Mondi is a global leader in packaging, paper and functional film production, contributing to a better world by producing sustainable by design products. With 24,000 employees across more than 30 countries, Mondi operates an integrated business across the entire value chain, enabling it to deliver a broad range of innovative solutions for both consumer and industrial end-use applications.
Here are two success stories from the coating of functional paper and films:
USE CASE 1
Traditionally, coating quality was verified through laboratory measurements, requiring frequent production stops while waiting for laboratory results, leading to regular interruptions. A new inline coating measurement system aimed to reduce these interruptions, but trust in its accuracy was essential.
Without systematic comparison, it was unclear:
As a result, frequent laboratory checks continued, limiting potential efficiency gains.
Mondi used Visplore to merge process data from the inline measurement system with corresponding laboratory measurement data. An automated Visplore template, executed via Visplore Automation Server, was set up to:
Visplore detects mismatches between inline and lab measurements, flagging runs that need sensor recalibration.
This automated feedback clarified which products and grades required sensor recipe adjustments.
USE CASE 2
In silicone coating, each product has a target coating amount to ensure quality. However, in daily production, some products, grades, or individual orders often exceeded these targets.
With high throughput, multiple grades and orders per day, and limited time for analysis, engineers lacked a systematic daily overview of production runs above target. Deviations were detected late, making recurring issues difficult to identify.
Mondi implemented a monitoring and reporting workflow with Visplore Automation Server, ensuring efficiency and cost savings:
Visplore automatically detects orders that used excess material and sends notifications.
Your team can then take action before the next production run of the same product to get closer to the target value.
These reports pinpoint where intervention is needed, without manual data preparation or analysis. The same setup continuously monitors production and enables engineers to act quickly, reduce excess, and maintain quality standards.
