International Paper (IP) is one of the leading paper manufacturing companies in the world. Pesmel has supplied a new roll handling and packing line to IP´s Riegelwood, NC fluff pulp mill in the United States.  The new Pesmel line is one key element of the production process, as it is capable to handle, sort and pack rolls with high capacity enabling the production to run continuously without stoppages.

In modern mills, the production capacity has reached such heights that it is impossible to continue working in the finishing areas without automated systems. Currently the general scenario is that there is a new set of rolls entering from the winder into the finishing in every two and half minutes. Thus the quality control, sorting, packaging and labeling has to be completed in a certain time. This sets requirements also to the automated system, not to mention to manual working phases.

From mechanical perspective, Pes-mel line looks like a typical handling line with packing equipment, but it contains applications of the very latest industrial automation. For example, sorting and packaging functions are fully automated.

The handling and packing line is fully integrated into IP’s IT system. The operator’s main task is to monitor the system as the handling and packing line effectively acts as a decision maker. After the winder has made the slits, Pesmel’s system communicates with the mill computer and reads what kind of packages are ordered as well as their quantity (the packet may include 1 to 4 rolls). From there, the handling and packaging line will generate the relevant processes accordingly.

Sorting
After the winder, the rolls enter to Pesmel system and roll sets are formed according to customer orders. As the sorting function with highly effective software architecture is a part of Pesmel’s system, no modifications will be required to the existing winder.

Packaging
The packaging functions include two axial and radial stretch film wrapping stations. Combined axial and radial wrapping ensures a moisture and dust proof package. The extended corner protection is confirmed with unique film folding function, which folds the stretch film at the roll ends during radial wrapping.
The packaging lines include the automated change of a stretch film roll as the film runs out. This function changes the empty film roll for a new one automatically without presence of an operator. The maximum pre-loading capacity is 8 pcs of 80 kg film rolls. The film roll storage magazine can be loaded while wrapping function is running.

Quality control
Pesmel system incorporates machine vision equipment that can be applied to multiple tasks, for example to detect second-rate products and thus avoid customer reclamations. The machine vision can also detect core hang out and scoped rolls. The second rate rolls will be rejected automatically.

Maintenance
Pesmel system is designed with a maintenance log. This log is able to collect all the possible errors within the system and report them to the high level IT system of IP. This function enables the maintenance specialists to review matters accordingly and schedule the maintenance tasks.