The Processmaster is an extremely beneficial tool in tile manufacturing and is used to inspect green or biscuit tiles during the production process.  It maximises production efficiency by saving costs and increasing the amount of first quality tiles produced, which in turn, increases turnover and profit.  The great success of the first generation of the Processmaster, together with positive feed back from customers who have been using the systems on their production lines, have driven Surface Inspection engineering department to develop the latest release of this highly successful product: The Processmaster 5G.  

The new system boasts a variety of important benefits:

• It can inspect tiles up to 660mm wide and can be installed on most mainstream production lines;
• It is built using a modular approach that at the same time reduces the footprint on the line and uses a separate console that can be located several metres away from the inspection chamber;
• The inspection chamber is rated IP65 and it can be used in the middle of glazing lines where water and glaze could affect the electronics if not protected;
• The illumination system uses solid state LED technology which has been well proven in the Flawmaster 5G.

Installed upstream of the kiln, preferably both before and after the glazing line, the  Processmaster 5G reduces production costs by allowing only good quality tiles to be decorated and fired.  Defective green tiles can be recycled into the production process rather than being rejected at the final quality inspection. This produces further savings, in addition to the gains made from avoiding unnecessary waste of glaze and energy on tiles that would surely be rejected at a later stage.  The Processmaster 5G classifies each tile according to pass or fail criteria and provides a signal to a reject mechanism to remove faulty tiles from the line.  The system will also recognise a drop in quality, for example, when particular defects occur consecutively on a certain number of tiles.  In such cases it is possible to stop the line, or warn the operator of a production problem.  The user can control the tile grading decision by adjusting an intuitive and comprehensive set of parameters. 

Savings are achieved in many ways:
• Faults are found earlier and corrected faster;
• Recycling is more efficient and more environmentally friendly;
• The Processmaster allows the company to yield 2%-4% more first quality finished tiles; 
Payback is usually less than one year.