Precision and accuracy are imperative in toilet tissue converting.
To help manage production and operational efficiencies, complex equipment is used, including toilet tissue roll packaging machines. Manual monitoring requirements can be numerous and keeping up with the adjustments can be difficult, especially for less experienced operators. Critical points along the production line are then vulnerable to error, including in fold and packaging operations.
How can overall equipment effectiveness (OEE), product quality, and waste reduction be managed consistently and perfectly given the need and reliance on human intervention and varying degrees of operator skill?
That’s a question Valmet set out to answer with Sam Operational Solution.
Sam is built around sophisticated sensor technology that constantly measures and monitors raw materials, finished products, and equipment performance at predetermined points where deviations likely occur.
Acting like a virtual production supervisor, Sam works alongside operators. Machine adjustments based on operator HMI input keep production parameters on track and operators safe.
Sam gives operators peace of mind because of the many benefits the technology offers. To better understand what that means, let’s look specifically at fold and packaging operations, and the alignment of Sam and toilet tissue packaging machines.
MTC Sam cut helps operators that can check the status of the blades of the rotating roll and to find if present a defective blade directly from HMI and control the blade set-up while machines are running. This means increased efficiency acting in advance by replacing or adjusting the blades performance decreases and machine downtime are prevented or avoided.
MTC Sam reel helps operators to adjust parameters increasing the machine’s efficiency. In “active” technology mode Artificial Intelligence interfaces send the information to the production line and automatically adapts the operating parameters via dedicated software.
Feedback sensors also monitor inverter speed, filter clogging degree, and any issues that may arise. In the “active” version, the automatic adaption of the vacuum pump and operating parameters are set according to paper type and permeability, and process parameters. Operators have the option of using the HMI for manual settings as well.
MTC Sam vacuum helps operators balance vacuum without the guesswork, and be proactive in addressing issues, including cleaning — thereby keeping the line running efficiently and safely.
Casmatic Sam pack helps operators leverage data to identify and pull defective packs, rather than relying on limited human capabilities. Accurate, reliable and easy to set up, the technology minimizes risk of human error and eliminates the possibility of non-compliant products getting to market.
Each Sam system measures different things at designated points on the production line, but the collective goal is the same: monitoring precision, accuracy, and quality throughout the tissue converting and packaging process. As such, these Valmet innovations act as virtual production supervisors that empower operators to do their jobs better, faster, and safer than ever before.