Today in modern Polymer plants an online quality control is done automatically and alarming the operators immediately so that the operators can react and avoid more damage to the final product. This "close loop"-concept also allows a grading of the pellet lot. The Film producers, the customers of the Polymer plants, also use web inspection systems to control their final product quality, the quality of the raw materials and also their process parameters. Between both control concepts exist some interrelationships and also problems, because the environment parameters are different. This relative correlation and the impact for the Polymer and film producers will be discussed with practical examples. In today's rough economic environment value added film extrusion needs more and more a 100% online production control. Modern web inspection systems alarm the operators immediately so that they can react and avoid more damage to the final product. Furthermore, the quality of the raw materials and also the process parameters are fully controlled. Today's state-of-the-art web inspection systems consist of fast standard CCD sensors, sophisticated lighting technology and a self-learning software to control and optimise the production process. Critical defects will be marked and reworked on a roll doctor. The web inspection systems are in some cases directly integrated into the IPC of the extrusion line, e.g. BOPP, cast or blown film lines. Also, this integration enables a roll data handling in combination with all the other production parameters. Application examples for customised web inspection systems will be discussed with regards to the integration costs to achieve the benefits and return from such an investment.
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