Papelera del Sur Achieves 80% Improvement in Wet-End Web Break Analysis
At Papelera del Sur in Tornquist, Argentina, operational efficiency and web break reduction are essential to sustaining high-quality coated board production. With an annual output of 60,000 tons on PM1, maintaining stable runnability is critical. When web break investigations began consuming valuable production time and were largely based on assumptions, the company reached a turning point. A more reliable and precise monitoring solution was needed.
A Critical Need for Change
Before implementing the Procemex Web Monitoring System, identifying the root causes of web breaks was challenging. The existing analog recording system provided limited visibility, and camera image quality did not support accurate root-cause analysis. Maintenance needs were also significant.
As a result, valuable production time was lost while trying to determine where breaks originated and what caused them. “We reached a point where the existing system was no longer sufficient,” says Sergio Hernández from the Engineering Department at Papelera del Sur.
The biggest challenge was not only downtime itself, but the time and uncertainty involved in identifying the true cause of breaks.
Choosing the Right System
To resolve the situation, the mill evaluated available alternatives and visited a reference site operating a Procemex system. Reliability, image quality, integration capability, strong references, and professional support were decisive factors.
The objective was clear: reduce web breaks by accurately identifying their root cause, especially in the most demanding area of the machine.
Starting at the Wet End
The project began in the wet end, widely recognized as the most break-prone and technically challenging section of the machine.
Installed and commissioned in Autumn 2025, the system includes eight Procemex ProClean pinhole smart cameras, eleven Eco Led lights, one mobile smart camera unit, and one server.
Cameras were positioned in the forming and press sections. The mobile camera was initially installed after the post-dryer section and later relocated to optimize monitoring coverage based on operational experience.
Most of the installation work was completed while the machine was running, minimizing downtime during final commissioning. A pre-installation site visit helped define optimal camera and lighting positions,
ensuring efficient implementation.
From Uncertainty to Accurate Web Break Identification
Today, the Procemex system is actively used during web break events to identify root causes originating especially in the wet end.
The impact has been substantial:
- Significantly reduced troubleshooting time
- More precise identification of break causes
- Faster and more efficient corrective actions
- 80% improvement in identifying web break causes in the wet end.
One practical example highlights the difference. The machine includes three forming tables. Previously, when web breaks occurred, there was no reliable way to determine which forming table caused the break, or why.
With the new system, the exact root cause can now be identified, reaction time has been significantly reduced, and operational uncertainty has been minimized.
Web break analysis has shifted from uncertainty to fact-based decision-making.
Reliable and Easy to Use
The mill describes the Procemex system as intuitive and reliable. Key features valued by the team include excellent image quality, replay functionality, event capture, remote access, and fast technical support. Camera cleaning requirements have proven minimal. Only periodic cleaning of the lighting is required. Operator involvement from the beginning played an important role in successful adoption. Once the benefits became visible, acceptance across the production team was fast.
“It is a reliable, high-quality system. Both the system and the service fully meet our needs. We highly recommend it,”
Sergio Hernández summarizes their experiences.
Looking Ahead
The Web Monitoring System, with a focus on the wet end, represents the first phase of the project. In the future, Papelera del Sur plans to expand web monitoring to additional web break detection locations across the machine.
With improved visibility and faster root-cause identification, the mill has taken a decisive step toward more stable and efficient production.
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