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Prod-IQ.quality convinces in the market: Over 40 systems in use!

Krefeld, May 12th, 2022 – Not only is there great market demand for Siempelkamp's excellence in process control, with over 200 Prod-IQ® systems sold, it also receives excellent references. The Turkish wood-based panel producer Orma has ordered the 40th Prod-IQ.quality MES system and system no. 41 will go to Pavatex, a Swiss manufacturer of insulation boards, and two more customers chose Prod-IQ.quality. Conclusion: Excellence wins out!

Prod-IQ.quality: Online quality control for internal bond and bending strength, density and other properties of the board

With the Prod-IQ® MES system, Siempelkamp provides plant operators with a digital system that draws valuable resources from system data. More productivity, higher plant speed, as well as a reduction of rejects and preventive maintenance are just some of the convincing advantages that Prod-IQ® can offer wood-based panel producers. “The highest possible increase in efficiency and effectiveness is one of the main concerns that Siempelkamp customers wish to ensure for their systems. With Prod-IQ® process control, we have created an intelligent system that combines the current megatrends of digitalization and sustainable production which are indispensable for system operators who want to stand out as pioneers in the market,” says Gregor Bernardy, Head of MES & Industrial IT at Siempelkamp Logistics & Service GmbH.

Recently, the Turkish wood-based panel producer Orma decided to order the 40th Prod-IQ.quality MES system, which has meanwhile been successfully commissioned at the Isparta site in a particleboard plant. Pavatex is also integrating the system into a new plant in France, after an existing plant at the same location had already been equipped with Prod-IQ.quality.

For Neslihan Demirel, Orma’s General Manager and owner, the investment in Prod-IQ.quality aims to significantly optimize production processes: “We chose Siempelkamp's Prod-IQ.quality because it is an excellent tool for achieving the highest level of operational excellence. Our primary concern here is that the system be intelligent and, at the same time, user-friendly."

Prod-IQ.quality: Using machine learning to achieve higher productivity and maximum efficiency

The principle behind Prod-IQ.quality is convincing: As soon as the board leaves the press, the software determines the product quality based on current process settings. A trend diagram visualizes the results. In addition, the software calculates the minimum quality reserve needed for ensuring compliance with the quality criteria. Since the fluctuation range can be clearly delimited, the plant’s production runs right at the optimal level. This increases productivity while maintaining the same quality and models production processes as efficiently as possible, because additional safety reserves are not required. Internal bond and bending strength, density, thickness swelling and surface soundness can all be precisely predicted online. Designed according to the principle of machine learning, Prod-IQ.quality uses every available laboratory control to adapt the process model.

Prod-IQ.profile: Raw density profiles

With Prod-IQ.profile, Siempelkamp is going a step further and expanding Prod-IQ.quality’s online quality control. This module predicts raw density profiles online and allows simulations of them to be made. Prod-IQ.profile is trained with raw laboratory density profiles and uses an advanced physical model for the prediction, which is based on the Virtual Hot Press (VHP) model. It simulates the raw density profile of the current board using the recorded material values, e.g. weight per unit of area and moisture, as well as press settings such as pressures, temperatures and speed. Plant operators achieve the desired product quality faster, receive a reliable online prediction, and get immediately available results. Losses from changeovers can be reduced, and the simulation enables the settings to be checked before the operator ultimately changes them. This system is currently being brought to market readiness with five selected, globally represented Siempelkamp pilot customers.

Further innovations are planned for 2022: The web-based Prod-IQ® dashboard platform is currently being developed and is focused on being able to easily compare a customer’s complex plant structures and multiple plants with each other — from any location on any device, with secure access. Global plant operators can access all production sites via a single system and can compare all plants at a glance via the web-based platform. This dashboard is now available

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