Measurement control system Corrugated 4.0

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Overview
The Corrugated 4.0 portfolio from BHS Corrugated provides modular software solutions and process control systems for the complete corrugated board production chain (Wet End and Dry End). The suite is designed to deliver reproducible board quality, reduce material and energy consumption and improve cost-efficiency through optimized automation and plant-level coordination.

Included modules and systems

• Corrugator Control Center (CCC): Centralized order management that receives host-system orders and coordinates settings across machines.
• Wet End Controller (WEC): Stores Wet End parameters for reliable grade reproduction; offers clear visualization and intuitive operation.
• Automatic Quality Change (AQW): Automatically adjusts quality-related settings on grade change for faster changeovers and higher average speed.
• Splice Synchronization System (SSS): Aligns splice points during grade changes to minimize waste.
• Roll Verification System (RVS): Verifies paper rolls before production and traces rolls back to orders for supply-chain traceability.
• Warp Control System® Advanced (WCS, WarpGrid, HydroBar): Optimizes Wet End temperatures and flatness. WarpGrid provides real-time laser-based warp measurement (±1 mm) and integrates with WCS for closed-loop correction. HydroBar applies targeted moisture to inner or outer paper sides.
• AutoPilot (API): Plant-level supervising system supporting operators in real time, optimizing production speed across process participants and using a Dynamic Temperature Loop to track paper temperatures and increase throughput.
• Zero Defect System (ZDS): Monitors bonding quality at multiple inspection points to detect defects, folds or splices; defective sections can be ejected at cutoff up to 400 m/min.
• Board Dimension Control (BDC): High-precision laser sensor and identification algorithm for recording cutting and scoring positions and monitoring caliper.
• BHS Resource Monitoring: Retrofit-ready sensor set providing physical consumption measurements for certification and sustainability documentation.
• Corrugator Camera System: Scalable video monitoring for live control-room images, quality assurance, remote assistance and documentation (up to 32 cameras).

Benefits and outcomes

• Reproducible board quality via stored Wet End and process settings.
• Faster grade changes and reduced waste through AQW and SSS.
• Improved flatness and product quality with real-time warp detection and closed-loop control.
• Higher safe operating speeds and coordinated plant production via AutoPilot and Dynamic Temperature Loop.
• Continuous quality monitoring and defect handling with ZDS and the camera system.
• Traceability of raw-material rolls to meet regulatory and customer requirements.
• Reliable resource and energy measurement to support sustainability reporting.

Technical characteristics / specifications

• Scope: modular software solutions and process control systems for Wet End and Dry End (Corrugated 4.0 portfolio).
• CCC: centralized order management across machines.
• WEC: storage of Wet End parameters for reproducible grades.
• AQW: automatic adjustment of quality-related settings on grade change.
• SSS: splice alignment to minimize waste.
• RVS: roll verification and order traceability.
• WCS / WarpGrid: laser-based warp detection (±1 mm) and closed-loop warp control; HydroBar for targeted moisture application (inner/outer side).
• AutoPilot: plant-level supervision with Dynamic Temperature Loop for paper temperature tracking and dynamic speed increase.
• ZDS: defect detection at inspection points; ejection at cutoff up to 400 m/min.
• BDC: laser sensor and algorithm for cutting/scoring position recording and caliper monitoring.
• BHS Resource Monitoring: retrofit-ready physical consumption sensor set for certification-ready documentation.
• Corrugator Camera System: scalable up to 32 cameras for live monitoring and documentation.
• Product series: Corrugated 4.0; Manufacturer: BHS Corrugated.