Monadnock Non-Wovens Achieves Accurate, Reliable Speed & Length Measurement with Fast ROI

“PROTON’s InteliSENS® speed and length sensors were easy to install and integrate. Their accurate measurement means they have not needed any recalibration and have eliminated length-related product losses and customer claims. They literally paid for themselves in weeks!” – Mr. Paul Stehlik, Engineering & Facilities Manager, Monadnock Non-Wovens, LLC

Monadnock Non-Wovens LLC

Monadnock Non-Wovens LLC (MNW) is a manufacturer of meltblown synthetic media roll goods for a wide variety of technical applications. Founded in 1998, MNW has the unique distinction of a management team with extensive experience in meltblown and specialty non-wovens technology. In addition to meltblown, MNW offers its customers the value-added processes of charge enhancement, laminating, and calendering. Its products can be enhanced with unique additives, colors, resins and treatments to create customized, high performance value-added properties.

MNW provides solutions and product innovations that meet or exceed the technical specifications often demanded by its customers. MNW solutions evolve from strong client partnerships that benefit from a fully equipped development laboratory for new products and materials. MNW works directly with its customers to manufacture materials with product consistency, high quality, superior performance and excellent value for money.

InteliSENS SL measuring on-line at Monadnock

InteliSENS® SL measuring on-line at Monadnock

MNW’s solutions include:

• Air Filtration
• Liquid Filtration
• Health and Safety
• Automotive
• Appliances
• Consumer – Special Applications
• Sorbent – Fine Fiber

Results

• Eliminated speed sensor recalibration
• No surface damage as experienced with contact measurement
• Consistent weight and thickness quality
• Reduced conversion slab-off
• Reduced product give-away
• Eliminated customer complaints for short length rolls

Monadnock Chooses PROTON

MNW’s products represented a unique series of challenges for accurate speed and length measurement on its multiple nonwoven lines and calendering operations.

First, because contacting sensors require a flat surface for effective operation, accurate speed and length measurement was not easily possible due to the uneven surface structure of MNW’s products. Second, these products are extensible in nature, so any change in the on-line draw, directly affects both the final basis weight and thickness qualities of the product. Third, MNW wanted to eliminate surface damage or impression caused by their contacting mechanical sensors Finally, MNW wanted to help reduce length losses through its conversion processes and eliminate either product give away or short delivery to its customers.

Following market research, MNW chose PROTON’s InteliSENS® SL non-contacting speed and length sensors to help solve its measurement challenges for its multiple lines and calender.

PROTON’s Doppler measurement technique provides extremely accurate measurement performance (better than 0.05%), irrespective of the products surface structure, with no maintenance compared to conventional contacting wheel/roller systems. MNW quickly recognized the potential value of this measurement in terms of quality, accuracy, maintenance and return on investment; while at an affordable price.

The InteliSENS® SL sensors were all installed before the reel windup on all of MNW’s lines replacing their contacting sensors. They have operated reliably for over ten years, surviving in harsh industrial environments without needing any maintenance or recalibration. MNW’s sensors are using industry-standard Bluetooth communications for their PROTON sensors and are interfaced to the plants Modbus units.

Results

InteliSENS SL sensor on Monadnock’s non-woven lines

InteliSENS® SL sensor on Monadnock’s non-woven lines

MNW have benefited from accurate speed and length measurement in a number of process, quality and productivity areas.

First, MNW’s manufacturing operations comprise of a number of discrete processes where the product is transferred from the base machines through converting operations (such as occasional calendering) with each step adding value. Now, with accurate length measurement, the rolls can now be made to a desired length to avoid “slab-off” losses along the way.

Second, customers expect to receive exactly what they pay for in terms of length delivery. MNW’s previous conventional speed and length transducers suffered from lack of accuracy due to the product’s surface structure. Because PROTON’s IntelliSENS SL sensor simply measures the speed and length of the moving sheet, it is immune to the surface structure and also eliminates contact damage.

Finally and most importantly, PROTON’s IntelliSENS sensors guarantees that MNW’s customers receive an accurate length product made to the correct basis weight and thickness quality specifications. In summary, MNW are delighted with the performance of their InteliSENS® SL sensors, in particular their:

• Reliability
• Low maintenance
• Absolute accuracy
• Low cost of ownership
• Ease of process interface
• Highly competitive purchase price

Click for more information on the Proton Products InteliSENS® non-contact speed and length sensors

Click to download the PDF version of this testimonial

Posted in Uncategorized | Comments closed

Flexible Interfacing Options for InteliSENS® Non-Contact Speed & Length Sensor

Proton Products, the global leader in non-contact laser Doppler speed and length measurement technology, has made interfacing its InteliSENS® non-contact speed and length sensor as straightforward as possible across a wide range of industrial instrumentation platforms.

InteliSENS Measuring Nonwoven Products

InteliSENS® Measuring Nonwoven Products

PROTON’s InteliSENS® speed and length sensors come standard with intelligent, easy-to-integrate capabilities that feature a broad range industry-standard or de-facto industry interfaces. According to John Kyriakis, PROTON’s chairman “Our customers have many different instrument and automation platforms, including analog, Programmable Logic Controllers (PLC’s), Distributed Control Systems (DCS) to name but a few. They are looking for a supplier who can offer direct, flexible and easy interfacing options to their processes without the need for further equipment and additional costs. PROTON have recognized this and have embedded this capability into their InteliSENS® sensor to literally give it ‘plug and play’ capability.”

The standard InteliSENS® interfacing options include Ethernet TCP/IP (Modbus), RS-232, and Proton CANBus communications. Optional interfaces include PROFIBUS, PROFINET, DeviceNet, Industrial Ethernet/IP, WiFi and Bluetooth which are available as a substitute for the Ethernet communications interface. Both the Bluetooth and WiFi interfaces provide wireless configuration and sensor monitoring to smart ‘phones, tablet PC’s and laptop PC’s. The DeviceNet interface offers connection to PLC’s and other process control instrumentation via an industry standard DeviceNet network. Alternatively, there’s the optional PROFIBUS or PROFINET and Ethernet I/P interfaces for connection to PLC’s and industry-standard networks.

The InteliSENS® SL mini and SLR mini sensors are suitable for numerous applications involving the measurement and control of speed, differential speeds (or draws) and length to help deliver a multitude of benefits across the industries they serve. PROTON’s InteliSENS® SL/SLR Mini Series non-contact speed and length sensors typically achieve a return-on-investment within a few weeks.

Click for more information on the Proton Products InteliSENS® non-contact speed and length sensors

Posted in Uncategorized | Comments closed

Growing Success of Compact, Non-Contact Laser Doppler Speed & Length Sensor for Web Industries

Proton Products, the global leader in non-contact laser Doppler speed and length measurement technology, announces its growing success with the smart new compact InteliSENS SL/SLR mini series of sensors. These laser Doppler speed sensors set new standards in accurate, reliable non-contact speed and length measurement of moving web products, unrivalled in performance and price.

InteliSENS Speed & Length Sensor Installation

InteliSENS Speed & Length Sensor Installation

The InteliSENS SL/SLR mini series sensors are designed to replace cumbersome, inaccurate and high-wear contact-wheel measurement devices used in web production processes, whose accuracy can exceed 2%. These contacting sensors are prone to excessive measurement errors due to slippage, vibration, wear and dirt accumulation; resulting in product give-away, production losses and non-conformance to specifications. The compact InteliSENS SL/SLR mini has the smallest footprint on the market and provides a direct replacement for contact tachometers and wheel encoders. The installation is simple and the sensors compact size can also permit speed and length measurements from parts of the process that were previously unobtainable.

The InteliSENS SL/SLR mini series sensors are solid-state devices with no moving parts for maintenance-free operation. Their non-contact measurement technique provides an industry-leading accuracy better than 0.05%, typically 0.02%. No marking, No slippage and No Moving parts. They provide the highest accuracy and repeatability with CEMID certified versions available. They come standard with intelligent, easy-to-integrate capabilities that feature a broad range of process interfaces. This includes Ethernet, RS-232 and WiFi communications as standard with optional PROFIBUS, PROFINET, DeviceNet, Industrial Protocol IP that can be substituted for the Ethernet communications interface.

InteliSENS SL/SLR Mini Series

InteliSENS SL/SLR Mini Series

The InteliSENS SL/SLR mini series is designed for use across a wide range of web industries including:

▪ Converting, Laminating & Coating
▪ Extrusion Sheet & Film
▪ Rubber & Vinyl Calendering
▪ Nonwovens and Textiles

The InteliSENS SLmini and SLR mini sensors are suitable for numerous applications involving the measurement and control of speed, differential speeds (or draws) and length to help deliver a multitude of benefits across the industries they serve. For example, accurate speed measurements are required for biax lines to control MD length elongation; speed synchronization for coaters to control flying splice changes and for draw control between various machine processes to assist drying a while avoiding on-line product breaks. Accurate length measurements are required throughout the converting processes for roll-length matching, cutto-length delivery, image positioning, product give-away avoidance and eliminating customer complaints due to short delivery. PROTON’s InteliSENS SL/SLR mini series provides extensive benefits for the web industries with a typical return-on-investment achieved within a few weeks.

Click for more information on the Proton Products InteliSENS SL/SLR mini series

Posted in Uncategorized | Comments closed

Wire & Cable India 2016 Exhibition

Proton Products welcomes you to visit us at Wire & Cable India 2016 in Mumbai from the 5th to the 7th of October 2016. We will be located at Hall 1, stand C04.

Proton Products will be exhibiting a full range of products including the revolutionary SL Mini Series (left) which are the smallest fully featured non-contact laser Doppler speed and length gauges on the market, with a foot print comparable to a smartphone. Proton Products NEW Super Fast DGK-2015 Diameter Gauge (right) will also be shown at the exhibition. The smallest diameter gauge in our DGK series, the DGK-2015 is ideal for insulation and small jacketing processes.

SL Mini SeriesDGK-2015 DIAMETER GAUGE

Posted in Uncategorized | Comments closed

Success at Wire China 2016 Exhibition (Photos)

The Wire China 2016 Exhibition is in full swing and the Proton Products booth is busier than ever. Please stop by to chat with one of our experienced and knowledgable representatives, and pick up a catalogue while we still have stock! We are located at booth W1D82:

Wire China 2016
Wire China 2016

Thank you to all those who have already dropped by and helped to make this the most successful Wire China Exhibition to date.
Posted in Uncategorized | Comments closed

Wire China 2016 Exhibition

Proton Products welcomes you to see our full range of products at the Wire China 2016 Exhibition in Shanghai, running from the 26th to the 29th September 2016. Please come visit our booth located at W1D82 where our representatives will be present to answer any questions that you may have.

New “SUPER FAST” InteliSENS® DGK-2015 Diameter Gauge

Proton Products NEW Super Fast DGK-2015 Diameter Gauge will be shown at the exhibition. The smallest diameter gauge in our DGK series, the DGK-2015 is ideal for insulation and small jacketing processes.
Posted in Uncategorized | Comments closed

New “SUPER FAST” InteliSENS® DGK-2015 Diameter Gauge

New “SUPER FAST” InteliSENS® DGK-2015 Diameter Gauge

InteliSENS® DGK-2015

Proton Products is proud to announce the release of our brand new “SUPER FAST” InteliSENS® DGK-2015 Diameter Gauge. The DGK-2015 (pictured left) is the smallest diameter gauge in our DGK series, ideal for insulation and small jacketing processes, where the maximum product diameter is 15mm. The SUPER FAST, 20,000 measurements per second DGK2015 is packed with standard features including WiFi, Ethernet, RS2343 and can be optionally fitted with PROFIBUS, PROFINET, EtherNet/IP, Flaw detection, and Statistics with logging and printing capability. For more details take a look at our DG-K Series Diameter Gauge page.

The InteliSENS® DGK-2015 Diameter Gauge will be exhibited alongside our full range of products at Wire Dusseldorf 2016 from the 4th – 8th April, Hall 11 – D77.

Posted in Uncategorized | Comments closed

Preheater Pioneers 50th Anniversary

The first induction preheater (pictured left) will be exhibited on the Proton Products stand at Wire Dusseldorf 2016 from the 4th – 8th April. We welcome you to come take a look and meet one of the inventors, Mr John Kyriakis – Proton Products founder, at Hall 11 – D77.

Mr John Kyriakis (left), Proton Products founder, and Wally Tole invented the induction preheater 50 years ago in 1966, which coincidentally was the last and only time England won the soccer world cup. 50 years of pioneering preheating technology for the wire and cable industry. The preheater shown in the picture is in fact the original, first ever preheater which was sold to AEI Cable Works in the UK. The preheater was High Frequency and featured Fully Automatic Temperature Control. It was in operation for over 20 years and when it was taken out of service the inventors repurchased the preheater which now sits in our headquarters as an exhibit piece.

Carrying the tradition of Preheater Pioneers the current range of Proton Products PH Series Preheaters continue to be best in class, with an outstanding EEE (Electrical Energy Efficiency) of 96%. That means 96% of the power consumed by the preheater goes directly to heat the wire. The ProThermic series of preheaters include a user interface for storing wire parameters and displaying the preset and actual wire temperature. If the production speed increases or decreases so does the power which maintains a stable temperature of the wire throughout.

Posted in Uncategorized | Comments closed

Wire Dusseldorf 2016 Exhibition, Germany

Proton Products welcomes you to Wire Dusseldorf from the 4th – 8th April, we look forward to meeting you at our booth in Hall 11 – D77 to see our range of measurement and control products for wire and cable manufacturing processes.

NEW at the show will be our latest “SUPER FAST” InteliSENS DGK-2015 Diameter Gauge. The DGK-2015 is the smallest diameter gauge in our DGK series, ideal for insulation and small jacketing processes, where the maximum product diameter is 15mm. The SUPER FAST, 20,000 measurements per second DGK2015 is packed with standard features including WiFi, Ethernet, RS2343 and can be optionally fitted with PROFIBUS, PROFINET, EtherNet/IP, Flaw detection, and Statistics with logging and printing capability. For more details take a look at our DG-k Series Diameter Gauge page.

Also at the show will be the complete range of InteliSENS gauges. Including the InteliSENS SL Series Non Contact Speed & Length Measurement Gauges, InteliSENS LN Series Lump & Neck Detectors, InteliSEN ST Series Spark Testers and the InteliSENS DG and DGK Series of diameter gauges.

Posted in Uncategorized | Comments closed

ICE Europe 2015 Exhibition Munich, Germany

Proton Products welcomes you to see our InteliSENS® SL mini and SLR mini Series laser Doppler speed and length gauges at ICE Europe 2015 Munich, Germany running from the 10th to 12th March 2015. We will be present to answer any questions that you may have.

The InteliSENS® SL mini and SLR mini Series laser Doppler speed and length gauges are the smallest, highest-performance and most economical non-contact laser Doppler speed and length gauges optimized for sheet materials and converting-industry applications.

Proton Products will be exhibiting in hall 6, stand 138 at the Munich Trade Fair Centre.

For further information, please contact our European Office:

Proton Products Europe N.V.
Nieuwbaan 81, B-1785, Merchtem-Peizegem, BELGIUM
Mr. Danny Buelens
Tel: +32 (0) 52 466 311
Fax: +32 (0) 52 466 313
E-mail: d.buelens@protonproducts.com

Posted in News | Comments closed