HOM E | L ATE ST NE WS | WARP‐I | GL UE ‐I | SURF ‐I | TE C HNIC AL INF ORM ATION | ABOUT THE C OM PANY | C ONTAC T

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A Case Study
In this short Note we will reference some results from our first installations of Warp‐I, an installation that now has been up running
for three years. This very first installation was done at Smurfit Kappa Sweden, Eslöv, and with the full support and
encouragegement from the Site Manager, Peeter Saarnak.

For more details of our measuring principles see this article.

Figure 1. shows the installation in the upper
stacker used in this case study. Thre cameras
are used to cover the full with of the
corrugator.
In Figure 2. the interface of the computer in
the control room of the corrugator is shown.
Besides the images of the stacks (just under
the stop bar) and the corresponding profiles
there are some calculated values for warp. For
each “Out” a value of the warp in % is given
together with the mean warp for the upper
stacker and lower stacker respectively. And
finally an overall mean value for the warp over
the full width of the corrugator is calculated.
In addition the degree of warp is also
expressed as the inverted radius (1/R), a
property that is independent of the
dimensions of the sheets. The full width of
the corrugator is analyzed for warp every 3:rd
second.

In this way the operators used our system for

two years to carefully, in real‐time follow, the Figure 1. A Warp‐I installation.
warp performance of the produced corrugated
board. Any deviation from specifications was
noticed and actions were taken to make corrections. The stored warp‐data was also used for traceability and follow‐up of produced
board.

In addition the plant started to compare their

own stored data of variables (speed,
temperature, moisture, paper grade etc.) with
the continuously monitored warp information.
This gave them the opportunity to increase
the understanding and fine tuning of the
process, not only with respect to productivity
but also to board quality.
In the autumn 2008 the Warp‐I System was
integrated with a quality control system from
Qualitek, USA. The overall mean warp‐value on
the corrugator was used as actual value.

Since all historical data are saved in a data

base it is possible to recall any time period in
the past. To demonstrate how the control
loop works we have chosen a period after a
maintenance stop on the corrugator when two
"outs" were run in the upper stacker. In Figure
3. the profiles of the "outs", calculated from
one single scan across the machine, are
illustrated.
 Figure 2. The Warp‐I Interface

Figure 3. Warp profiles

Figure 4. illustrates the average warp across the machine versus time for the chosen time period. Initially the desired value for the
warp was set to be within 0 and ‐0.8 % (down warp). As can clearly be seen an increase in warp was observed under the first 12
minutes at which point an automatic correction of the wrap arms on the double backer took place. After a total time of 20
minutes it was decided to set the desired values to be within 0 and ‐0.4 %. After 25, 35 and 45 minutes automatic correction of
wrap arms brought down the warp‐value to 0 %. At 32 minutes the DB‐liner was spliced.

Figure 4. Warp measurements with contol loop active.

The diagram shows both the accuracy and consistency in the measurements and the possibility to use this information to set up a
closed loop control for warp performance.

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