PAPER TECHNOLOGY INTERNATIONAL - When small defects become big losses: Why process stability is becoming the key competitive factor in tissue production. Andrea Friedrich, Account Director Europe Pulp & Paper, ISRA Vision - Paper Technology International 2026 - Book - Page 125

PAPER TECHNOLOGY INTERNATIONAL - When small defects become big losses: Why process stability is becoming the key competitive factor in tissue production. Andrea Friedrich, Account Director Europe Pulp & Paper, ISRA Vision

PAPER TECHNOLOGY INTERNATIONAL - When small defects become big losses: Why process stability is becoming the key competitive factor in tissue production.
Andrea Friedrich, Account Director Europe Pulp & Paper, ISRA Vision
INTRODUCTION:
A web break is one of the most visible and disruptive events in tissue production. When it occurs, operators react immediately,
production stops, material is lost, and valuable time is spent restoring normal operation. In converting, rethreading the web after a break can
take considerable time, creating signi昀椀cant downtime and production losses.
Web breaks rarely happen without warning.
Long before the break itself, the production process often
provides signals that something is changing. Small holes, edge
defects, contamination, wrinkles, irregular crepe structures, and
other imperfections can appear in the material. At 昀椀rst glance, they
may seem insigni昀椀cant. They are frequently early indications of
process instability, machine wear, or developing quality issues.
For tissue producers operating in an increasingly competitive
market, the ability to recognize and act on these signals has
become a critical success factor. Process stability is no longer just
an operational objective. It is increasingly a source of competitive
advantage.
Why tissue production is becoming more challenging
Over the last decade, tissue manufacturers have faced
growing pressure from multiple directions. Customers expect
consistent quality. Production lines continue to increase in speed
and ef昀椀ciency. At the same time, manufacturers must control costs,
reduce waste, improve sustainability, and maximize asset utilization.
Every unnecessary stop, every ton of wasted material, and every
quality deviation have a direct impact on pro昀椀tability.
Modern tissue machines are engineering achievements
capable of delivering impressive production volumes. However,
higher speeds also mean that small abnormalities can develop into
serious problems much faster than in the past.
A minor defect that might once have remained
inconsequential can now trigger signi昀椀cant downstream
consequences. As production speeds increase, the available
reaction time decreases. Process stability therefore becomes
increasingly important - not only for quality assurance but also for
maintaining productivity and pro昀椀tability.
Image 1: IntelliCam-Cam.
The warning signs hidden in the web
Every meter of tissue produced contains information
about the health of the manufacturing process. Defects are often
viewed solely as quality problems. They can also serve as valuable
indicators of process conditions. A hole may point to issues
with wires or felts. An edge defect may indicate wear in critical
components. Contamination may reveal cleaning requirements.
Wrinkles or creases may suggest tension-related issues within the
machine.
The important point is that these defects rarely occur in
isolation. They are often symptoms of underlying process conditions
that, if left unaddressed, may eventually result in larger quality
issues, production instability, or web breaks. By viewing defects as
early warning signals rather than isolated events, manufacturers
gain an opportunity to intervene before more costly consequences
arise.
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