In the example above, it took nearly one month before the moisture variation in the base sheet showed up in the rolls waiting to be coated by our customer. Unfortunately, it took several months just to start looking at the paper machine and the coating base, and these defects and the costs associated with these claims amounted to over $400,000, before corrections were made and the mapping for weight, and moisture, variation was corrected. The eventual proof was found in coating base rolls that had been set aside or quarantined at the specialty coating plant and then returned to the paper mill for machine and winder operators to see and feel the severity of ridges in the coating base. Roll hardness profiles, such as those provided by a ACA Systems RoQ, were also proven as a tool for measuring roll quality defects such as the ridges that developed even in the uncoated base paper.
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