automatically slow converter for preclassified slow down type defects
Web Inspection System (WIS) Reducing defects on the tissue machine with web inspection system 100% Inspection high resolution images and specific classified defects Low total cost of ownership and installation no cleaning issues with lighting and consistent image quality
Web Break Monitoring (WBM) Improve machine efficiency by substantially decreasing sheet breaks WBM recording for precise root cause analysis Reduce defects being sent to converting Reduce sheet breaks on tissue machine
Consistent Image Excellence Quickest Exposure NO blurry image Self Cleaning Light and Lens all in one design HD+ camera and high intensity synchronized LED light Exceptional Light Sensitivity Consistent crisp image quality Exact Defect Identification, Exact Root Cause Analysis, and Precise Reel Mapping
Case Study Tissue Machine Test Report Edge Crack: image 2
Case Study Tissue Machine Test Report Repeating Holes: image 3
Case Study Tissue Machine Test Report Chemical / pigment splash: image 4
Case Study Tissue Machine Process Disturbances Holes In general, TM had 50-70% more holes vs. ZZZZ MP1 where our team conducted test Holes were concentrated on the 50 cm area from the edge: In the half sheet view, no repeated holes were detected in the center of the sheet. Especially the area within 10 cm of the edge had many pinholes and larger holes ~30-40 % of the holes were detected also on the Yankee cylinder, before the creping bladechemical / pigment spots Chemical / pigment spots Continuous chemical or pigment spots were detected at the pressure roll and at creping blade Normally these spots are coagulated spots of fillers bound with chemicals (retention aid, etc.). TM probably does not use filler in the furnish though, for which reason our team recommends analyzing chemical composition of the spots in the lab and correcting the issue since the spots could stick to the cylinder, causing breaks.
Case Study Results & Recommendations The purpose of the test was to show smallest details IntelliCam can detect on a fast machine. From the images we could see even fiber lumps in the sheet and 1 mm holes WIS system recommended to detect very small defects not causing sheet breaks for root cause analysis with WBM and show all defects as a map. On a similar machine, over 50% reduction and holes can be achieved. 6 - camera WBM system recommended to reduce breaks. Standard break reduction >50% giving project ROI <3 months. Recommended positions Felt to Yankee transfer TS & DS, Yankee exit Creper Blade TS & DS, Reel TS & DS for turn ups, and one mobile HD+ Intellicam for mill wide troubleshooting or integration into fixed WBM with Defect Detection at all locations. UCS system for production improvement at converting. Slow down for critical defects and eliminate bottle neck in production throughput. Increase combined total machine efficiency (TME) for tissue machine and converting process.
Total Machine Efficiency Improvement Total # of Break Events (Former to Reel) reduced 50% A tissue mill reported a Total Machine Efficiency (TME) improvement of ~ 2% as a direct result of their latest system implementation. Based on their QCS report below and monthly average production yield, TME savings translates to approximately $ 900,000.00 USD/first year system in service.
Tissue & Converting Machine Efficiency Improvement