This Group includes the commercial facility in Green Bay, WI where there is a wide demo room for customers to have the opportunity to see and test many of our products first hand. Pulsar Engineering holds over 89 patents and patents pending around the world. In recent years, Pulsar Group has launched many innovative solutions dedicated to the tissue industry, focusing on the Industry 4.0 concept for the generation of the “smart factory”.
QUATIS machines are able to collect a large amount of data in real time and to inform handlers of issues with the product or machine, allowing them to fix problems quickly and efficiently. This helps reduce the amount of non-compliant products and jams in the machinery, and increase the efficiency considering same operators number, working hours and equipment. Since the QUATIS machine was launched, customers have been able to manufacture tissue while checking 100% of the production flow along with the measurement of the level of quality obtained and set within the parameters identified by the customer. This gives the customer assurance that the products intended for sale conform to the requirements, increasing the quality perceived by the end user.
The lines are equipped with remote monitoring systems and management software
Currently for the Quatis for packs, checked non-conformities include non-compliant bottom cross sealing, side sealing and print centering as well as paper that gets stuck in the pack, incorrect roll orientation, missing roll(s) and the presence of handle. QUATIS is also able to create a more efficient, accurate production of unwrapped products such as toilet paper rolls, kitchen paper, industrial rolls and folded products. Not only does the QUATIS system control 100% of the production, but it also implements quality control in real time, directly on the conveyor system with no operator intervention.
This also gives the opportunity to adequately improve the upstream machine settings, thereby increasing the efficiency of the line and consequently, production capacity. QUATIS machines are available in two models. The first can inspect the products, collecting and processing data for overall production analysis. The second has the benefit of an ejection unit, which inspects and analyses production data as well as automatically ejecting non-conforming products. QUATIS for both wrapped and unwrapped products are currently stand-alone machines that allow them to easily be installed in new or existing converting lines. Pulsar also offers remote support service for 6-24 months after the machine is purchased in case the format needs to be changed, new recipes need to be created and for any training required for employees.
Important results of QUATIS installation
To demonstrate how installing QUATIS machines in a converting, packaging and palletizing line can improve the efficiency of the entire production process and whole line settings, we analyzed the data of one of the many machines installed all over the world. This identified several interesting issues.
First, we looked at the effects of overturned rolls at the infeed of the packaging machine and how it would affect the end user, distribution chain and the machine itself. While overturned rolls may cause dissatisfaction with the end user and distribution chain, there was also a high chance that rolls incorrectly positioned would cause a jam in the machine. We analyzed this data over a six months’ period with a line composed by a rewinder, an accumulator, a log-saw, a QUATIS rolls machine, a bag-filler machine, a bundler and a palletizer to study the number of overturned rolls inspected by a QUATIS machine. In this time, the number of overturned rolls was 50.168, representing the 0,2% of total rolls manufactured.
However, without the presence of a QUATIS machine, we estimated that operators could only detect about half of the overturned rolls, adding up to about 25,084 rolls. At least 50% of the mispositioned rolls entering the packing system caused a jam. This caused major changes in the time it takes to produce the product. In fact, the non-compliant rolls that caused a jam in the bag-filler machine estimated 60 added seconds for each bag. This adds up to 415 hours of down production time over the course of six months.
Once the QUATIS machine was installed, the company participating in the study was able to save that time because of the system’s ability to detect non-compliant products, discarding them without jams in the packaging machine. The ability to save this time also helped the company save money and become much more efficient.
Work alongside the customers
On an annual basis, these data show an increase in production time to be estimated in 830 hours of time producing non-compliant, overturned rolls. We also calculated the OEE increase, which added up to +3.72%. By installing a QUATIS machine, the search for the cause of the mispositioned rolls is eliminated, which results in a much higher efficiency level. Through this new service, Pulsar Engineering will provide its customers with real-time service of data collection, analysis and reporting through the machine’s online connection.
At Pulsar, not only do we believe in innovation, we also believe in the integration and cooperation between people, organizations and nations. We work alongside our customers in the process of production lines in the tissue converting industry to create top-of-the-line machines, equipment and software that work together to increase product quality and improvement of everyone’s standard of living.