Spectrometer-based Sensors for On-line Quality Control in Paper and Nonwovens Production, TAPPICon25

The global shift towards sustainable materials is driving innovation in alternative and bio-based coatings, barriers, binders, and raw materials for the paper, packaging, and nonwovens industries. Solutions include reducing plastic use, replacing plastics with recycling-friendly materials like latex-based barrier coatings, and using bio-based, biodegradable materials. Accurate measurement and control of coat weight, binder amount, or raw material composition are essential due to the higher cost and complexity of these new materials. Quality control and on-line measurements are vital for optimizing energy use, raw material consumption, waste, and minimizing downtime in manufacturing. New near-infrared spectroscopy (NIR) technology has been developed to tackle these challenges. Reflection-type sensors are designed for coatings in paper and board manufacturing, while transmission-type sensors are used in tissue, nonwovens, and special papers manufacturing. This paper introduces the new spectrometer technology, highlighting advancements in NIR linear array spectrometers, optomechanical design, and new calculation algorithms. Examples include minimizing plastic use, measuring barrier coatings, raw material and binder measurements in nonwovens production, and tissue applications. Based on extensive on-line testing, the new sensors measure reliably low coat weights (under 1 g/m2) of conventional and bio-based coatings and binders.

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