Justifications and cost savings for BunScanners

The most beneficial location for the 1st BunScanner is on the pour line, just downstream of the cut-off saw.

A BunScanner here will:

Provide near-real-time profile size and shape information directly to the pour head operators
Produce a “hot dimensions” record for each bun. This record can be used to calculate bun density, volume, board-feet, etc

Saving scrap by pouring as close to the required finish dimensions (+ shrinkage) is the most beneficial use of a BunScanner.

The most beneficial location for a 2nd BunScanner is downstream of the cold chop saw, ie the saw that cuts the cured long buns into short blocks (typically 6’-12’ long) without removing top or side skins. A BunScanner here will produce a “cold dimensions” record for each block. This record can be used to:

Directly compare to the “hot dimensions” of the same section of the long bun and derive shrinkage ratios. This information allows subsequent pours to be made closer to the minimum required cold block size
Provide an inventory list of various blocks so that larger-than-nominal blocks and smaller-than-nominal can be used more intelligently without undue rejection or scrap removal
Provide dimensions to downstream intelligent saw controllers which can maximize the material to be cut from the block

The above benefits are maximized if every short block cut from long buns is put through this 2nd BunScanner. Where plants are not laid out to conveniently allow this, a short transfer conveyor can be installed under a BunScanner to provide these scan records.

There are other locations where BunScanners can be installed, including:

Directly in front of an intelligent saw, with a direct dimension file transfer to the saw
On transfer lines to trucks for delivered size billing

BunScanners are not required at these secondary locations if information from the first two BunScanners described above is properly tagged and saved in the plant inventory control database. The key to utilizing two BunScanners to maximum advantage is to tie them into your plant database and to associate hot and cold dimension records with unique bun IDs. The more this can be done without operator interface (barcode readers, etc) the better

Why Use An Integrator?

Because there are many different laser measurement technologies, each with particular application issues when used for foam measurement, the selection and design of a laser-based measurement system must be made carefully.

Published specifications for laser measurement accuracy should not be taken at face value because actual results in foam measurement applications can be much worse. A properly applied laser based measurement system can achieve comparable measurements to laboratory off-line results with all the advantages of real-time in-process feedback, but an improperly applied system can be a disappointment.

A consultant or system integrator with particular expertise in the application of laser devices to foam dimensional measurement can be of great value to a foam manufacturer when in-process measurement systems are being considered. RangeMetrics is that system integrator.

For more information on foam laser measurement issues, contact us.