Producing on-spec paper every time, it’s automatic!

Modern automated testing systems, like the L&W Autoline, are designed with user-friendliness in mind. An operator of any skill level could walk up to a system equipped with an intuitive touchscreen, as easy to navigate as a smartphone, and get to work. Built-in analytical tools take the guesswork out of interpreting data, presenting clear insights at a glance.

 In many mills we have seen that trust and confidence between the lab and production improves when an “impartial referee” reports the measurements. Operators no longer question sampling or testing methods, while lab technicians can rely on the system's consistent and trustworthy results. This trust fosters a more proactive and positive approach to quality management, eliminating the need for unnecessary discussions about retesting and instead allows operators to focus on corrective actions.

 Even the testing process itself makes life simple. After each reel change, a sample is collected by the system, eliminating the need for manual intervention. The entire cycle, from sample collection to analysis and data generation, can be completed in ten minutes. That's a ten-fold improvement over traditional methods, freeing up valuable time for operators to focus on more strategic tasks.

 Automated paper testing isn't just about better data; it's about empowering your workforce to achieve more.

A US paperboard mill was urged to adopt automated paper testing by its sister mills in Europe, which had been using the technology for several years. The benefits they achieved are a testament to the transformative power of this technology.

Within months of implementing the L&W Autoline system, production and quality teams were not only confident in the results, but also empowered to embark on a Six Sigma project, a method used by businesses to improve their business processes by reducing defects and increasing quality and efficiency. Their goal: reduce basis weight while maintaining tensile strength – a delicate balance.

During the project, thanks to the new high-resolution CD profiles they could get, the team saw that there was excessive variation in tensile tests in one specific position on the machine. The repeatability of automated paper testing enabled the mill personnel to focus on and resolve factors that were affecting that position.

Previously, manual testing's limited reach left them blind to crucial variations across the paper web. Automated testing provided a deeper understanding, thanks to more testing positions across the reel and consistent positioning.

Prior to automation, the mill was forced to over produce basis weight to ensure strength specifications were met. This resulted in wasted materials and higher costs.

The high speed of automated testing enabled multiple test strips per reel in just four minutes. This allowed for basis weight reduction, product recipe updates, and a dramatic decrease in rejects. Due to the testing repeatability, the mill achieved over $1 million in annual savings through adjustments based on data like tensile stiffness orientation. Other significant operational benefits included a 2-3.5% basis weight reduction, a large chemical cost reduction as strength additive usage lowered by 23.5%, and a staggering drop in paper rejections due to low tensile from 65 tons per month to zero.

This case study is a compelling example of how automated paper testing isn't just about data – it's about empowering teams, optimizing processes, and achieving significant cost savings while maintaining exceptional quality.

As the paper industry continues to evolve, the need for robust and efficient quality control measures will only become more critical. Eventually, we will reach a point where quality is no longer a guessing game, unlocked by the potential of automated testing and quality control. The days of manual testing and its inherent limitations may  soon be behind us and in its place, a wealth of data that will allow mills to paint a detailed picture of their operations and product properties.

This continuous process optimization and feedback loop empowers operators to make adjustments on the fly, ensuring consistent excellence in every roll of paper produced. When paired with systems such as ABB’s Quality Control System, visibility of operations is enhanced further, providing access to even more data points to optimize operational costs and make high-quality, on-spec paper.

At a time when satisfying the balance between cost and customer satisfaction has never been higher, automation delivers the quality that customers crave while minimizing waste and streamlining production for maximum efficiency.

The paper industry is no stranger to innovation, and automated testing represents the next chapter in this ongoing story. By embracing this powerful technology, papermakers can not only ensure a brighter future for their businesses, but also guarantee a future filled with paper of exceptional quality – one meticulously crafted roll at a time.