Process sensitivity
Small quality deviations in raw material input, temperature, or line speed propagate directly into product quality. By the time a defect is visible, it's already in the batch.
Precision continuous manufacturing. The platform that proves it.
Nonwovens are a high-precision continuous process where small quality variations produce large impact. The customers who buy nonwoven products across medical, hygiene, filtration, and industrial applications have little tolerance for product inconsistency.
The nonwovens problem set
Small quality deviations. Large consequences.
Raw material substitutions
Input changes that look financially viable can destabilize a process. Validating the impact before a change goes live is cheaper than discovering it after a scrapped run.
Zero-tolerance customers
Medical and hygiene grade failures are not reworkable. A defect is a loss. Prevention, not detection, is the only acceptable outcome.
Why this works in nonwovens
Same concepts, different variables
Golden-run centerlining, root cause analysis, and real-time quality prediction were hardened on paper machines, a web process with the same structure as yours: continuous formation, drying, winding, and grade/SKU changes. The concepts map directly. Only the variables change.
No industry template needed
Models are built from your line's own historical data: basis weight, thickness, tensile, whatever defines your product. Not from paper assumptions.
Grade/SKU logic carries over
The same grade/SKU-transition logic that manages a wide range of grades/SKUs in paper handles your product changeovers automatically.
Your historian, unchanged
Connects to your existing historian or SCADA in about 30 minutes. No rip-and-replace, no new data pipeline.
01 / The golden run
Intelligent Centerlining™
Every line has a best version of itself. Centerlining compares live production against your best historical runs and gives operators quantified adjustments to hold the process there, which is exactly what a precision web process needs.
- Specific setpoint amounts, not vague alerts
- Separates controllable variables from uncontrollable ones
Live vs. golden run
02 / Multi-variable quality events
Root cause analysis
When a quality metric breaches its limit, the platform ranks the 10–15 most likely contributing variables by influence, across linear and non-linear relationships, so a multi-variable event gets a shortlist instead of a war room.
- Ranked by quality deviation severity and relative importance
- Redundant signals filtered out automatically
Root cause, ranked
03 / Before the defect is in the batch
Real-time quality prediction
Quality predictions update every 30 seconds across the parameters that define your product, so the team sees a drift while there's still time to correct it, not when offline testing finds it after the roll is wound.
- Trend-focused quality predictions that drive action
- Recommendations every 15 minutes, only when needed
Precision deserves proof
See how the golden run maps to your line.
Bring your quality metrics and six months of historian data. We'll show you what the models would see, then decide together whether a pilot makes sense.
Historian connected in ~30 minutes. Full deployment in under two weeks.
Get in touch
Have a question?
Whether it's our platform, your process, or a free in-depth process data analysis and pilot you'd like to see in action, let us know.