Quality tracking for mills and plants of the future

Test lab quality information and analysis for pulp, paper and nonwoven manufacturing

TestCentral is a paper and nonwoven quality tracking system which consolidates measurement from the test laboratory and scanner measurement profiles. As part of its service, Panther interfaces the paper lab bench instruments and multi-test devices into TestCentral.

Test values are stored in a relational database, allowing tracking by reel, set, and roll. Backtenders and machine tenders have real-time access to turn-up profiles and test information which allows operators to decide quickly how to meet customer specifications and conserve time, material and energy.

TestCentral builds statistical roll results using PantherStats, a unique statistical analysis tool which eliminates statistical anomalies associated with highly-filtered QCS statistics. PantherStats produces actual as-sold roll quality data for paper mills with or without MillTools MES.

Track quality with an eagle eye

Accurate, reliable quality statistics
Improves performance with actual as-cut roll results
Provides wet-end look-ahead quality data to adjust machine for in-process production
Supports winder decisions for pattern changes to save paper and improve yield
Reduces manual labor with automation
Supports multi-machine and multi-mill best practices
Reduces maintenance and parts costs due to non-proprietary components

Allows the mill to view actual stats for a roll versus filtered information
Permits users at any level to continuously query the server for reel and test information without compromising data
Improves customer service by allowing reps to access test results at any time
Removes the need for storing printed reports generated from the manual and scanning control systems
Eliminates need for recording quality data on clipboards and green sheets
Uses exclusive PantherStats to “standardize” 100% roll quality statistics

Integrates any combination of manual testers, automatic testers and machine profile data
Includes the TestGrid, viewable simultaneously at the lab, winder, and machine tender stations
Includes downtime tracking with mill-specific codes
Certificate of Analysis (COA) reports
Uses a simplified Graphical User Interface (GUI) with point and click navigation

Quality tracking on your terms

TestCentral 2.0 addresses the needs of every mill. Track reel, set and roll quality with a fully-automated or completely manual test lab and anything in between. Our system shares quality data seamlessly with MillTools 2.0 and third-party MES platforms.

PantherStats

PantherStats is an exclusive and embedded algorithm delivered with TestCentral. PantherStats uses raw profiles and lab tests to calculate actual reel and roll statistics based on industry defined standards regardless of the source of the originating data. Since machine control profile statistics are filtered, composited and smoothed for control purposes, they cannot provide accurate, actual “as cut” roll statistics that build reliable production results for shipped rolls.

PantherStats resolves these fundamental statistical errors, and TestCentral recalculates the actual statistics against the finished as-cut winder roll. This re-calculation also overcomes quality error problems whenever winder pattern changes are made between planned and actual production patterns.

TestGrid

The TestGrid displays reel and roll/cake-level test results in a webpage that is used by wet-end operators, machine superintendents, and mill managers to see consolidated quality anywhere in the mill when the reel is accepted in the lab and recorded in the database. Visual and audible notifications indicate each new reel or doff. PantherStats test and profile statistics post immediately to the TestGrid as data is captured automatically and inserted into TestCentral’s open relational database in date/time stamp order, and with roll/set and reel number associations.

Lab personnel may enter, view and edit data in the TestGrid, while other users may view and analyze data with browse-only privileges. Colored-coding calls attention to values exceeding advisory and off-grade limits as well as statistical outliers (likely erroneous manual entries). Drilldown functionality allows user to observe trends and make machine adjustments to remain on grade. TestCentral displays actual and accurate quality results across the entire reel or doff instead of relying on filtered, masked machine control statistics.

You can also drill down into to display individual machine and lab tests. For example, view the Basis Weight test ranges alongside actual Basis Weight profiles. The TestGrid provides ample warning if lab tests trend toward a warning or failure limit. The TestGrid reports page access, a user message log and help files.

TestGrid browser

The Test Grid Browser provides access to products tests and limits, machine runtime history, reel summaries with drill down and reports by authorized users without modifying data or interfering with laboratory operations. Users may view planned-versus-produced roll information when interfaced with mill’s MES.

The TestGrid Browser was the result of collaboration with mill users who needed to find information quickly and easily without searching through large amounts of generic information. Users saves valuable time retrieving information for reports and customer service by consolidating quality with production information via a common portal.

Flexible testing

Both current reel and look-ahead testing options are supported. This allows different mill testing processes to be incorporated, including last-reel or next-reel quality result assignment.

Paperless profile average recording

PantherStats is applied uniformly to both machine profile and lab test data. With TestCentral, all scanning profiles — each data box — and associated data are saved electronically, eliminating any need for handwritten recording and printing.

Certificate of analysis

A standard web-based Certificate of Analysis (COA) report provides a report on roll quality. Customized COA Reports are also available based on unique mill or customer requirements. Panther offers a service to build the COA per customer requirements to include the required data and desirable layout for produced rolls when they are shipped on a Panther manifest.

Export data

Test values from the TestGrid and the reports can be exported to other software packages, such as Microsoft Excel.

Configuration for your mill

Product Target

Product Target enables the paper mill to re-create products and grades inside TestCentral 2.0, setting up associated tests with associated run targets and tolerances. And you can configure products for estimated weight.

User Manager

Administrators create group security privileges for TestCentral. These group privileges enable and restrict specific functionality within applications.

Mill Configuration

Set up customer master files, configure mill-specific database options and apply settings to the various application options, aligning TestCentral with your mill’s process and workflow.

Options to streamline laboratory operation

InputNode

InputNode is allows users in the lab to quickly accept automated test results throughout the mill, using a mobile tablet, touchscreens mounted on moveable arms or stationary workstations adjacent to bench test instruments. This simple-to-use software increases the efficiency of lab personnel running multiple tests on a sample.

Lab interfaces

Interfaces to external devices and systems are a necessary part of successful lab systems. It is important to collect data from various sources, including physical testers, paper machine system profile scanners, process information systems, MES systems and business systems. All these various sources play a role in the ability of TestCentral to provide a comprehensive accounting of finished roll quality results. Furthermore, accurate and uniform results can only be achieved via the unique underlying PantherStats technology.

Discrete Tester Interfaces

For bench instrument single-variable testing

TestCentral has dozens of existing interfaces that collect test data automatically from bench top instruments. The operator inserts the paper test strip and pushes a button on the test device to begin testing. The test is taken and the data is available to the operator in the InputNode application. This includes single and/or multiple-test samples.

Automatic Multi-tester Interfaces

For automatic multi-testers

TestCentral includes an interface to automatic testing systems such as ABB’s L&W Autoline and Technidyne’s PROFILE/Plus. When the auto-tester is run, the system automatically captures the test results. Panther develops custom interfaces for a number of grade-specific testing and rules.

ReportsWeb

ReportsWeb is the Panther report selection tool which enables a user to define the scope of a report using filters. For example, the user selects the machine ID, production date, and downtime category to view the standard Downtime Summary report automatically. ReportsWeb can be used by any authorized mill or corporate user.

Web-enabled displays provide instantaneous access to TestCentral data from any remote company Intranet browser. This provides a means to investigate and resolve production quality inquiries quickly and efficiently.

TestCentral Reports

On-screen and (resultant) hard copy reports provide PantherStats-driven reel, roll and set summaries as well as all product tests. Users may choose to display other process information. The standard displayed and hard copy reports include:

Reel Summary
Grade Summary
Lab Quality Summary
Grade Quality
Down Time Summary
Down Time Detail
Product Test Limits
Reel Average
Roll Average
Test Profile

OPC 2.0 client

The OSI (PI) SDK Client is used to interface to the OSI PI system to exchange data and profile information when PI is the preferred user system for data extraction. This requires the user to have a copy of the OSIsoft PI DAP server SDK interface for operation.

Base System & Other Support

TestCentral is supported by a set of common database and other software modules to provide a complete integrated approach for paper mill production management. The base system and other support applications include:

Database: an open SQL database developed and supported by Panther
Software utilities: common modules for system setup of grades, products, user rights, function activation and reports

Support Information

Panther Systems supplies complete turnkey services from conception through startup, plus continuing long-term support for installed systems.

Services include project management, site survey, system specification, gap analysis, system requirements, configuration, database population, training (on-site and remotely), and installation.

Continuing Services include access to a 24/365 Panther HelpDesk, account management and software updates.