improving sealing inspection with data and edge computing

The sealing process at Rockwool involves fusing plastic film layers together with heat, resulting in a strong and watertight seal. Although the principle seems simple, in practice it presents many challenges:

1. Variable product conditions: Sealing the insulation material is done with different types of films. It is precisely the variability that creates challenging conditions to always guarantee a tight seal.
2. Limited quality control: Traditionally, the quality of seals was only tested at random. This meant that faults were often noticed late in the process. By continuously measuring the parameters - under which the seals are “made” - continuous quality control can happen.
3. Large number of variables: Sealing quality is affected by multiple parameters such as temperature, pressure and process speed. This made it difficult to ensure consistent quality.
4. Implementation across multiple sites: The solution had to be rolled out at multiple production sites and on different types of machines worldwide, including Roermond (Netherlands), Malkina (Poland) and Toronto (Canada). This required a modular, scalable and connected approach.

To address these challenges, Vintecc developed an innovative solution combining machine learning and edge computing for real-time quality control.

Through co-creation and very close collaboration, Rockwool and Vintecc implemented an advanced detection system using data-driven algorithms and edge computing. The core of the solution included the following components:

1. Real-time data acquisition: Several sensors continuously monitor parameters such as temperature, pressure and vibration. This provides detailed insight into the sealing process.
2. AI-driven quality control: Through data-driven modelling and anomaly detection, the system can detect anomalies in real-time and indicate whether a seal has been applied correctly. When an anomaly was detected, the line is automatically stopped.
3. Edge computing: The accurate analysis of the seal is performed locally on an industrial PC, allowing fault detection to be done immediately by an operator on-site, without depending on cloud connectivity. However, all edge components are remotely updateable.
4. User-friendly interface: Operators get access to a dashboard that allows them to easily understand machine performance and intervene in a timely manner in case of quality problems.
5. Flexible implementation: The sealing inspection system was designed so that it could be implemented at multiple production sites with different machines. This made the solution scalable and easily adaptable to specific requirements.

This approach allowed Rockwool not only to detect problems, but also to intervene proactively to prevent errors.

Thanks to the implementation of this solution, Rockwool saw significant improvements in their production process:

1. Reduction of product complaints: Real-time detection of sealing errors drastically reduced the error rate.
2. Increased efficiency: Operators had to spend less time on manual inspections and were able to react faster to problems.
3. Scalable implementation: The solution was successfully rolled out across multiple sites, enabling Rockwool to maintain a uniform quality standard.
4. Optimised resource utilisation: Because potential defects were identified faster, wasted material could be reduced.

The project proved how a combination of data-driven algorithms and edge computing can not only improve quality, but also increase operational efficiency and save costs.

1. Rockwool and Vintecc prove that technological innovation and in-depth process knowledge not only go together, but reinforce each other. By combining advanced sensors, smart operational settings and data-driven algorithms, operators' expertise is directly integrated into an automated “supervisor”.
2. Driving industrial progress, we have deployed data-driven quality control and real-time data processing to take the sealing process to a new level. The result?
3. A sealing production process that is smarter, more efficient, scalable and future-proof - where quality and innovation come together seamlessly.
4. This use case proves that industrial companies, in collaboration with the right technology partners, can transform their processes and gain a strategic competitive advantage.
5. Thanks to the combination of data and edge computing, Rockwool stands stronger than ever in the market and remains a leader in innovation, even in a rapidly changing industrial world.