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Web Imaging Dirt Count for pulp and paper

For pulp producers or high quality and packaging grade manufacturers, the ABB Web Imaging Dirt Count system detects and counts the amount of dirt on 100 percent of the sheet in real time. Connectivity to mill-wide systems and integration with ABB's quality control and automation systems ensures that defect data can be acted on immediately.  

Not only can corrective action be taken earlier, but quality measurement becomes more accurate, leading to less downgraded paper and higher profitability.

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Defect map with dirt summary tab

Dirt analysis, trend and profile

Mill challenges
  • Visible dirt in pulp, paper and paperboard significantly reduces the quality of end products
  • Calculating dirt counts manually is inaccurate and delays root-cause analysis
  • High dirt counts decrease profit margins by hindering ability to charge appropriate prices
  • High dirt counts reduce margins due to required reprocessing

A more effective solution to measure dirt count in real time
Existing quality measurements evaluate a portion of the product, which assumes that defects are evenly distributed throughout the sheet. This means good quality product could be erroneously downgraded. ABB's full-sheet dirt count, coupled with high resolution CMOS digital cameras and advanced machine learning  tools, provides an exceptional understanding of dirt distribution--even on the fastest and widest, modern paper machines. Papermakers gain a more accurate assessment of quality and therefore can increase profitability.

Defect size classifications to ISO/TAPPI/ANSI standards
Dirt detection and analysis are performed by specialized, high-speed FPGA devices. Defects as small as 0.02 mm2 may be detected, which enables ABB’s Dirt Count feature to be fully compliant with all defect size classifications of ISO/TAPPI/ANSI standards. 

Features
  • Real-time, online dirt detection and analysis of 100% of the web
  • Detection, classification and reporting defects as small as 0.02 mm2
  • Dirt detection and analysis are performed by specialized, high-speed FPGA devices
  • System design handles the high processing loads associated with dirt count while, in parallel, continuing to deliver reliable defect detection
  • Intuitive user interface
  • Connectivity to mill-wide systems and integration with ABB DCS and QCS
Benefits
  • Provides consistent and repeatable results
  • Enables operators to take corrective actions--earlier
  • Improves production yield and quality
  • Ensures defect data can be acted on not only at quality management, but also at QCS process control levels
  • Improves process management
  • Drives higher profitability 
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