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 126

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

PAPERTECHNOLOGYINTERNATIONAL
This shift in perspective fundamentally changes the role
of quality information. Instead of merely documenting what went
wrong, defect data can help explain why problems are developing in
the 昀椀rst place.
When recurring defects become maintenance signals
Some of the most valuable information does not come from
individual defects but from recurring patterns.
A defect that appears repeatedly at regular intervals often
points to a speci昀椀c machine-related issue. Worn blades, damaged
wires, contaminated machine elements, or other mechanical
conditions can leave recognizable signatures within the product.
These recurring patterns can provide important clues about machine
health and maintenance requirements.
Historically, many maintenance activities have been
performed according to 昀椀xed schedules. While preventive
maintenance remains important, 昀椀xed intervals do not always re昀氀ect
the actual condition of equipment.
In contrast, process-related defect information offers a
more direct view of what is happening inside the production line.
If recurring defects indicate developing wear or contamination,
maintenance can be planned based on actual machine behaviour
rather than assumptions alone.
This approach offers two important advantages. First, it can
reduce the risk of unexpected failures. Second, it can help avoid
unnecessary maintenance activities that increase costs without
creating additional value.
The limits of human observation
Tissue manufacturing has always depended on experienced
operators. Their knowledge remains essential for maintaining stable
production and responding to changing conditions. However, even
the most experienced operator faces limitations.
Modern production lines run at speeds that make
comprehensive visual inspection virtually impossible. Large web
widths and continuous production generate vast amounts of
information every minute. Valuable indicators of machine condition
or product quality may be present within the material stream,
but they can easily go unnoticed when relying solely on human
observation. This is not a question of expertise or commitment. It is
simply a consequence of scale.
As production speeds increase and quality requirements
become more demanding, manufacturers need additional tools to
provide objective visibility into the production process. Access to
continuous, data-driven information helps ensure that important
signals are identi昀椀ed consistently rather than depending on chance
observation.
Image 2: Tissue defect web break 1.
126
From quality control to process intelligence
For many years, inspection systems were viewed primarily
as quality-control tools.
Their purpose was straightforward: identify defects and
separate good material from bad material.
Today, leading manufacturers are beginning to extract
additional value from inspection data. Instead of focusing exclusively
on defect detection, they are using quality information to gain deeper
insight into process performance and operational stability.
This evolution re昀氀ects a broader trend across manufacturing.
The most valuable question is often no longer:
“Did a defect occur?”
Instead, manufacturers increasingly ask:
“What does this defect tell us about the process?”
By analysing defect patterns, frequencies, locations, and
trends over time, organizations can uncover relationships that would
otherwise remain hidden. These insights can support root-cause
analysis, reveal recurring issues, and help identify improvement
opportunities across the production process.
Inspection data therefore becomes more than a quality
record. It becomes a source of operational intelligence.
Breaking down the barriers between quality and maintenance
In many manufacturing environments, quality assurance
and maintenance have traditionally operated as separate functions.
Quality teams focus on product performance and compliance.
Maintenance teams focus on equipment reliability and uptime.
However, the underlying causes of quality issues and
maintenance problems are often closely connected. A worn
machine component can generate defects in the product. If those
defects worsen over time, they may eventually lead to web breaks,
downtime, or production losses. In this sense, product quality and
machine health represent two different views of the same process
reality.
Forward-thinking manufacturers are increasingly recognizing
the value of connecting these perspectives. When quality
information is shared with maintenance teams and maintenance
insights are incorporated into quality analysis, organizations
gain a more complete understanding of process behaviour. This
transparency supports faster root-cause identi昀椀cation and enables
more targeted corrective actions.
Rather than reacting to individual problems, production
teams can focus on preventing them.
Image 3: Tissue defect web break 2.
Image 4: Tissue defect web break 3.

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