Top misconceptions for Paper Testing Automation in Paper Industry

Some paper mills remain hesitant, despite the fact that solutions for paper testing automation have never been more important or useful. We take a look at the most common false beliefs about automated paper and board testing.

Mills that have adopted automated paper testing systems have been able to optimise their processes more quickly, increase their quality compliance, and decrease their off-spec product for the better part of three decades.

It may be surprising that some mills have not yet adopted automated testing technology, given the many advantages it offers. This is especially true considering the convenience and speed with which modern systems can verify quality standards.

However, several mills are hesitant to abandon traditional benchtop testing processes due to myths regarding automated testing. This blog covers the myths and misunderstandings that cover the topic of why Paper industries should shift to paper testing automation services. Group Nish is an excellent service provider of instrumentation, automation, as well as EPC Electrical for Paper Industries in Gujarat.

Myth #1 - Paper testing automation is an expensive process:

Paper mills have a positive ROI very quickly because of the improved quality as well as a decrease in rejects from using automated paper testing methods, despite the greater initial cost compared to stand-alone instruments. When compared to manual testing, automated testing can speed up by a factor of ten, provide more precise results, and maintain quality data without human intervention.

Automated testing yields instantaneous, remotely accessible results that, if available, can be integrated with other tools to evaluate the effects of process tweaks. Saving money on quality control and reserving human resources for enhancing quality is made possible by decreasing reliance on manual testing. With more and better data on paper quality, paper mills may more easily achieve Six Sigma standards of quality.

Myth #2 - Automated Testers Don't Always Deliver Reliable Results Compared to Independent Test Devices:

Since the beginning of automated testing, producers have aimed to make their products conform to the same measuring principles as benchtop devices, using the same calibration as well as ISO methods to the same standards. Since the automated testing module and the benchtop instruments use the same components, there is no need for a correlation.

Myth #3 - It's not necessary or affordable to conduct thorough cross-machine sample testing:

Tests performed by hand often collect data in just three locations over the entire machine, from which fine-tuning of the process is then possible. However, automated systems can take measurements more frequently while still taking the same amount of time.

This not only provides a more precise mean, but also continuously reports profile data that can be utilised to validate online sensors and fine-tune the profile across machines for factors like moisture, base weight, thickness, and gloss. Accurate measurements are essential for controlling these factors, which can otherwise negatively impact product quality. Automated testing eliminates the requirement for additional human labour or material expenditures to accomplish the same enhanced testing frequency and detailed CD profiles that would otherwise be achieved manually. Group Nish offers quality services for 21 CFR Automation and SCADA for Paper Industries in Gujarat.

Myth #4 - A lot of special training is needed to run and maintain an automated tester:

The newest generation of automated testing technologies can be used with little or no training. Testing begins with a touch of the screen after a paper sample has been inserted into the device, and the results are compiled into reports that can be shared around the mill. When the same measuring principles are used, the upkeep for handheld and benchtop instruments is nearly the same.

Myth #5 - Testing feedback time isn’t important:

There is a common misconception that the quality data is only utilised for quality assurance and not for the process as well as quality and optimization, so it is not crucial to have quick access to test findings. The paper must be conditioned for a few hours before testing according to industry standards. However, if machine operators can get quality data within 15 minutes after a turnup, they can avoid making papers that don't meet quality standards and the cost of rejecting them.

Automated equipment used for paper testing can take a strip of paper the width of a machine from a finished paper reel and run it through a battery of tests in a variety of cross-direction locations in under ten minutes, providing immediate results to operations. This eliminates the need for time-consuming and error-prone manual testing procedures such as sample preparation, conditioning, data entry, computations, data compilation, and comparison to quality standards.

Myth #6 - It's difficult to maintain machinery that's running all the time:

In order to ensure accuracy, automated equipment used for the paper testing process must operate consistently and reliably around the clock, seven days a week. When it comes to maintaining their own equipment, most users have a service agreement in place. It is important for mills looking to implement automated testing to ensure that the equipment supplier chosen by them has a trustworthy, global network of service agents to manage this need and that any necessary repair won't disrupt the system. If you are looking for the most popular as well as distinct services of EPC Electrical for Paper Industries in Gujarat, Group Nish is the most reliable brand offering quality instrumentation and automation services in the industry.