Preventing Paper Breaks with AI: Anomaly Detection in High-Speed Paper Manufacturing

In the paper manufacturing industry, even the most minor anomalies, such as tension issues or minor folds, can quickly escalate into major production disruptions. Machine downtime, rewinding losses, and reduced product quality are typical results of undetected faults. To combat this, Dataguess introduced a proactive, AI-powered anomaly detection system tailored for high-speed paper production lines.

The Challenge: Hidden Anomalies That Disrupt Production

Paper manufacturers often face:

• Holes and burst areas in the paper web

• Unopened folds and improper winding

• Tension inconsistencies

• Pipe-related issues, such as a short pipe or blockage

  
  

Each of these anomalies poses a risk of causing machine stoppage, paper breakage, or downstream quality problems.

The Dataguess Solution: Project Studio Applied to Paper Lines

With its powerful Project Studio platform, Dataguess designed and implemented an AI-driven anomaly detection system that integrates directly with production equipment and PLCs.

1. Multi-Line Data Collection:

   • Images and process data were gathered from 8 different production units.

   • Machine downtime events were used as benchmarks to correlate anomalies with failures.

2. Model Training and Strategic Placement:

   • AI models were trained using diverse data sources from multiple lines.

   • These models were then deployed at key control points along the production line.

3. Real-Time Monitoring and Action:

   • Upon detecting potential anomalies, the system triggers early alerts to the PLC.

   • The system either slows down or halts production before a paper break occurs, minimizing damage and waste.

     
     

Results: Reduced Downtime, Higher Efficiency

By catching early signs of failure before they escalated, the AI system prevented paper breaks, minimized stoppages, and maintained consistent production quality. Operational efficiency improved, and costly production losses were significantly reduced.

Key Benefits:

• Early detection of subtle anomalies before they cause breakdowns

• Intelligent integration with PLCs for immediate corrective action

• Reduced machine downtime and material waste

• Increased line reliability and product consistency

  
  

Make Downtime a Thing of the Past

With Dataguess Project Studio, paper manufacturers can move from reactive to predictive operations, protecting uptime and product integrity.