January 23, 2025
Chicago-based CoparSolutions brings the latest technology and the precision of Machine Learning to the corrugating process. Total Corrugator Control (TCC) integrates multiple quality and production enhancing products into a cohesive system that automates the production process, reduces human interaction, overrides costly operator mistakes, and maximizes machine performance.
Closed-Loop System
When crews identify quality issues they typically make “best guess” adjustments based on their experience, which in today’s environment may lack in tenure. Every change has an inherent dwell time, where crews must wait for the paper to travel through the machine before seeing the result. The time required to resolve issues in this manner may lead to a substantial amount of waste and reduced profitability.
Other aspects can also affect final product quality, including individual roll quality and moisture variation. Speed changes require multiple adjustments to maintain paper temperatures and effective starch application. Ideally, all variables should be changed in unison to maintain consistent board quality throughout the order.
TCC improves production by replacing operator “best guess,” open-loop adjustments with closed-loop procedures, which continually monitor and correct critical corrugator processes. When the machine speed or paper characteristics change, finite adjustments are implemented immediately throughout the process to maintain consistent board quality.
Enhanced Security
TCC enhances security by eliminating shared passwords and unauthorized access to critical system parameters. The latest 3D face recognition technology ensures only authorized employees have access to modify configurations, perform machine calibrations, or adjust temperature or starch settings. All modifications are time-stamped with employee information to provide transparency and accountability.
Streamlined Troubleshooting
TCC keeps maintenance crews informed of component status and detects failing parts if they break. When a faulty part is detected, a blinking notification icon is displayed on-screen right next to the failing component. Touching the icon takes the user to a troubleshooting screen, which allows them to view information about the sensor, including wire terminal numbers, expected voltage levels, repair/replacement videos, and even part numbers.
Staying Connected, Saving Time
Instant text or email notifications may be sent to designated employees when critical events occur. This feature eliminates the time lag between the occurrence and when management is made aware of the situation.
Authorized employees may request a parts quote right from the main console’s troubleshooting screen. This feature expedites the ordering process and ensures the correct parts are ordered. After a request is made, CoparSolutions’ trained staff prepare a quote, which is returned for approval before the item is shipped. For general, noncritical questions or problems, employees can message Copar’s Service Department directly from the interface.
On Demand Training
TCC includes access to step-by-step troubleshooting procedures. These integrated videos provide guided instructions, which help keep the corrugator performing at maximum speed and productivity. The videos are integrated locally into each operator touchscreen and do not require internet connection.
More Than Just Outstanding Equipment and Systems
CoparElectric, a division of CoparSolutions, provides complete electrical, mechanical, and maintenance services to its customers throughout North America. CoparElectric services are not limited to Copar equipment. It also provides virtually any electrical or mechanical service a plant may need, from full corrugator installations to machine upgrades, plant maintenance, and machine relocation. In fact, it is often the choice contractor of major OEMs for projects throughout North America.
Jim Burrows
President
jmburrows@copar.com
708-496-1859
www.coparsolutions.com
