Instrumar Fiber System

POWERFUL SENSOR AND SOFTWARE SOLUTIONS COMBINE TO GIVE UNPRECEDENTED INSIGHT INTO YOUR SYNTHETIC FIBER PRODUCTION AND QUALITY.

How It Works

The Instrumar Fiber System gives you unprecedented insight into your operation’s fiber production and quality.

Now you can detect fiber defects when they happen, monitor your entire production anywhere in your plant and transition your lab from spot checks to investigating specific problems with directed, intelligent testing.

The Instrumar Fiber System enables you to identify issues in yarn quality while it is being processed. The fiber sensor, installed on manufacturing equipment from any OEM, enables continuous real-time quality monitoring and allows for immediate intervention by your plant staff.

With just one small electromagnetic sensor mounted on each threadline, powered by Instrumar’s sophisticated analytics software, the Instrumar Fiber System gives you detailed insight and control over your production like never before.

Simple and intuitive dashboards communicate real-time production metrics at a glance, in an easy-to-understand graphical format.

From the plant floor to the executive office, our graphical displays work with any screen – stationed or mobile. The Instrumar Fiber System can even works with your existing sensors, allowing you to import and display their data as well!

Why Instrumar

The Instrumar team is committed to achieving the efficiency and sustainability goals of our clients. With the Instrumar Fiber System, your processes are leaner, you have fewer customer quality claims, and your product is more sustainable.

The traditional lab testing process is time-consuming and less accurate than Instrumar’s intelligent sensors. And, because the system is working while the yarn is in process, your production staff can intervene before the defects even happen.

The Instrumar Fiber System gives you unparalleled, plant-wide insight and control over your operations. See the benefits of real-time quality management and how it can transform your fiber production!

Features


THE INSTRUMAR FIBER SYSTEM PROVIDES A WIDE RANGE OF FEATURES AND A HOST OF BENEFITS AT ALL LEVELS OF YOUR ORGANIZATION – FROM THE PLANT FLOOR TO THE EXECUTIVE OFFICE.


Proven Performance

The Instrumar Fiber System is suitable for a range of fibers and their weights. Our technology has been refined through decades of in-plant experience, monitoring a variety of man-made fibers from 20 – 6000 dtex.

Robust Design

Our sensors are made with durable aluminum housings and industrial-grade components that have been designed for (and proven) in harsh plant environments. Operating under high yarn tensions, speeds, and abrasive polymers, our sensors are also well suited for recycled feedstock. Some of our Instrumar sensors have been in operation for 20 years!

Self-cleaning & Low Maintenance

Instrumar sensor elements are continuously cleaned by the fiber running over them, eliminating the need for scheduled, manual cleanings. Signal intensity remains constant throughout the life of the sensor.

Flexible Installation Locations

A discrete (7cm x 7cm) sensor footprint means the Instrumar Fiber System can be installed in a variety of locations – even those tight, hard-to-reach spaces – on machines from any OEM.

Swappable

The Instrumar Fiber System works on a “plug-and-play” principle. Individual sensor units can be easily and quickly swapped out in the rare event of failure, with quick rebooting to minimize machine downtime.

Industry Standard Components

The Instrumar Fiber System uses Devicenet communications protocol and standard industrial controllers commonly employed by fiber plants around the world.

POWERFUL & UNIQUE ANALYTICS

Constantly monitoring every meter of your fiber production and reporting data 5 times every second, the Instrumar Fiber System algorithms can monitor a range of production variables that no other system can catch or interpret with just a single sensor:

  • Spin Finish Variation
  • Missing/gained filaments
  • Slubs
  • Node count
  • Node quality
  • Twist
  • Denier variation
  • Thick/thin section detection
  • Bulk variation
  • Anti-stat presence/variation
  • Thread presence

CUSTOMIZABLE FAULT DETECTION

The Instrumar Fiber System comes equipped with advanced fault-monitoring. Metrics can be set by plant personnel for events such as denier evenness, spin finish variation, anti-stat presence and node count.

CUSTOM FINGERPRINT FAULTS

To help you save time, the Instrumar Fiber System can capture and store events unique to your plant’s processes and products. These faults can be stored and saved in the system’s memory for reuse in future production runs, ensuring you meet your customers’ quality tolerances.

ACTIONABLE ALARMS

The Instrumar Fiber System features customizable alerts, which can be set to notify key personnel – from machine operators to plant managers – when production problems are identified. Alarms can be on-screen, positional LED alarms, printed on labels and emailed to key personnel.

AUTOMATIC GRADING

In addition to fault setting, the Instrumar Fiber System allows you to define package grades, which the system then automatically calculates based on quality defects detected during the product run. Grades can be displayed in real time, printed on labels, emailed to key personnel, and also made available in history reports.

DIRECT SHORT-DOFFING & CUTBACK UPON FAULT IDENTIFICATION

The Instrumar Fiber System software can trigger instructions to your winders for them to short-doff or cutback when key faults are identified or downgrading occurs, with alerts and labels created for follow-up action.

AUTOMATIC PRINTER LABELS

The Instrumar Fiber System software can send critical production information (date/time/product ID, position, etc.) as well as grading and other quality information to plant floor printers (for certain printer configurations) for label printing tailored to your operations.

Analytical Reports

The Instrumar Fiber System does more than just monitor your fiber production. Insightful, easily-read, automatically generated reports can be made for any shift or time period, providing comparative information across machines, shifts and products. Production information can be filtered by fault type, grade and package size. Report data can include:

  • Yield
  • Exception (downgraded) Package Summaries
  • Statistical Process Control Summaries
  • Package Trend Summaries
  • Machine Efficiency
  • Shift productivity and comparisons
  • String-up times and comparisons
  • Break-type information (such as doff breaks)

THIRD PARTY SIGNAL INTEGRATION & ALARMING

Our system was designed to integrate with existing technology. Signals from other plant sensors or machine data can be integrated via hardware or software into the Instrumar Fiber System, and additional alarms for these other signals can be created and monitored.

DIRECT ACCESS TO HISTORICAL DATA

Information on every package and line-break is stored in the Instrumar database, and can be made available to you for additional longer-term data analysis.

SCALABLE, WEB-BASED DISPLAYS

Graphical, intuitive dashboards displaying critical production information can be installed on a variety of devices across the plant – from the executive office to the plant floor. Instrumar Fiber System displays are scalable and able to present critical performance data – regardless of the number of positions/threadlines you have in operation.

CUSTOMIZABLE PRESENTATION

Instrumar Fiber System data displays can be customized to focus on production metrics that matter to your individual plant or operations.

PLANT-FLOOR INTELLIGENCE

With the Instrumar Fiber System, you can easily add large screen monitors on your plant floor to display dashboard information, providing production shift personnel with real-time data to quickly identify problems and accelerate string-ups and flag maintenance issues.

SUPPORTS EXTERNAL PLANT INFORMATION

Instrumar Fiber System dashboards can easily display any additional web-based information that you may wish to communicate, such as safety alerts or other production metrics.

Getting Started


ENJOY CONSISTENT DELIVERY OF SUPERIOR PRODUCT WITH THE INSTRUMAR FIBER SYSTEM.


Our dedicated and insightful team will work with you to assess your needs and provide recommendations on the best system to future-proof your fiber production. Here’s how we typically work with our customers to start delivering value with the Instrumar Fiber System as quickly as possible:

Fact-finding Discussion

It’s amazing how much money a half-hour discussion has saved our customers over the years.

Test Installation

After developing our solution, new Instrumar customers often like to conduct trials on a few threadlines.

Budget Approval

We’ve been in this business a long time, and we understand the capital and operational budgeting processes used by many fiber producers.

Implementation

Once budget approval is in place, we’ll work with your engineering, process and plant personnel to plan for the implementation of the Instrumar Fiber System.

Ongoing Partnership & Support

We consider ourselves to be your partners in improving your quality and production.

Over the years, the Instrumar Fiber System has helped some of the world’s best fiber producers find solutions to their production issues. We welcome the opportunity to discuss your plant’s unique challenges and determine how the Instrumar Fiber System can help you. One simple phone call could transform your business and make you a hero within the company – we’ve seen it before!

Are you ready for real-time quality monitoring in addition to better fiber production metrics?

The Instrumar Fiber System gives you unparalleled, plant-wide insight and control over your operations. See the benefits of real-time quality management and how it can transform your fiber production!