We are taking a gigantic technology leap with our new BM7 board machine in Gruvön Mill,” said Maria Egnes, the EUR 550 investment program leader at BillerudKorsnäs, Sweden. The inauguration festivals took place September 2019. One year later Gruvön Mill KM7 was ramping up its quality products as liquid packaging board, white top kraftliner, cartonboard and cup stock. “The designed capacity of BM7 is 550.000 t/a.”
“Division Board continued to deliver higher sales in all segments. Positive contributions came from a good progress on BM7. Efficiency measures was taken throughout the company,” said Lennart Holm, Acting President and CEO in BillerudKorsnäs´ half year report 2020.
The Finnish company Procemex delivered OnePlatform Web Monitoring and Inspection system to Gruvön Mill and at the same time BillerudKorsnäs Gävle Mill as well.
In very beginning BillerudKorsnäs set up an internal team to review which web inspection and monitoring system can provide the best answers to ever increasing customer quality requirements. The team consisted of BillerudKorsnäs Gruvön and BillerudKorsnäs Gävle automation, product quality, and project experts. The purpose was to acquire Web Monitoring & Inspection systems for Gruvön new BM7 and Gävle BM4 covering board machines, winders and one doctor winder. The key requirements set by BillerudKorsnäs were performance, system architecture and support.
“Beyond typical high quality board defects, such as narrow streaks (0.05 mm), various spots and defects in different layers of board, a special emphasis was laid on capability to detect also small elevated defects that could cause product safety issues in further converting phases. This request was completely new and had never been carried out by so far,” says Antti Lagerbohm from Procemex.
Based on BillerudKorsnäs’s needs for both liquid packaging paper and board quality measurement, Procemex developed a new elevated particle measurement, that was installed on a liquid packaging paper machine (PM4) in Gruvön to verify the performance in real production environment. After few algorithm and mechanical design iteration rounds, the targeted goals were reached under Henrik Ekman’s and his quality colleagues’ supervision at Gruvön.
“After evaluating the systems from all suppliers Procemex was one of the preferred supplier to our board machines. Procemex have a good product and our cooperation in past project have been very success ful,” says Henrik Ekman.
“It is very an important feature to be able to measure elevated defects due to our customer’s requirements. We are really happy with our Procemex systems,” says Henrik Ekman.
There are today over 150 cameras ensuring Gruvön BM7 product quality and production efficiency. The 44 web monitoring cameras are positioned along the board machine to visualize root causes of web breaks and product defects. Over 100 cameras are inspecting the board in 3 different locations. The first inspection location is transmission measurement before coating, the 2nd measurement is located after coating and is focused on coating defects. Before reel board is still once more inspected with both side reflection measurements and transmission measurement.
The information about defects and their locations is transferred to a winding unit. Here it is possible for operators to slow down or stop winder to reject defected parts of board. Here BillerudKorsnäs sees in which customer roll defects are located and makes quality decisions accordingly.
“As the system contains a lot of smart cameras with a significant amount of data flow and as there may be needs to expand the system in the future, it was seen beneficial to be able to virtualize the system into BillerudKorsnäs’s own data center,” states Antti Lagerbohm.
“As the Procemex smart cameras process defect data and videos already inside its own shell, the smart camera architecture enables sending the processed data directly to the data center servers. Now the performance capacity adjustment is in BillerudKorsnäs hands in its own VMware environment.”
BillerudKorsnäs has a service contract over the system containing 24/7 remote support, remote diagnostic report every 2nd month and 2 service visit weeks every year.
Text from Magazine ‘Paperi ja Puu’ – Creating Bioeconomy 2020
Procemex at Gruvön, Sweden