Innovative inspection solutions meet stringent requirements of the hygienic industry
Continuous quality control even at highest production speeds and lowest area densities
"Health is man's most valuable asset" - this popular wisdom leads to the demand of perfect material quality in the production of spun bond. Since it is increasingly used in medical applications and for hygiene products, which means it has direct skin contact, foreign matter and contamination must be excluded. In addition, time constraints and competitive pressure in the industry require that production lines become faster. A requirement of inspection systems is that their defect detection performance has to increase in proportion to the increase in web speeds. Even given these challenging conditions, ISRA VISION's innovative optical technological solutions offer 100% quality control: Smallest defects are clearly detected and classified at highest production speeds - even at 1200 m/min, the tiniest fruit flies do not remain undetected.
The properties of spun bond material are a challenge for optical inspection systems. With a possible density of just 7g/qm, the material has an extremely challenging inhomogeneous structure. Despite this, ISRA systems reliably detect defects down to 200 µ on webs with a width of up to 5200 mm. Typical defects include insects, holes, contaminations or consolidation defects.
This performance capacity is made possible by using highly developed technical components: The most rapid cameras available, operating at frequencies higher than previous models by a factor of 4, as well as a revolutionary light concept comprising of individually controllable white LED illumination. The SMASH high performance web processor is another cornerstone of the highly efficient system and an additional reason why manufacturers worldwide rely on ISRA in order to meet customer’s high quality demands.
The wide range of colors of spun bond reaches from ecru to white, light blue to green and even black. Quite frequently, such a variety is produced on one and the same system. By using additional color line scan cameras, even differently colored fibers from previously produced batches may be detected and classified as such inline, so that the delivered quality remains perfect.
Users receive a detailed defect log from the system which includes important data and information for quality management. This is the basis for process optimization and increased production efficiency. The correctness of data is ensured by ISRA due to sophisticated classification technology. Even if a defect is detected from three different camera perspectives, it is only included for evaluation once.
At the end of the production line, the integrated quality check module comes in: defective rollers are sorted out rapidly and reliably and replaced by spare rollers from the intermediate storage. The Rewind Manager generally allows to render even imperfect rollers marketable, e.g. by removing flies subsequently. This consistent conception ensures that defective products will not leave the facility.
Conclusion: System solutions by ISRA VISION even pass the acid test of spun bond production and support manufacturers in producing perfect quality. For users, the technology is the key to continuous inspection and to optimizing production along the entire process chain.