Published 06-04-2021
| Article appears in April 2021 Issue

AI to boost paper production speed and efficiency

06-04-2021
rolled up cardboard

A unique AI-based lighting technology that enables detection of previously invisible print-critical defects is set for its first installation.

Paper industry automation and technology specialist Valmet will deliver its IQ Web Inspection System (WIS) to leading European container board manufacturer Progroup’s paper machine PM2 in Eisenhüttendstadt, Germany.

Previous Velmet installations were part of the PM2 machine’s latest world record. PM2’s last 24-hour world record of 1,751 m/min was set in 2019. During the record run, the 10.85-metre-wide PM2 produced corrugating medium at a basis weight of 80 g/m² with an overall efficiency of 94 percent, adding a seventh world record to the PM2 machine’s overall tally

Karl Achleitner, Progroup senior vice president, operations paper, says, “We selected Valmet’s machine vision system because it provides the most advanced technical setup on the market. By using artificial intelligence, we are consistently continuing Progroup's strict digitisation course.”

The Valmet IQ Web Inspection System (WIS) technology involves 53 intelligent 8K dual-line TDI cameras, fully controlled powerful multibeam LED lighting and cutting edge image processing and classification. 

This provides the information needed to track down the origins of web defects and increase production quality and efficiency. The result is a fibre-based product that meets the highest standards for visual quality, printing performance, and high efficiency converting. The IQ Web Inspection System enables operators to quickly shift their focus to specific quality problems.

Central to the system is the Valmet Industrial Internet (VII) providing the ability to combine data from multiple platforms in the mill. This constitutes a step change in web inspection analytics. Coupled with Velmet DNA – a single Distributed Control System, this system means that – rather than fixing problems after they have occurred – users can make pre-emptive changes in machine operation to maximise product quality and machine efficiency. 

The new system also includes a winder control package to take the fullest advantage of the new web inspection capabilities.

“This is the most comprehensive machine vision order we have received, with web inspection and web monitoring fully integrated into the Valmet DNA Automation System. For the first time, the Valmet Industrial Internet enables the real-time combination of WIS data with other process and quality system information to radically improve problem solving efficiency. With advanced data processing, defect and anomaly prediction is vastly improved and changes or interruptions to production can be reduced more effectively,” says Marko Toskala, director, quality management systems, automation, Valmet.

 

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