Bridging Safety and Process Control: AI-Enabled Mitigation, TAPPICon26

Industrial environments in the pulp and paper sector are characterized by high-speed machinery and numerous pinch zones that pose significant entrapment and crushing risks. Conventional safety measures—such as physical guarding, interlocks, warning signage, and lockout/tagout (LOTO) procedures—remain essential but are inherently reactive and static, as defined in established safety standards such as OSHA and ISO frameworks [1], [2]. These approaches often lack the responsiveness required to address dynamic operational conditions in real time and rely significantly on human compliance [3].

This paper presents an AI-driven safety approach that transforms traditional safeguards into an active, adaptive control mechanism. An AI-augmented safety monitoring system is deployed at a pulp and paper facility using existing camera infrastructure, computer vision techniques based on modern object detection frameworks, and machine learning models to continuously monitor designated pinch zones. When a potential hazard is detected, the system interfaces directly with programmable logic controllers (PLCs) to initiate real-time enforcement actions.

In addition to real-time hazard mitigation, the system enables predictive insights into equipment health and operational risks, aligning with established predictive maintenance methodologies. Although not developed as a Safety Instrumented System (SIS) under IEC 61511, it functions as a powerful monitoring system with integrated control capabilities, designed to improve safety performance metrics as a part of the overall safety management system for mills. Results from a case study deployment indicate measurable improvements in safety performance, reduced downtime, and strong return on investment, supporting broader adoption of AI-enabled safety within high-risk industrial environments.

TAPPI conference proceedings and presentations, technical papers, and publication articles provide technical and management data and solutions on topics covering the Pulp, Paper, Tissue, Corrugated Packaging, Flexible Packaging, Nanotechnology and Converting Industries.

Simply select the quantity, add to your cart and your conference paper, presentation or article will be available for immediate download.