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Industrial Video Solutions Inc (IVS), a US-based specialist in automation for the papermaking industry, is leveraging FLIR infrared (IR) thermal cameras to obtain valuable data from paper machines as part of a patented system that boosts machine control and efficiency. Recent developments in thermal signature analytics have expanded the applications of thermal cameras beyond routine troubleshooting; they now contribute to paper machine control, energy usage benchmarking, wet streak detection, and the identification and prediction of certain classes of sheet breaks.

Moisture and temperature directly affect both paper properties and machine runnability - making the measurement of these parameters essential to the papermaking process. However, despite the presence of visual spectrum cameras in several machine locations, some aspects of the papermaking process remain invisible to operators. This problem is attributable to factors such as steamy operating environments, visual camera limitations, and a lack of tools that convert camera images into actionable data.

The solution arrives in the shape of ThermoVision, an IVS-patented system featuring FLIR IR cameras at its core. With its FLIR cameras, ThermoVision sees real-time moisture profiles in any paper machine location, mapping them to a multi-functional thermal profiler. The system can provide real-time, full-width, cross-direction (CD) moisture and temperature profiles, as well as real-time machine direction (MD) profile variations. Moreover, profile analytics provide insights into dewatering and drying efficiency - critical for energy benchmarking.

ThermoVision facilitates the real-time detection and classification of wet streaks and spots, as well as the real-time detection of embedded foreign materials, such as metals in fluff pulp. A key capability of the system is its ability to provide visibility in steamy machine locations. Using a FLIR IR camera to capture an image of a pulper vortex, for example, allows users to see through steam and visualise the vortex in full detail, including the position of the chain and vortex edges. This ability is indispensable for monitoring locations within the machine like trim squirts and dryers.

While it only requires a single FLIR IR camera to execute all ThermoVision analyses, multi-camera systems are more effective for complete process troubleshooting, optimisation, and improvement. It is even possible to feed data from a combination of IR and visual spectrum cameras to an artificial intelligence (AI) module. This neural network learns the relationship between the forces exerted on the paper, paper vulnerabilities, and process upsets - such as sheet breaks - with the goal of predicting runnability issues.

Seven-figure savings

“Armed with new data for maximising paper machine performance, we estimate substantial savings for ThermoVision users,” says Slawek Frackowiak, President and CEO of IVS. “For example, reductions in energy consumption and paper breaks, alongside increases in productivity, can lead to annual savings in the region of $1.3 million on a 300,000-ton liner-board machine.”

He continues: “We came across the potential for this technology by chance. We had already patented our ProcessVision technology, which extracts pixels from an image to effectively turn an area-scan camera into a linear camera, when a potential application provided us with a new idea.”

On papermaking machines, excessive moisture often leads to sheet breaks - a major runnability issue. IVS was invited to quote for a project in Poland that sought to use IR cameras instead of a traditional sheet break system.

“I had no idea why, so I started investigating,” says Mr Frackowiak. “I discovered that while a few competitors had started using IR cameras for displaying video, they were not doing anything with that output. In a papermaking machine, temperature is inversely proportional to moisture, so we set about developing a new system – ThermoVision - which combines the concept of our existing ProcessVision with FLIR thermal cameras.”

This idea has led to the award of multiple patents pertaining to thermal vision - in particular, temperature being inversely proportional to moisture in the papermaking process.

“Of course, anyone can mentally make that conversion, but a system based on that concept is our patent. I was surprised no one else had thought of it. We’ve also patented specific outputs from the technology, such as predicting sheet breaks and runnability issues.”

The FLIR solution

Depending on the application, IVS uses either FLIR A50/A500 or A70/A700 FLIR IR thermal cameras.

“With their higher resolution, we tend use FLIR A70/A700 models for papermaking machinery applications,” reveals Mr Frackowiak. “However, ThermoVision can also benefit machines that produce corrugated paper for packaging. We use FLIR A50/A500 series cameras for corrugators as these applications do not require the same level of resolution, helping to minimise costs for customers.”

Rugged, IP66-rated FLIR A50/A500 and A70/A700 series cameras offer multiple field-of-view options, image streaming, and simple integration with the specific needs of customers. By providing quick access to thermal characteristics, users of these cost-effective cameras can maximise asset uptime and minimise maintenance costs.

“In my opinion, FLIR IR cameras are competitively priced considering the capabilities they offer. During my initial research, I came across other thermal cameras of similar specification, but they cost more. We’re incredibly happy with FLIR IR cameras and now standardise on these models.”

Seeing is believing

There are essentially two ways of adopting ThermoVision on a papermaking machine. First, as an add-on to existing sheet break systems. FLIR IR cameras see ‘invisible’ defects that visual spectrum cameras cannot. The system also detects wet streaks in real time, helping to prevent costly sheet breaks that can lead to hours of downtime.

Second, the system can involve sending the sheet-wide thermal profile to a quality control system (QCS) scanner. A QCS scanner moves back and forth across the sheet, a process that takes anything from seconds to minutes. However, using data captured by FLIR IR cameras, it is possible to feed the QCS in real time. While the control system will not likely work in real time, capturing images with FLIR IR cameras at 30 frames per second, for example, means the system can provide an average profile every second, supporting ultra-fast control system decisions.

“A big issue with a QCS scanner is its location at the end of a papermaking machine,” explains Mr Frackowiak. “From placing pulp on the wire, ready for manufacturing into paper, to running through the entire machine and reaching the QCS scanner, no quality measurement checks take place. However, by positioning a FLIR IR camera at the beginning of the process, perhaps in the press section, we can immediately detect defects like wet streaks or incorrect moisture profiles. This is important because some start-up processes can take hours, with papermaking plants unable to thread the web due to problematic sheet breaks. We now have a way of letting them know why, saving significant time.”

Several papermaking facilities are already taking advantage of the technology. Following the award of its patents, IVS now has two papermaking systems running with ThermoVision in the USA, as well as a corrugator. Multiple quotations have been sent to further potential customers, with some planning to include ThermoVision in their next capital expenditure budget.

With the right innovation and technology,  even a mature process like papermaking can see step changes in key metrics - such as quality, efficiency, uptime, and control. Thanks to the ingenuity of proprietary IVS systems and the capabilities of FLIR IR thermal vision cameras, papermaking is set to reach a whole new level.

Vio Lightweight Drone Payload Features NDAA-Compliant Boson Radiometric Thermal Camera Module.

GOLETA, Calif.,— Teledyne FLIR, part of Teledyne Technologies Incorporated, today announced Gremsy, a leading provider of advanced gimbals and payloads, as the latest collaborator in the Thermal by FLIR® program. Gremsy integrates the Boson® radiometric thermal camera module as part of its gimbaled National Defense Authorization Act (NDAA) compliant Vio F1 drone payload. Assembled in the USA, the Vio F1 is an advanced, lightweight electro-optical/infrared (EO/IR) payload for asset and infrastructure inspection, disaster relief, firefighting, search and rescue (SAR), and public safety missions.

The Vio F1 features a Sony 4K Block Zoom EO sensor with up to 240x zoom and a 640 x 512 radiometric NDAA-compliant and ITAR-free Boson thermal camera with up to 8x zoom. The payload also integrates a 2,400-meter laser range finder, making it an ideal option for industrial inspections and applications.

With its integrated sensors, users can seamlessly engage the advanced functionalities of the payload through its diverse and intuitive viewing modes, allowing for individual and combined visible-thermal views. “Working with the global leader in thermal imaging through the Thermal by FLIR program empowered Gremsy to drive innovation and get Vio swiftly to market,” said Vinh Tran, CEO at Gremsy. “Our goal was to create a payload that is compatible with multiple platforms, including Pixhawk, CubePilot, and Skynode, and to offer an easy-to-integrate solution for any drone maker, including BLUE UAS providers.” 1/2 Vio’s Artificial Intelligence (AI) features provide advanced detection and auto zoom capabilities that are critical for public safety and SAR operations.

AI detection offers accurate and automated identification of key objects, including humans, vehicles, and boats. Layered with AI Auto Zoom, the system can automatically zoom in on the selected object for the best and most useful view. The zoom level in tracking mode automatically adjusts as the object moves closer or farther away, eliminating the need for teams to adjust the zoom during flight. “Gremsy is a known innovator in advancing aerial imaging technology, making it an ideal candidate for the Thermal by FLIR program,” said Dan Walker, vice president, product development, Teledyne FLIR. “The Vio offers precision and accuracy, plus the upcoming implementation of our radiometric JPG file format will soon enable pilots to leverage the FLIR Thermal Studio Suite analysis and reporting software.” Teledyne FLIR’s Thermal by FLIR program is a cooperative product development and marketing program created to support original equipment manufacturers (OEMs). The program enables streamlined integration of Teledyne FLIR thermal camera modules into products and provides go-to-market support for resulting innovations. Click here for details about Boson and visit the Thermal by FLIR page for additional information about the program. Click here for more information about the Gremsy Vio F1.

National Grid Electricity Transmission is the latest company to join EEMUA as a corporate member.

National Grid Electricity Transmission is a business unit within the wider National Grid Group. It develops, owns and maintains the high-voltage electricity transmission network in England and Wales. The system consists of approximately 4,500 miles of overhead line, over 900 miles of underground cable and over 300 substations.

EEMUA and National Grid Electricity Transmission have well aligned objectives in terms of safety, the environment and operating performance. The sharing of good practice across different industries and global regions afforded by engagement in EEMUA will help support National Grid Electricity Transmission in the safe operation of its physical assets as it looks to connect more and more low carbon electricity to the network – crucial in helping the UK achieve its net zero ambitions.

The Engineering Equipment and Materials Users Association

EEMUA has released Edition 4 of EEMUA 191, Alarm systems – A guide to design, management and procurement.

Since it was first published in 1999, EEMUA 191 has become the globally accepted and leading guide to good practice for all aspects of alarm systems.

The new edition has been comprehensively updated and restructured to improve ease of use. The terminology has been aligned to that used in the latest editions of the standards and the opportunity has been taken to include new material on alarm management for remote sites.

Alarm systems form an essential part of the operator interfaces to large modern industrial facilities. They provide vital support to the operators by warning them of situations that need their attention and have an important role in preventing, controlling and mitigating the effects of abnormal situations.

EEMUA 191, developed by the users of alarm systems in industry, gives comprehensive guidance on designing, managing and procuring an effective alarm system. It is intended to help in improving existing systems and in developing new facilities during plant construction or during alarm system refurbishments. Both of the international standards for the management of alarm systems for the process industries, ISA 18.2 and IEC 62682: 2023, are aligned with EEMUA 191.

EEMUA 191 is primarily concerned with alarm systems provided for people operating industrial processes. These include alarm systems in industries such as chemical manufacture, power generation, oil and gas extraction and refining and others. However, much of the guidance is generic and with appropriate interpretation can be applied in other sectors. The guide has been used successfully as a basis for training in the rail and transport sectors, in the nuclear industry, and elsewhere.

www.eemua.org

Brady Corporation offers a new, more cost-efficient solution to quickly detect unstable Li-ion batteries in storage. Able to automatically measure 0,5°C temperature differences per second, the solution provides the accuracy and speed needed to isolate unstable batteries before they become a safety risk.
 

Fast and accurate
Brady’s new battery temperature monitoring solution involves 3 components: self-adhesive battery-free UHF RFID labels with embedded temperature sensors, RFID readers with up to 16 antennas, and a customisable RFID software platform.

The self-adhesive UHF RFID-embedded labels can be applied inside battery cell boxes for fast temperature change detection. Alternatively, every battery cell can be labelled with Brady’s on-metal, printable UHF RFID labels to enable more elaborate advantages in Li-ion battery supply chains.

Every second, the RFID antennas and readers automatically power all labels and sensors in range to collect temperature readings with 0,5°C accuracy. Every temperature reading, and matching battery storage location, is collected by the RFID software platform. When customisable temperature thresholds are reached, the software platform triggers 3rd party devices via standard API.

With almost continuous, automated and accurate temperature monitoring, warehouse stakeholders can receive early warnings via sms, email or even racking warning lights. They can be guided in time to specific warehouse locations for unstable Li-ion battery isolation. Alternatively, Brady’s software platform API can also trigger an autonomous vehicle to automatically remove an unstable battery.


Cost-effective
Battery-free UHF RFID labels with embedded sensors are a more cost-effective battery temperature monitoring solution than powered RFID tags or IR cameras.

UHF RFID labels and their temperature sensors receive power wirelessly from RFID antennas and readers in range. They are available at significantly lower costs - up to 5 times less than battery-powered RFID tags - and do not require maintenance.

The number of RFID readers needed to completely cover storage locations in a warehouse heavily depends on warehouse setup, racking height and storage volume per racking compartment. Brady can connect up to 16 antennas to a single RFID reader that provides high accuracy, high speed temperature monitoring for all storage locations in 12 metre wide and 4 metre high racking.

The automated, and almost continuous, nature of the temperature monitoring solution enables Li-ion battery manufacturers and logistics companies to significantly increase safety and reduce risk at advantageous costs.

Automated inventories
By adding an RFID reader gate at designated warehouse exits, Brady’s solution can also enable automated, real-time warehouse inventories.

RFID labelled items are read by Brady’s RFID readers the moment their label enters reader range. When they pass through a designated RFID reader gate, these items can easily be subtracted from the inventory by the RFID software platform.

When used in this way, the solution can provide cost-effective battery track & trace inside the warehouse from entry to exit, complete with battery cell box or battery cell temperature fluctuation in between.

For more information, contact Brady Corporation via This email address is being protected from spambots. You need JavaScript enabled to view it.. www.brady.co.uk

The symptoms of Climate Change are now very apparent with increases in global temperatures, more frequent storms and flooding where they are not expected and overall changing weather patterns being some of the noticeable warning signs.

Can industry help asks Doug Hart, chairman, Hart Door Systems.  Clearly industry, from manufacturing to storage across the globe, can assess the efficiency of the premises they occupy with the ever open door being the most obvious area of wastefulness. In busy and intense warehouse or production facilities, leaving doors open is generally seen as acceptable.

The result is costly heated air escapes, the temperature within the building drops and heating struggles to get back to an acceptable level. More often than not when the door is opened again it is possibly left open because operatives find it much more convenient.

For temperature control and energy management, the automatic door such as Hart’s Speedor is the solution. Speedor’s fast-action is  the perfect answer. With quality engineering and durability, Speedor high-speed doors will maintain temperatures within a building while keeping energy costs at an acceptable level.

No matter the industrial classification, Hart can manufacture industrial door systems customised to meet specific needs. As an example the Speedor Storm variant is ready for anything the weather can throw at it. Be it a factory, warehouse, storage facility or any kind of plant operation, where doors must be open frequently for people and traffic the Speedor Storm can withstand wind up to ‘wind class 5’ as defined by DIN EN 12424.

Whether it’s access for deliveries, forklifts or people, there are far too many businesses that leave major entrances open for an unnecessary amount of time. The knock-on effect is wasted heating, higher costs and a less than optimal working environment.

Speedor Storm is designed specifically to take care of this. It can help with productivity because entering and leaving can be done more rapidly than non-automatic doors. Further it enhances the working environment because the high-speed operation, even on large doors, means there are no unnecessary open stages.

In turn this lowers energy consumption, important at a time when the cost of energy shows little sign of improving and of course reduced energy use has a positive impact on Climate Change.

In conclusion Hart Door Systems’ Speedor range can make a very significant contribution to energy conservation and a carbon footprint. The combination of automation and high speed operation prevents the passage of heated or cooled air escaping from a building only to heat the car park for instance.

www.hartdoors.com

Making it more accessible than ever to a global audience. This multilingual support ensures that users can interact with the software in their preferred language, improving usability and reducing the likelihood of errors caused by language barriers. The enhanced accessibility fosters seamless communication and integration across international teams, streamlining workflows and boosting productivity. By catering to diverse linguistic needs, ESI-USB© empowers users worldwide, demonstrating a commitment to inclusivity and a more personalized user experience.

ESI-USB© software by ESI Technology Ltd is a powerful tool for managing and analysing data from our digital pressure transmitters like the GD4200-USB and GD4200HUSB (for use in Hydrogen applications). With an intuitive interface, it supports real-time data acquisition, monitoring, and logging, enabling seamless communication and accurate data transfer. Users can visualise pressure trends with graphical tools, export data for analysis in formats like CSV, and monitor system performance efficiently.

Designed for applications such as industrial monitoring, laboratory research, calibration, and field testing, ESI-USB© is compatible with advanced communication protocols like RS-485 and Modbus. Optimized for Windows 8.1, 10, and 11, it ensures reliability and versatility for professionals needing dependable digital pressure measurement solutions.

Hart Door Systems has completed several contracts for its brand leading Speedor Storm door for a number of sectors across the UK.

Ranging from leading manufacturers to an international airport, multiple orders for Speedor Storms have been reported.

"In addition to a rise in demand for the Speedor Storm high-speed door, we have also delivered eight ATEX comprising four fire shutters and four insulated shutters for a wind turbine project," says Gordon Kipling, Hart's Northern Sales Manager. "Orders for Speedor Storms range from two to eight doors. It has been a remarkable level of activity."

Hart’s Speedor Storm is a wind-resistant high-speed industrial door ready for anything the weather can throw at it. "It is an exceptional door for use in factories,  warehouses, storage facilities, indeed for any kind of plant operation that must be open frequently for people and traffic," adds Mr Kipling.

"Wind resistance for the Speedor Storm is up to ‘wind class 5’ as defined by DIN EN 12424. This means that it can withstand winds of up to 70mph for large external openings up to 8m x 8m."

www.hartdoors.com

Landia UK is marking its 30^th anniversary of business. Set up in 1994 as a subsidiary of Landia A/S in Denmark (established 1933), the UK company began as a humble, two-person operation with Liz Robinson, and the late Hugh Vaughan.

Today, Liz Robinson, together with Paul Davies, lead the company that prides itself on helping companies find solutions to their wastewater/slurry pumping needs, serving the water, food, farming and biogas industries, plus many more. Landia UK’s longevity mirrors the proven long-lasting operation of its low maintenance equipment, which they say offers customers unrivalled total cost of ownership.

“From a standing start as a complete unknown 30 years ago, we’ve firmly established our reputation as problem solvers, with great products and tailored solutions,” said Liz Robinson.

“I want to thank our hard-working team for their dedication and belief in what we provide, which to some at first, doesn’t appear to be cheapest, but will, in the long-term almost certainly prove to be so.”

Recent successes for Landia UK include its digester mixing system for the biogas sector, with landmark installations for Yorkshire Water, Scottish Water, Eco Verde Energy and Cannington Bio Energy. In addition, Landia UK has won significant praise for its work in helping provide pumping/aeration solutions to the Timothy Taylor’s Brewery, Deeside Cereals, plus numerous farms all over the United Kingdom and Ireland.

Landia UK’s Paul Davies, added: “We’re very proud of marking our 30^th anniversary, but year in, year out, demand continues to grow for our pumps, especially where hard-to-handle solids in wastewater and slurries create big problems for equipment that isn’t robust enough. We also pride ourselves on the back-up we always give to our customers. After a sale, unlike some, we don’t just walk away.

“We’re also into our 18^th consecutive year of offering training and career opportunities to prospective local young engineers, which is now paying dividends. Members of our team who learnt their trade as apprentices in the workshop are now out in the field, servicing and selling Landia equipment. These talented young people will play a key part in our future.”

www.landia.co.uk