In the paper industry, large rolls of paper are converted into smaller ones before shipping to customers. Ensuring these rolls are perfect is crucial, but traditionally, this final quality check is done by people. This can be slow, inaccurate, and even dangerous for workers who have to climb on platforms to inspect the rolls.

ECS has a new solution that uses lasers and cameras to automatically inspect paper rolls. This system can identify several issues that can affect a roll's quality, including:

• Roll face profile: The sides of the roll should be perfectly straight, and the core (the cardboard tube in the center) needs to be aligned correctly.

• Interlace roll condition: Sometimes, smaller rolls get stuck together and need to be separated before shipping.

• Roll length and diameter: Each roll needs to be the correct size according to the customer's order.

How the system works:

A laser and a high-resolution camera are positioned above the conveyor belt carrying the rolls. The laser projects a line onto the roll, and the camera captures an image of it. Software then analyzes the image to measure any deviations in the roll's profile.

Benefits of the system:

• Improved accuracy: The laser system can measure much more precisely than a human inspector.

• Increased safety: Workers no longer need to climb on platforms to inspect rolls.

• Reduced waste: By catching defects early, the system can help to prevent rolls from being wasted.

• Better quality for customers: Customers will receive rolls that meet their exact specifications

The results:

A paper mill tested the ECS system for one month. The results showed that the system was very effective at identifying roll defects. In fact, it caught some defects that human inspectors had missed.

The future of paper roll quality control:

While the current system requires human confirmation of some defects, future versions may be able to eliminate the need for human involvement altogether. This would further improve safety and efficiency in paper mills.

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