Building Materials
Void Detection
Real-time thermal inspection system that catches voids before the dryer, enabling faster production with consistent quality.
Void Detection
During gypsum wallboard production, defects such as voids and lumps often appear as hot or cold spots. Left undetected, they can compromise board quality, increase rework, and waste energy. Traditional rule-based vision systems struggle to detect these defects consistently because of fluctuating factory temperatures and variations in board width, thickness, and material. As production lines run faster to increase output, the likelihood of voids forming also grows, making early and reliable in-line detection essential for maintaining quality and reducing waste.
What OneView Delivers
Eigen’s AI-powered thermal inspection system detects these defects in-line before the cutter and dryer, helping manufacturers catch problems early in one of the most energy-intensive stages of production.
Using high-speed thermal cameras and AI, the system continuously monitors temperature variations across any board width or thickness—from 150 to 620 fpm. Data is processed in OneView Cloud, where operators can visualize defect size, location, and trend data in real time.
The system also offers configurable severity-based alarms that connect to PLCs for immediate corrective action (light stacks or audible alerts). Operators can filter insights by product type, making it easy to adapt to different board compositions without manual configuration.
Defects
A side-by-side look at how our vision system reveals what the human eyes can’t see.
Industries
Energy Savings: Detects defective boards before the dryer, preventing waste of one of the most energy-intensive stages.
Comprehensive Detection: Identifies multiple defect types - voids, lumps, hot and cold spots, with full sheet-width thermal coverage.
Consistent Quality: Provides real-time board health feedback and severity-based alerts to help operators fine-tune process parameters.
Scalable & Flexible: Adapts seamlessly to varying product thicknesses, widths, and materials—no manual setup required.
Simplified Monitoring: Easy access to cloud-based defect trends enables faster decision-making, reduced rework, and improved process stability.
Industries
Energy Savings: Detects defective boards before the dryer, preventing waste of one of the most energy-intensive stages.
Comprehensive Detection: Identifies multiple defect types - voids, lumps, hot and cold spots, with full sheet-width thermal coverage.
Consistent Quality: Provides real-time board health feedback and severity-based alerts to help operators fine-tune process parameters.
Scalable & Flexible: Adapts seamlessly to varying product thicknesses, widths, and materials—no manual setup required.
Simplified Monitoring: Easy access to cloud-based defect trends enables faster decision-making, reduced rework, and improved process stability.
Types of Products
A leading drywall manufacturer noted that limited visibility into voids often forced them to slow production to avoid quality issues. After integrating Eigen’s AI inspection system, they gained real-time insight into void formation and could adjust process parameters on the fly.
According to the customer, “The ability to see and correct issues in real time has allowed us to maintain quality without sacrificing speed.”
Line rates increased from 450 ft/min to 460 ft/min, resulting in roughly $100,000 in additional monthly revenue, or $1.2 million annually, not including savings from fewer field rejections and reduced waste.
Void Detection
During gypsum wallboard production, defects such as voids and lumps often appear as hot or cold spots. Left undetected, they can compromise board quality, increase rework, and waste energy. Traditional rule-based vision systems struggle to detect these defects consistently because of fluctuating factory temperatures and variations in board width, thickness, and material. As production lines run faster to increase output, the likelihood of voids forming also grows, making early and reliable in-line detection essential for maintaining quality and reducing waste.
What OneView Delivers
Eigen’s AI-powered thermal inspection system detects these defects in-line before the cutter and dryer, helping manufacturers catch problems early in one of the most energy-intensive stages of production.
Using high-speed thermal cameras and AI, the system continuously monitors temperature variations across any board width or thickness—from 150 to 620 fpm. Data is processed in OneView Cloud, where operators can visualize defect size, location, and trend data in real time.
The system also offers configurable severity-based alarms that connect to PLCs for immediate corrective action (light stacks or audible alerts). Operators can filter insights by product type, making it easy to adapt to different board compositions without manual configuration.
Defects
A side-by-side look at how our vision system reveals what the human eyes can’t see.
Industries
Energy Savings: Detects defective boards before the dryer, preventing waste of one of the most energy-intensive stages.
Comprehensive Detection: Identifies multiple defect types - voids, lumps, hot and cold spots, with full sheet-width thermal coverage.
Consistent Quality: Provides real-time board health feedback and severity-based alerts to help operators fine-tune process parameters.
Scalable & Flexible: Adapts seamlessly to varying product thicknesses, widths, and materials—no manual setup required.
Simplified Monitoring: Easy access to cloud-based defect trends enables faster decision-making, reduced rework, and improved process stability.
Industries
Energy Savings: Detects defective boards before the dryer, preventing waste of one of the most energy-intensive stages.
Comprehensive Detection: Identifies multiple defect types - voids, lumps, hot and cold spots, with full sheet-width thermal coverage.
Consistent Quality: Provides real-time board health feedback and severity-based alerts to help operators fine-tune process parameters.
Scalable & Flexible: Adapts seamlessly to varying product thicknesses, widths, and materials—no manual setup required.
Simplified Monitoring: Easy access to cloud-based defect trends enables faster decision-making, reduced rework, and improved process stability.
Types of Products
A leading drywall manufacturer noted that limited visibility into voids often forced them to slow production to avoid quality issues. After integrating Eigen’s AI inspection system, they gained real-time insight into void formation and could adjust process parameters on the fly.
According to the customer, “The ability to see and correct issues in real time has allowed us to maintain quality without sacrificing speed.”
Line rates increased from 450 ft/min to 460 ft/min, resulting in roughly $100,000 in additional monthly revenue, or $1.2 million annually, not including savings from fewer field rejections and reduced waste.
