5 benefits of using smart cutting and waste reduction system in the FIBC industry

15.10.22 12:32 PM By Ekta

India’s Flexible Intermediate Bulk Container (FIBC) industry is considered to have the highest growth opportunities in the global FIBC market. This growth is driven by increased international trade and favorable initiatives by the Indian government to drive manufacturing in the nation. Industries in India that use FIBCs, like food products, agriculture, pharmaceuticals, chemicals, and fertilizers have seen considerable growth over this period, which has also driven the growth in FIBC sales. According to experts, the Indian FIBC industry is set to grow at a rate of 2x in the year 2022-23. 

To capitalize on this growth in domestic sales and exports, stringent quality standards and optimal waste reduction are essential. During the cutting process in FIBC manufacturing, an error can result in entire cut sheets being discarded owing to a defective sheet. Typically, the FIBC industry has depended on skilled, experienced personnel keeping an eagle eye on materials and machines to ensure a defect-free process. As production ramps up, this becomes impractical, costly, and potentially hazardous, with so many people deployed on the production floor. 

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Hence, a machine vision-based, AI-enabled system like the Kiara Web Inspection System (KWIS) can detect these defects and perform cutting accurately, reducing wastage by as much as 50%. 

Installs onto your existing machinery

KWIS is a compact, robust system that can be installed directly on an existing Cutting machine. It consists of a mechanical assembly for support, an optical assembly for image capturing, and a computing assembly for distance measuring and stopping. 

Machine learning for ongoing defect recognition and prevention

The system can be programmed with parameters of current cut length, material, and tolerance levels, and machine learning allows KWIS to learn about new kinds of defects on the go. The process relies on a machine learning model that is trained with thousands of defective and defect-free images. Machine learning is a continuous process, making the system smarter with more time and data.

Rich, informative defect reports, available on multiple devices

KWIS is able to provide digitalized, easily accessible data on frequency and types of defects, allowing manufacturers to identify trends and problem areas, and take the requisite steps. The computing assembly includes a high-end industrial PC, a cloud-node for data analytics and reporting, accurate stopping logic, and a touch-panel PC. This makes reports available on a variety of end-user devices.

Versatile enough to catch all defects

The system is able to recognize and flag the whole gamut of potential defects, including: knots, dust, gaps, holes, breakages, missing warp/weft, and extra warp/weft. In case a defect is found, the stopping distance is calculated and communicated to the PLC to give the proper signal. 

Real-time defect detection

Using its bank of data on defects, KWIS identifies defects and cutting in such a manner as to reduce material wastage. In case a defect is found, the stopping distance is calculated and communicated to the PLC to give the proper signal. In case of variable length between camera and cutting station, multiple encoders ensure accurate distance measurement. If there are multiple simultaneous defects with distance less than the cut length, this distance is updated. 
In addition, the system is customizable as to number of cameras, line-light length, processor specs, and can be deployed on most cutting systems. This ensures that your KWIS installation is geared towards the particular needs of your KWIS manufacturing unit. 

To find out how KWIS can use the power of smart cutting and waste reduction to maximize profitability and reduce wastage in your FIBC manufacturing process, get in touch with us today! 
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