Grupo DR1 Uses Voliro T to Cut Chimney Inspection Time by 40% for Brazil’s Largest Paper Exporter

Case Study Overview

Maintaining the structural integrity of industrial chimneys is crucial for operational efficiency and safety—but traditional inspection methods involving scaffolding or elevated platforms come with high costs, production downtime, and safety risks.

To address these challenges, Grupo DR1, a leader in industrial drone inspections, deployed the Voliro T drone equipped with an advanced high temperature ultrasonic probe to conduct a real-time thickness measurement inspection at Klabin, Brazil’s largest producer and exporter of packaging paper. This approach allowed for a full chimney inspection while operations remained uninterrupted, demonstrating how advanced drone technology is transforming industrial asset integrity management.

Summary of Key Outcomes

The Challenge: High Costs, Downtime, and Safety Risks in Chimney Inspections

Industrial chimneys are exposed to extreme temperatures and harsh environmental conditions, making regular thickness testing critical to preventing structural failures. However, traditional inspection methods presented major operational challenges:

• High costs & production downtime : Scaffolding setup required shutdowns, impacting productivity.
• Significant safety risks: Workers faced exposure to extreme heights and temperatures.
• Inefficient manual inspections: Traditional methods took days, increasing labor costs and reducing productivity.

Klabin needed a safer, more efficient solution that could provide accurate data without disrupting operations.

How Voliro T Transformed Klabin’s Inspection Process

By deploying the Voliro T drone equipped with an advanced ultrasonic sensor, Grupo DR1 revolutionized Klabin’s chimney inspection workflow. The unique capabilities of the drone enabled:

• Inspection at multiple angles: The drone’s rotating structure ensured comprehensive data collection, far surpassing manual methods.
• Real-time monitoring: Instant high-resolution ultrasonic scans provided engineers with immediate feedback.
• Operational continuity: Inspections were performed without halting production, eliminating costly downtime.
• Reduced costs and optimized resources: Removing the need for scaffolding and elevated platforms resulted in significant financial savings.

Cutting Costs and Enhancing Maintenance Planning

The high-precision data collected using the Voliro T drone enabled engineers to identify wear and corrosion points in the chimney, ensuring:

• Early detection of structural issues: Preventing costly failures before they occurred.
• Optimized maintenance scheduling: Allowing Klabin to plan proactive maintenance rather than emergency shutdowns.
• Improved resource allocation: Prioritizing high-risk areas with data-driven decision-making.

Advanced Voliro T High Temperature UT Sensor Technology for Extreme Conditions

The inspection was conducted using an ultrasonic sensor capable of withstanding temperatures up to 260°C, allowing the process to take place while the chimney remained fully operational. This minimized shutdown requirements, optimized efficiency, and reduced operational costs.

The Future of Industrial Chimney Inspections

With the success of this project, Klabin has embraced drone-based inspections as a new standard for improving efficiency, safety, and cost-effectiveness in industrial asset management. The ability to perform precise, real-time inspections while assets remain operational has redefined expectations for asset integrity monitoring in the paper production industry.

As more industrial facilities look to minimize downtime and optimize maintenance costs, advanced solutions like Voliro T are proving to be the future of industrial inspections.