Answers to common questions about web inspection, web monitoring, web break analysis, defect detection, and machine vision solutions for paper, board, pulp, and tissue production.
Web inspection helps paper, board, pulp, and tissue producers detect, classify, and locate defects on a moving web.
Web monitoring helps operators understand process events, web breaks, and runnability issues through synchronized camera views.
Combining web inspection and web monitoring gives mills both quality data and visual process understanding. Read more about the Procemex OnePlatform system.
Web Inspection System continuously detects, classifies, and visualizes a defect map with photographic image quality. Web Monitoring System provides synchronized, high-speed video views at key machine sections, allowing operators to see what happened around events such as web breaks. Used together, they reveal root causes across the entire machine and allow operators to move seamlessly between inspection and monitoring in a single interface.
The superpower is synchronization. Procemex OnePlatform keeps web inspection and web monitoring on a single, frame-accurate timeline, so every defect, and break is time-locked across all camera positions. Operators can jump from an alarm or defect map directly to synchronized video—seeing the seconds before, during, and after—so root causes are found fast and the line is back up to speed sooner. On top of that, a single UI, database, and server cut complexity, spare parts, and maintenance compared to running separate systems.
Detection accuracy depends on the chosen measurement geometry. Procemex Smart Cameras are designed to detect even micron-level defects at full machine speed. Advanced 3D defect detection resolves elevated defects starting from ~100 µm, with typical resolution settings of 0.1–0.15 mm (grade/speed dependent).
Strobed LED lighting and high‑sensitivity CMOS sensors enable 5–20 µs exposures that freeze motion, producing crystal‑clear images. Transmission/3D solutions are used on lines running well over 1000 m/min, and Procemex Smart Cameras are proven on machines beyond 2000 m/min.
Procemex ProClean pinhole camera technology forms a powerful air barrier through a 5 mm pinhole in front of the camera housing—no protection window that would get dirty—so images stay sharp 24/7, even in the harshest conditions.
Layout depends on grade, machine speed, and line design. Procemex experienced engineers position cameras to ensure full‑width visibility and high‑resolution coverage at the right points to pinpoint root causes.
Procemex OnePlatform web inspection and web monitoring system communicates over standard TCP/IP, manages an SQL database, and supports importing reel/grade data via OPC, making it straightforward to exchange key production context.
TCP/IP networking and SQL data management are native to OnePlatform; OPC is supported for exchanging reel, grade, and other mill data.
Because image analysis occurs within Smart Cameras, a single server can support the entire system (comprising over 200 cameras), with options for virtualization, replication, and seamless backups. Read more about Procemex system architecture.
Operators get auto‑generated event thumbnails from all camera positions, synchronized within two frames, plus history trend tools, and AI‑assisted analyses (e.g. AI‑based Pick‑Up Drop‑Off Analysis) to find root causes faster and prevent repeats.
Procemex OnePlatform is designed for dual-screen use. The intuitive UI lets operators choose what they need to do in the moment: investigate the root cause of a web break, review a paper/board defect and decide the follow-up actions, or consult the built-in Expert database for guided troubleshooting.
On screen, operators get synchronized, real-time views from all relevant cameras, one-click event selection, frame-accurate playback (seeing the seconds before, during, and after), and unlimited digital zoom. With WIS enabled, the interface adds a live defect map with powerful filtering and built-in reporting, allowing you to quickly create, customize, and export inspection reports—supporting fast decisions and clear handovers between shifts.
ATC utilizes precise MD/CD defect locations, allowing winders and re-reelers to stop only when needed, supporting high throughput and successful encoding at speeds of up to 2000 m/min.
Smart Camera Autoshutter provides even exposure and illumination across multiple grades and shades, enabling automated grade settings, even with hundreds of variants.
Like all systems, regular maintenance is needed to ensure, that the system works optimally. Maintenance needs to be systematically managed, planned, and promptly executed according to a preventive maintenance plan and we recommend having a service agreement. When talking about camera maintenance, ProClean pinhole design dramatically reduces cleaning needs and keeps camera images clear and sharp. Procemex offers remote diagnostics, updates, and on-site assistance to maintain optimal performance.
Yes. Procemex OnePlatform System (web inspection and web monitoring) is future‑proof and backwards compatible. All systems since 2002 remain extendable. With system extensions, mills can achieve significant cost savings without having to invest in an entire system. By extending the system with the most advanced technology, you can get the best out of your existing system.
Procemex provides operator training (UI, reporting), maintenance training (hardware, alignment, replacements), advanced courses, and live online sessions tailored to your needs. Find out more about Procemex trainings.
Annual software releases include new features and security fixes; most updates are remote. Procemex also manages OS patching, antivirus definitions, and secured backups to ensure fast recovery.
Service Agreements are modular (e.g., 24/7 remote support, diagnostics/reporting, updates, training, on‑site). Extended warranties are available when covered by an active agreement and system audit.
For a deeper overview of how Web Inspection, Web Monitoring, ProClean cameras, defect classification, and OnePlatform architecture work together, read our full guide.
“The installed system has High Angle Web Inspection and patented 3D defect detection. Efficient detection of indents, outdents, and wrinkles on coated boards, ensures that the liquid packaging board produced continues to fulfill end users’ ever-increasing quality requirements.”
Today, the Procemex web monitoring system is actively used during web break events to identify root causes originating especially in the wet end. The impact has been substantial, with an 80% improvement in identifying causes of web breaks in the wet end.
