Procemex to supply web monitoring and inspection system to SCA Obbola, Sweden
GRAZ, AUGUST 12, 2024. Procemex, a new ANDRITZ GROUP member has received an order from the Swedish paper mill SCA Obbola to supply a OnePlatform Web Monitoring & Inspection System for their PM2, the world’s largest high quality kraftliner machine.
PM2, which started up in November 2022, is 9.6 m wide and has a design speed of 1,400 m/min and a production capacity of 725,000 t/y. The scope of supply also includes Automatic Target Control for the machine’s winder.
The new system will fully replace the existing web monitoring and inspection system and will be set up in the customer’s virtualized environment. It will be delivered with a comprehensive service agreement ensuring continuous 24/7 technical support and regular on-site and remote maintenance to keep it performing at the highest level. Commissioning of the system is scheduled for the fourth quarter of 2024.
The high-resolution web inspection system will have two measurement geometries: High-angle reflection for the top side of the sheet for comprehensive surface analysis and transmission web inspection for complete product quality assurance. The efficiency of the winder is optimized by Automatic Winder Target Control (ATC).
The fully integrated web monitoring system includes 34 extremely light-sensitive Procemex Lumina Supersense smart cameras and powerful Procemex Eco strobe lights. Each web monitoring camera position incorporates the latest Procemex ProClean pinhole technology, ensuring uninterrupted sheet visibility and minimizing maintenance efforts.
The modern, integrated, and high-resolution Procemex web inspection and monitoring solution will provide SCA Obbola with new opportunities and technical solutions to improve the product quality and production line efficiency.
The core of SCA’s business is the forest, Europe’s largest private forest holding. Around this unique resource, SCA has built a well-developed value chain based on renewable raw material from their own and others’ forests. SCA offers packaging paper, pulp, wood products, renewable energy, services for the forest owners and efficient transport solutions. SCA was founded in 1929 and has its headquarters in Sundsvall, Sweden.
ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. Sustainability is an integral part of the company’s business strategy and corporate culture. With its extensive portfolio of sustainable products and solutions, ANDRITZ aims to make the greatest possible contribution to a sustainable future and help its customers achieve their sustainability goals. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydropower and Environment & Energy. Technological leadership and global presence are cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 30,000 employees and over 280 locations in more than 80 countries.
Procemex Procemex is a global leader in integrated web monitoring, web inspection and machine vision systems for the pulp, paper and printing industries. With over two decades of experience, Procemex excels in designing and delivering premium systems and providing comprehensive after-sales services to ensure highest end-product quality and minimized production downtime. Procemex is a member of the ANDRITZ GROUP.
Nippon Dynawave Packaging: Superior Product Quality and Increased Uptime with Procemex Web Monitoring and Web Inspection System
Nippon Dynawave Packaging, a leading manufacturer of high-quality paperboard for cartons and cups, is dedicated to enhancing the quality of its end products. To achieve this goal, the company decided to invest in a new Web Monitoring and Web Inspection system. In 2020, they installed the Procemex Web Monitoring System, followed by the Procemex Web Inspection System for their L3 product line in 2022. The Procemex 3D web inspection solution ensures that the products from the paper machine are free from defects such as indents, outdents, wrinkles, and other by-products of the paper-making process.
Finding a Reliable Partner for Superior Defect Detection
Nippon Dynawave Packaging identified the need for a more reliable defect detection system, urging them to search for new solutions to replace their previous setup. They aimed to find a reliable system with superior defect detection capabilities to enhance the detection of wrinkles, indents, and outdents and to improve machine uptime. Quality of system support services and spare part operations were also things they evaluated in their decision-making.
Prior to choosing Procemex as their long-term quality partner, Nippon Dynawave Packaging and Procemex conducted an on-machine trial to demonstrate the capabilities of the 3D web inspection solution. The trial’s image quality and defect detection capabilities were impressive, leading to a decision to fully implement the defect detection system. The 3D Web Inspection solution with Procemex Smart Camera technology was successfully installed and commissioned in 2022, marking the beginning of a successful partnership.
Procemex’s solution stood out during the selection process for the new web monitoring and inspection systems. Its unique features, such as System Virtualization, industry-proven Smart camera technology, smooth System Integration, and reliable Service Operations, made it the best value proposal.
Accurate and Reliable Defect Detection
After the factory approval testing and training, the new system was installed at Nippon Dynawave Packaging’s board mill in Longview, Washington. With over 1,000 systems installed worldwide, Procemex leveraged its extensive experience to ensure quick and efficient system installation.
The installed system has High Angle Web Inspection and patented 3D defect detection. The advanced 3D defect detection technology enables the efficient detection of indents, outdents, and wrinkles on coated boards, ensuring that the liquid packaging board produced continues to fulfill end users’ ever-increasing quality requirements.
The fully integrated web monitoring system features today 19 Procemex smart cameras, and powerful Procemex Eco strobe LED lights. Each web monitoring camera position is equipped with the latest Procemex ProClean pinhole technology, ensuring uninterrupted sheet visibility while significantly reducing maintenance requirements.
“Our images remain cleaner and clearer. The Procemex ProClean Pinhole cameras require less cleaning and maintenance. This allows us to place these cameras in environments where other cameras would struggle, all while maintaining excellent image quality,” explains Dustin Bales, the paper machine assistant manager of L3.
Increased efficiency in Winder Operations
The implementation of the Procemex OnePlatform System has significantly enhanced the efficiency of winder operations at Nippon Dynawave Packaging. The Procemex OnePlatform system provides operators with a clear defect map, complete with exact coordinates and the type of defects accurately marked. Easy access to sharp and clear defect images gives operators a clear understanding of the nature of the defect, enabling them to make quick and informed decisions. As a result, the winder operations have become more efficient, leading to a noticeable increase in quality and productivity.
Based on accurate knowledge of the machine’s directional and cross-directional defect location, Nippon Dynawave Packaging’s winder operators can make educated decisions about whether to run the winder at full speed, slow it down, crawl, or stop the winder to patch the defect. These decisions can be made either manually by the operators or the process can be automated.
“We are very pleased with the system operation. When we tell it to stop, the winder stops exactly at the position where the defect is located. Although I can’t provide a specific metric to quantify the increased efficiency it has brought to our process, I know it is significantly higher,” Aaron Harman, the Process Manager of Nippon Dynawave Packaging’s Extruder Department, comments.
One comprehensive system for complete web monitoring and inspection
The Procemex OnePlatform solution offers a single, comprehensive system for complete web monitoring and inspection. Designed for seamless operation between web monitoring and inspection, it combines user-friendly functionality with advanced system virtualization, enabling operators to resolve issues efficiently. This unified approach enhances machine uptime and boosts overall production efficiency, ensuring smooth daily operations.
“The Procemex OnePlatform system is very user-friendly. I can access the server remotely from my laptop, troubleshoot things, and help guide operators and foremen to resolve issues faster.
Being able to select a synchronized camera view and not having to scroll through all the video footage. It helps to reduce the time to find what caused the web break,” says Dustin Bales.
Reliable Support and Service Operations
Nippon Dynawave Packaging emphasized the need for reliable support and service from the start of the project, highlighting its impact on system uptime. The comprehensive service agreement with Procemex ensures continuous 24/7 technical support and regular on-site and remote maintenance to keep the system performing at the highest level. Procemex’s commitment to responsive and proactive service has not only met but exceeded these expectations, ensuring smooth and uninterrupted operations.
“The Procemex OnePlatform System has now been running for almost two years. And they continue to support us every day. Procemex did not just come and sell us something and disappear; they have been with us every day when we have had concerns or questions, and we have been able to solve them very quickly. So far, everything has been working really well,” says Perry Brandenburg, Paper Machine Manager at Nippon Dynawave Packaging.
Oops! This video will not be shown because you have disabled the marketing cookies. To see the video, accept marketing cookies.
Detect potential problems before they become visible to traditional web monitoring system. By analyzing video footage in real-time, AI identifies and notifies operators of potential problems before they become visible to traditional web monitoring system.
AI sees edge drops very efficiently. Much earlier than traditional web monitoring cameras.
Helps to prevent web breaks very efficiently.
Saves operators’ time
AI analyses the videos real-time, pinpoints the important parts, and gives alerts to the operators
The system summarizes the relevant events in a quick and easy-to-review format. Events captured over the weekend can be reviewed in less than a minute.
Procemex to supply web inspection and monitoring system to Billerud’s Gävle mill, Sweden
Procemex, a member of the ANDRITZ Group,has received an order from Billerud to supply a OnePlatform web monitoring and web inspection system with winder and re-winder controls for the board mill in Gävle, Sweden.
This new system will replace the existing ones, enhancing reliability and performance. With this investment, Billerud will strengthen its capability to meet the highest quality needs of its liquid board packaging customers and increase its production efficiency. System installation is scheduled for the third quarter of 2025.
Procemex’s scope of web inspection includes multiple measurement geometries and technologies to efficiently detect various types of defects. High-resolution low-angle reflection and 3D defect detection will ensure effective identification of elevated defects and indents. The innovative Procemex UV light detection technology will detect even the most subtle oil defects, ensuring superior product safety for BM5’s liquid packaging board. The scope also includes high-resolution high-angle reflection and transmission detection for comprehensive product quality assurance.
Throughout the system, a total of 120 smart cameras will be provided. The fully integrated web monitoring system features 40 extremely light-sensitive Procemex Lumina Supersense smart cameras paired with powerful Procemex Eco strobe lights. Every web monitoring camera position is equipped with the latest Procemex ProClean pinhole technology, guaranteeing continuous sheet visibility while reducing maintenance needs.
The scope of supply will also include winder and re-winder control (ATC), enabling efficient and optimized winder operation.
Additionally, Procemex will provide system installation supervision, commissioning, training, and start-up support.
ABOUT BILLERUD Billerud makes high performance packaging materials for a low carbon society. Billerud is a global leader in paper and packaging materials made from cellulose fibers, and passionately committed to sustainability, quality and customer value. Billerud serves customers in more than 100 countries through nine production units in Sweden, USA, and Finland and around 5,800 employees in 19 countries. Billerud is listed on the Nasdaq Stockholm.
Billerud’s production facility in Gävle, Sweden, is a world-leading manufacturer of liquid carton for packaging of beverages and food products intended for users with very high demands on stability and printability. Material to about 200 million beverage containers (single portion) is produced in Gävle each day, which means that every fourth beverage container in the world contains liquid carton made by Billerud in Gävle.
ABOUT ANDRITZ GROUP
International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems, services and digital solutions for a wide range of industries and end markets. Sustainability is an integral part of the company’s business strategy and corporate culture. With its extensive portfolio of sustainable products and solutions, ANDRITZ aims to make the greatest possible contribution to a sustainable future and help its customers achieve their sustainability goals. ANDRITZ is a global market leader in all four of its business areas – Pulp & Paper, Metals, Hydropower and Environment & Energy. Technological leadership and global presence are cornerstones of the group’s strategy, which is focused on long-term profitable growth. The publicly listed group has around 30,000 employees and over 280 locations in more than 80 countries.
ABOUT PROCEMEX
Procemex is a global leader in integrated web monitoring, web inspection and machine vision systems for the pulp, paper and printing industries. With over two decades of experience, Procemex excels in designing and delivering premium systems and providing comprehensive after-sales services to ensure highest end-product quality and minimized production downtime. Procemex is a member of the ANDRITZ Group.
Make your Web Inspection & Monitoring Investment Future Proof
Are you protecting the value of your system investment? Conducting scheduled maintenance and system modernizations significantly extends the life cycle of the web monitoring and inspection system. Well-maintained systems help mills reduce waste and improve cost-effectiveness. Scheduled maintenance actions, reusing parts, and using the system according to user instructions extend the system’s lifespan.
Durable Systems and Seamless Upgrades
Procemex systems and software are carefully designed to ensure a long life cycle. Our unique system architecture enables effective remote support thanks to the capability of remotely troubleshooting smart cameras. This speeds up problem solving and avoids unnecessary travel. In software development, new system features and functionalities are available to all our customers, as you don’t need to buy a new system to enjoy new features. As our customer, you have the freedom to choose which new features you want to add to the existing system.
We strive to provide cost-effective new ways to enhance the system performance of our existing customers. For example, all new cameras and lights that have been developed fit existing Procemex systems perfectly, meaning there is no need to renew the entire system when using the latest camera or light technology. Additionally, we offer extensive repair services for different system parts, assuring cost-effective repairing.
Customer Collaboration
Our service offering has been developed in collaboration with our customers to support their internal maintenance and production processes. The key factors determining service success are planning, scheduling, and regularity. Additionally, continuous mill personnel training and their skill enhancement are crucial, as people may change jobs, forget what they have learned, and technology may be updated.
Investment in Life Cycle is an Investment for the Future
To achieve the best possible system performance over its lifetime, it is important to regularly maintain it, follow the user instructions, and use original spare parts. This minimizes unplanned downtime and avoids unexpected costs. Scheduled maintenance not only helps save unnecessary expenses but also improves the system’s performance throughout its lifetime. This results in cost savings by optimizing end product quality, improving machine runnability, and using raw materials and energy in a smart way.
Expense or Investment?
Investing in maintenance and the life cycle is often viewed as an expense rather than an investment for the future. We are convinced that it should be considered an investment with a clear payback. Indeed, the life cycle service guarantees the return on investment throughout the system’s life cycle.
When investing, the focus is often on choosing a system that meets performance requirements at an acceptable level and at the time the investment is made. It is difficult to anticipate all the end customer’s long-term quality-related needs. The Procemex One Platform system is genuinely future proof. System development is made in close collaboration with our customers, ensuring our system also meets evolving customer needs.
Contract-based Service for Increased Predictability and Cost Savings
Procemex has invested significant resources and expertise in its service operations to ensure smooth and efficient operation. Our global service team is dedicated to providing timely support and service, allowing our customers to focus on their core business.
Choosing a contract-based service can be very beneficial, as it provides professional support when necessary. It also brings increased predictability and helps in scheduling maintenance. With a service contract, you can avoid maintenance cost peaks and ensure that your systems are always in top condition, providing peace of mind and cost savings in the long run.
Data security is a big concern today and is an essential part of Procemex’s life cycle services. With a service contract, the Procemex applications are regularly updated, and your system is safe from external threats.
Author: Ari-Pekka Räisänen, Director, Customer Service Projects and Product Development
Read Next
Remote Services
Remote Services allow you to solve your web inspection and web monitoring system problems anywhere, and at any time. As our client, your mills will maintain a high performance and receive a quick response in the event of a system failure.
Today, most problems can be solved remotely (over 90 %). Whether you experience unexpected issues with your system or you would like to have an overall review of the system’s current functionality or wish to receive remote audit-based development suggestions from our specialists, we are here for you.
Integrated Web Monitoring and Inspection System – Procemex One Platform
Procemex OnePlatform, is an Integrated Paper Web Monitoring and Paper Web Inspection system. OnePlatform is designed for analyzing paper web breaks and paper defects in one integrated system. This makes it easy for operators to understand the inter-relations between web inspection and web monitoring and move flexibly between the ‘two systems’. Understanding the real root causes for paper defects and web breaks created in the dryers, in the press, and in the forming section has never been easier.
Higher Customer Satisfaction and Line Efficiency with Procemex Web Monitoring and Inspection System
In the pursuit of achieving supreme customer quality requirements, Metsä Board Äänekoski found itself at a crossroads. The need to enhance the Web Inspection and Monitoring capabilities had become vital, driven by the solid commitment to excellence. After thorough research and planning, the path ahead became apparent, and Metsä Board Äänekoski embarked on a transformative journey with Procemex.
Procemex to supply web monitoring and inspection system to SCA Obbola, Sweden
Procemex, a new ANDRITZ GROUP member has received an order from the Swedish paper mill SCA Obbola to supply a OnePlatform Web Monitoring & Inspection System for their PM2, the world’s largest high quality kraftliner machine.
PM2, which started up in November 2022, is 9.6 m wide and has a design speed of 1,400 m/min and a production capacity of 725,000 t/y. The scope of supply also includes Automatic Target Control for the machine’s winder.
The new system will fully replace the existing web monitoring and inspection system and will be set up in the customer’s virtualized environment.
JYVÄSKYLÄ, 4.6.2024. Procemex has been acquired by the international technology Group ANDRITZ. This strategic acquisition marks increased service availability, operational readiness and further strengthens the portfolio of smart- camera-based solutions.
Photo: Mika Valkonen and Stephan Keuschnigg-Zingl
Procemex’s smart camera-based solutions help customers ensure product quality and minimize costly production downtime. With over 20 years of industry experience, Procemex has delivered over 1,000 systems and over 20,000 smart-cameras to customers worldwide. Procemex team consists of more than 100 vision system experts and operates from Finland and subsidiaries in Germany, Japan, and the US.
Procemex operations will continue under the current leadership as well as under the strong product brand of Procemex for Vision System products. Mika Valkonen, the CEO of Procemex says:” We see that this enables Procemex to strengthen its global market leader position in those geographical areas that have not been so strong earlier. ANDRITZ local sales and service presence enhances our capabilities to offer systems with full life cycle services virtually in every part of the world.”
Jarno Nymark, ANDRITZ Executive Board Member responsible for the Pulp & Paper business area, says: “Procemex’s advanced solutions perfectly complement our product portfolio for improving plant operations in the pulp and paper industry. Machine vision systems are a fundamental building block for plant autonomy. We look forward to welcoming the Procemex team to ANDRITZ and working together to provide the best customer support.”
About ANDRITZ ANDRITZ is a globally leading supplier of plants, equipment, automation solutions and services for hydropower stations, the pulp and paper industry, the metalworking and steel industries, as well as environmental and green energy-focused sectors. The listed Group is headquartered in Graz, Austria. ANDRITZ has around 30,000 employees and operates in over 80 countries with 280 locations worldwide.
About Procemex Procemex is the global leader in vision business in pulp and paper industry, specialized in designing and manufacturing smart camera and lighting solutions for integratedweb monitoring and web inspection.
Founded in 2000, Procemex has gained leading expertise in the industry and has deliveries in over 40 countries. Procemex has delivered over 1,000 systems and over 20,000 smart cameras. It has a team of more than 100 vision systems experts and operates from Finland and has subsidiaries in Germany, Japan, and the US.
A comprehensive range of AI-enhanced analysis applications take web inspection and web monitoring to a completely new level. They improve production flow and product quality, manufacturing efficiency and operator safety.
Procemex advanced 3D technology takes defect detection to the next level.
Oops! This video will not be shown because you have disabled the marketing cookies. To see the video, accept marketing cookies.
VIDEO: Detecting small dents and elevated defects with Procemex 3D Defect detection.
Detecting small dents and elevated defects on fast-moving board (folding box board /coated board/liquid packaging board) can be a tough task. The 3D defect detection technology represents a significant advancement over traditional methods.
Traditional inspection methods often rely on 2D imaging, capturing surface irregularities but lacking depth perception. This in most cases leads to a lack of identifying subtle or elevated defects.
High quality 3D images enable a better way to analyze and understand defect root causes. When combining 3D measurement with other measure geometries, a complete analysis can be performed.
With a resolution as fine as 0.1×0.1mm and processing capabilities exceeding 600 MHz, the 3D technology introduced by Procemex operates at a level of detail and speed that significantly surpasses all traditional methods. This allows for detecting 3D defects starting from as small as 100 micrometers on a high-speed machine running at 1000 m/min or even beyond.
Procemex Celebrates Milestone: 1000 System Deliveries Worldwide
Procemex has successfully delivered the 1000th system, marking a significant achievement in its commitment to transforming the paper and board production industry. The 1000th Procemex system is delivered to the US.
With a strong global presence, Procemex has solidified its position as a trusted partner for businesses worldwide seeking cutting-edge solutions for web inspection and monitoring. Repeat orders speak for their language. Some customers have placed repeat orders on Procemex systems 70 times.
In addition to the milestone system deliveries, Procemex has deployed an impressive 20,000 cameras globally, effectively monitoring paper and board production lines across the world. This extensive reach underscores Procemex’s impact on enhancing production efficiency and quality in the industry.
“We are excited to reach this milestone of 1000 system deliveries. Our global footprint, highlights the trust our clients place in Procemex’s advanced One Platform solution,” said Mika Valkonen, the CEO at Procemex.
Procemex remains dedicated to advancing web inspection and monitoring technologies, empowering industries to achieve new levels of efficiency and quality.
Superior UV-light Based Oil Detection in Food Packaging
In the world of food packaging, ensuring the highest quality standards is a top priority. One often-overlooked aspect is the detection of oil defects on packaging boards, a critical element in the food industry. The commonly used traditional detection methods fall short, capturing only around 50% of oil defects. With the patented Procemex UV inspection you get close to 100% certainty in safeguarding your product quality and customer satisfaction.
In this article, we explore why detecting oil defects is crucial, the potential consequences of overlooking them, and how cutting-edge Procemex UV-light-based Web Inspection technology aids in recognizing them in board manufacturing.
Importance of Inspecting Oil Defects
The packaging board acts as the first line of defense for preserving the integrity and safety of food products. Oil defects, if left undetected, can compromise this crucial barrier, and pose serious risks to both the packaged product and consumers. The significance of identifying oil defects lies in maintaining the hygienic and safe qualities of food-grade packaging.
Consequences of Overlooking Oil Defects
Undetected oil defects can lead to contamination of packaged food, risking the health and safety of consumers. The permeability of oil through the packaging material can introduce foreign substances, altering the taste, texture, and quality of the enclosed product. Additionally, oil defects can accelerate the deterioration of food products by promoting oxidation and spoilage. This can result in a significantly reduced shelf life, causing economic losses for both manufacturers and retailers.
In the food industry, regulatory bodies set the standards for packaging materials to ensure consumer safety. Failure to identify and rectify oil defects may lead to non-compliance with these regulations, inviting legal repercussions and damage to a brand’s reputation.
Recognizing Oil Defects with UV-Light
UV-light technology is transforming the oil defect detection on food packaging board with its ability to detect previously invisible oil defects using ultraviolet light. UV-light illuminates oil defects, making them visible on the packaging board.
Certain materials, such as contaminants and oils, can exhibit fluorescence when exposed to UV light. This means that they absorb the UV radiation and re-emit it at longer wavelengths that are visible to the human eye. The fluorescence effect under UV light often provides a higher contrast between defects and the background material. This heightened contrast enhances the visibility of defects, making them stand out more prominently.
Incorporating UV-light into the defect detection process allows manufacturers to identify and address oil defects on the spot, ensuring that only flawless packaging material reaches the next production stages. This gives board manufacturers confidence in identifying and addressing oil defects that might escape detection through traditional methods.
Traditional Oil Detection Technologies
There are different oil defect detection technologies available on the market. The most commonly used technology is the grayscale- and shape-based detection. This commonly used technology can detect up to 50% of Oil defects.
Another quite commonly used way utilizes blue light in oil detection as blue light can cause fluorescence in certain materials and thus increase slightly the contrast of oil defect. The effectiveness of blue light however in triggering fluorescence is considerably lower than that of UV light reaching around 50% detection level.
Benefits of the new Technology
UV-light-based Web Inspection System emerges as a powerful new tool, providing superior visibility and enabling reliable real-time quality control. With the patented Procemex UV-light Web Inspection technology, we reach almost 100% accuracy in inspecting oil defects.
The patented UV-light oil defect detection technology can be integrated into all delivered Procemex Web Inspection systems. Also, to mill’s existing Procemex Web Inspection frames, offering a cost-effective way to elevate your current Web Inspection capabilities.
Are you ready to elevate your commitment to product and customer safety? With Procemex, you are not making compromises; you’re choosing a solution that brings you close to 100% confidence in identifying and addressing oil defects.
The Web Inspection System equipped with patented UV defect detection technology is now available for full-width and high-speed paper and board machines. Please contact our sales team to learn more.
Procemex Smart Camera Excellence Center to a brand-new office in Tampere
We celebrated the opening of our Smart Camera Excellence Center in Tampere, Finland, where more than 20 skilled professionals are developing cutting-edge technology for Procemex smart cameras.
The event was opened by Mika Valkonen, the CEO of Procemex and Antti Kaunonen, Chairman of the Board of Procemex.
We are dedicated to continuously develop our core competence, smart camera technology to meet the evolving needs of our customers. This ensures that our customers worldwide can enjoy superior performance, leading to better product quality and cost efficiency.
