New Insights uses a
systematic approach to collecting and analyzing data, predicting
breaks, and reducing downtime through break prevention. Our
program can be effective for many types of mills and machines
because it is always tailored to meet customer individual needs.
Program Components:
• Fiber optic web break detection
• Event capturing through video monitoring
• Data analysis
• Web break prediction
• Prevention through consistency control
• Prevention through furnish stabilization
Detection
Fiber Optic Web Break Detectors have been proven reliable where
nothing else has worked. False breaks are virtually eliminated!
Monitoring
Multiple Video Camera System record the events that lead up to
and include a break. Fully automatic systems allow subsequent
visual review and archiving of the recorded breaks.
Analysis
With the information compiled from the break detectors and
monitors, the next step is to analyze the information. In order
to determine the main reasons for the problems, this data is
then combined with other process and raw material information.
Typically answers can be found in the raw material, the stock
preparation and in machine settings. Our partner, QISoft Ltd's
QIS - Quality Information System is the ultimate tool for this
type of analysis.
Prediction
New Insights has, together with select strategic partners,
developed revolutionary new on-line key parameter predictors and
web break prediction tools.
Prevention Through Furnish Stabilization
Fully Automatic On-line Quality Control Wet Labs run multiple
sample streams in 10-12 minute cycle times. That gives highly
reliable information about the characteristics of the pulp
entering the machine chest, including consistency, freeness,
fiber length, fiber length distribution, tensile strength, tear,
burst, as well as optical characteristics, such as color,
brightness, and light scattering. These characteristics can be
continuously measured and immediately displayed, networked, and
printed.
Prevention Through Consistency Control
This requires a complete understanding of how the entire process
control system functions in and around the control location. All
of its elements - agitators, dilution valves, dilution headers,
pumps, consistency measuring technology, sample extraction and
handling, loop tuning, control strategy and design - must work
together as a well-managed system to achieve the desired results
- improving the quality of the end products through variability
reduction.
