14 ABB


Countering myths about automated paper testing


There’s no good reason why a paper mill shouldn’t be using automatic quality testing systems, argues pulp and paper expert Martin Fairbank PhD, who here debunks eight myths often used to maintain the status quo


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utomated paper testing has been available to paper and board mills for several decades, and the mills that use such systems are reaping


the benefits of faster process optimisation, improved quality compliance and reduced off- spec product. Given the many positive outcomes of


automated testing, it may be surprising that there are mills that have yet to invest in automated testing technology, particularly since modern systems are easier than ever to operate and provide unparalleled speed for confirming quality specifications. Yet some mills are reluctant to forego


traditional benchtop testing procedures due to misconceptions about automated testing. With insight from Jonas Andersson, who has more than 30 years of global pulp and paper industry experience specialised in testing and paper quality and is currently global product manager for automated paper testing at ABB, this article debunks some of the common myths and addresses some of the misconceptions about making the transition from manual to automatic testing.


Myth no1: Automated testing is too expensive While automated paper testing systems have a higher initial cost than stand-alone instruments, mills achieve a good payback fairly rapidly through quality improvement and a reduction in rejects. Automated systems, as shown in Figure 1, are capable of testing up to ten times as many measurements in the same time as it takes for manual testing, delivers better accuracy and can automatically store and manage quality information. The results generated by automated testing are


instantly available remotely and if available, can be linked with other tools such as data historian systems to enable analysis of the impact of process adjustments. Reducing dependence on manual testing also frees up human resources


May/June 2020


to focus on quality improvement while reducing quality control costs. Paper mills focusing on Six- Sigma levels of quality achievement will benefit greatly from the increased volume and accuracy of paper quality data.


Myth no2: Paper mills need to upgrade to an advanced quality system in order to fully utilise all the test data automated testing provides. Modern automated testing provides all the analytical tools needed to review paper quality and optimise production. Detailed cross-machine information makes it easier to maintain high quality across the width of the entire jumbo reel while ensuring all rolls delivered meet end-users’ required specifications. Built-in dashboards typically include tools to


follow both short- and long-term quality trends and detect deviations so corrective actions can be taken. While results can be transmitted to other quality systems, the built-in data


visualisation software includes the necessary functions for quality management, so it is not necessary to upgrade any other systems to see immediate value.


Myth no3: Automated testers give different results than stand-alone testing equipment Since the dawn of automated testing, equipment manufacturers have striven to use the same measurement principles as the benchtop instruments, following ISO procedures and calibrated to the same standards. No correlation is required when an automated testing module uses identical components as the benchtop instruments, thus providing identical test results.


Myth no4: Detailed cross-machine sample testing is not necessary and too expensive Manual testers typically take measurements at only three positions across the machine and the process can be adjusted using these measurements. Automated systems, however, can make more frequent measurements, for example, every 30 cm across a 10 metre-wide machine, in the same time or less, as shown in Figure 2. This not only gives a more accurate average,


but constantly provides profile information that can be used to verify online sensors and adjust the cross-machine profile of parameters such as moisture, basis weight, thickness and gloss. Without accurate measurements, these parameters cannot be controlled, and quality suffers. To achieve this manually, more resources and more budget are needed, whereas with automated testing, no extra labour or material costs are required to obtain this increased testing frequency as well as detailed CD profiles.


Figure 2: the dashboard data


Myth no5: Operation of an automated tester requires extensive training to operate and maintain The latest automated testing systems are simple to operate, requiring the minimum of training. For example, with ABB’s newest L&W Autoline


Pulp Paper & Logistics


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