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PBP Optel Sp. z o.o.

Strona główna
Polska
Wroclaw
PBP Optel Sp. z o.o.

Ultrasonic technology / NDT / Research & Development / Fingerprint recognition

Welcome to visit www.ultrasonic.technology or www.optel.pl

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30/07/2026

"It can’t be tested.”

That is usually where our work begins.

A wall too thin. A weld too complex. A pipe too hot. A signal buried under geometry and noise.

These are not reasons to stop. They are engineering questions waiting for answers.

At PBP OPTEL Sp. z o.o., we don’t start with an off-the-shelf catalog. We start with a single question: What must the sound reveal?

By combining ultrasonic physics, custom transducers, high-speed electronics, multichannel acquisition, and dedicated software, we determine:

Can the signal be detected?
Can the measurement be repeated?
Can it be automated?
Can it perform under real industrial conditions?

Sometimes the right transducer doesn't exist yet. Sometimes the electronics must be redesigned from scratch. Sometimes the answer is simply hidden deep within the signal.

Send us the component others call impossible to inspect. Share the geometry, material, target defect, or process parameter.

Let us turn your measurement challenge into a proven industrial solution.

Have an inspection problem that standard systems can't solve? Let’s talk in the comments or via DM. 👇

10/06/2026

Case Study: Automated Ultrasonic Inspection of Steel Pipes Directly on the Production Line

OPIPE-STEEL by PBP OPTEL
In steel pipe manufacturing, weld quality is not just a technical parameter.
It is a production decision.

Can the pipe move forward in the process?
Can it pass hydrostatic and acceptance testing?
Can it be safely used in demanding Oil & Gas applications?

For manufacturers of longitudinally welded steel pipes, manual ultrasonic testing has clear operational limitations:
❌ high operator dependency
❌ limited repeatability
❌ slower defect localization
❌ unstable acoustic coupling
❌ risk of unnecessary rejects caused by coupling losses
❌ downtime, rework and delayed quality decisions

To address these challenges, PBP OPTEL developed and implemented OPIPE-STEEL, a fully automated inline ultrasonic inspection system for NDT of steel pipes.

The system is built around two synchronized inspection subsystems:
🔹 WELD inspection
Dedicated to longitudinal welds, transverse defects, heat-affected zones, pipe ends and edge areas.
The sequence includes 15 inspection steps, each assigned to specific probes and physical zones of the pipe.

🔹 BASE MATERIAL inspection
Dedicated to detecting laminations and delaminations in the pipe wall.
The system uses independent channels and gate logic to distinguish real material indications from temporary loss of acoustic coupling.

At the core of OPIPE-STEEL are OPCARD-2.2 ultrasonic flaw detection cards, operating with 100 MHz sampling, and OPMUXv12 multichannel multiplexers.

But the real value goes beyond signal acquisition.
The key element is integration with production line automation.

Dedicated hardware adapters transmit defect signals directly to the PLC, control coupling media and monitor pneumatic inspection arms.

This allows the system to detect discontinuities and protect the process against mechanical risks, coupling failures and unstable inspection conditions.

The result:
✅ inline inspection instead of sample-based control
✅ repeatable evaluation of welds and base material
✅ automatic defect signalling to the PLC
✅ reduced operator dependency
✅ improved process safety
✅ structured calibration and inspection documentation
✅ faster quality decisions directly on the production line

In industrial NDT, detecting a defect is only part of the challenge.

The real goal is to build a stable, automated inspection architecture that supports quality decisions in real time.

OPIPE-STEEL is a practical example of how ultrasonic testing can become an integrated part of modern steel pipe manufacturing.

Ready to integrate automated inline NDT into your production process?

👇 Comment “OPIPE” or contact us directly, and we will share more technical information about the system architecture and ultrasonic inspection modules.

08/06/2026

Case Study: How to Detect EBW Weld Defects in Gear Wheels Without Destroying a Single Part

In automotive manufacturing, there is no such thing as a “small” weld defect.

Especially in gear wheels and drivetrain components welded by Electron Beam Welding, EBW.

EBW creates narrow, deep welds with minimal thermal distortion. But every weld must survive fatigue, vibration, torque and long-term mechanical stress.

A microscopic lack of fusion, shrinkage crack or internal discontinuity can become the starting point of premature gearbox failure.

The problem with traditional inspection

Destructive testing and metallographic analysis are accurate, but the tested part is destroyed. Manufacturers can inspect only samples, not every component.

Sample-based quality control always leaves one question:

What about the parts that were not tested?

Radiographic testing, RT, can also be slow, expensive and less effective when detecting narrow planar defects typical of EBW welds.

The solution: OPeBeamCtrl by OPTEL

OPTEL developed OPeBeamCtrl, a multi-probe ultrasonic system for 100% EBW weld control in gear wheels and drivetrain components.

The system delivers:
🔹 360° circumferential weld scanning
🔹 432 to 65,535 points per weld circumference
🔹 Interchangeable probes for different diameters and geometries
🔹 Automated defect detection and digital reporting

What makes it different?

Instead of raw signals, the operator receives a real-time B-scan view of the weld cross-section.

The software detects discontinuities, defines their size and type, identifies their angular position and calculates their share across the weld circumference.

This helps assess mechanical impact and avoid both accepting defective parts and rejecting good ones.

Built for Industry 4.0
Each inspection can start with barcode identification.
The system scans the weld, analyzes the data and generates a digital PASS/FAIL report.

Data can be transferred to MES or ERP systems to monitor trends and identify process drift.

The business impact

✅ No destructive waste in routine quality control
✅ 100% component traceability
✅ Reduced risk of claims and recalls
✅ Faster weld inspection
✅ Lower operational costs

Weld quality cannot be a statistical assumption.
It must be proven.

Part by part.
Weld by weld.
Every time.

📩 Want to check if this technology can be adapted to your line?

DM us or contact us: [email protected]

03/06/2026

The invisible layer inside a crude oil tank can cost millions. 🛢️

In large-scale crude oil storage tanks, the most critical information is often hidden beneath the surface.

Oil.
Emulsion.
Water.

Three layers. One tank. High stakes.

For Oil & Gas operators, knowing where these phase boundaries are is not just about optimization. It is about safety, crude quality, energy efficiency and reducing downtime.

The challenge

Traditional measurement methods struggle in crude oil tanks because the internal environment is complex, unstable and harsh.

The transition zone between oil and water is rarely a clean line. It is often a dense, changing emulsion layer that is difficult to identify accurately.

When this boundary is unclear, operators risk:

❌ removing valuable oil with wastewater
❌ leaving too much water in the tank
❌ compromising crude quality
❌ reducing downstream efficiency
❌ increasing energy consumption
❌ creating operational and environmental risks

The OPTEL solution

At PBP OPTEL, we developed a dedicated multi-channel ultrasonic system for monitoring liquid distribution directly inside crude oil storage tanks.

The system uses 40 ultrasonic transceiver channels to create a detailed acoustic profile of the tank interior.

Not from assumptions.
Not from manual dip checks.
Not from delayed laboratory samples.

But from real-time ultrasonic profiling directly in the process environment.

What makes this solution different?

🔹 Intrinsically safe design for ATEX / Ex-zone applications
Engineered for safe operation in explosive hazardous areas.

🔹 40-channel ultrasonic profiling
A vertical sensor array provides detailed information on liquid layer distribution inside the tank.

🔹 Real-time phase boundary detection
Supports identification of boundaries between oil, emulsion and water.

🔹 Better process control
Operators gain reliable data for dewatering, separation management and automation.

The result

✅ greater visibility inside the tank
✅ precise control over separation and dewatering
✅ reduced risk of product loss
✅ safer automation of demanding processes
✅ higher confidence in operational decisions

This is where ultrasonic technology becomes more than measurement.

It becomes process intelligence.

At PBP OPTEL, our Wrocław-based team supports industrial partners from testability analysis and feasibility studies to custom OEM hardware integration on-site.

In modern Oil & Gas, the question is no longer:

“Can we measure it?”

The real question is:

“Can we understand what is happening inside the process before it becomes a problem?”

Let’s make the invisible visible.

📩 Contact our engineering team to discuss custom ultrasonic solutions for liquid measurement, phase detection and process automation:

👉 [email protected] | [email protected]

19/05/2026

Dr inż. Agnieszka Bicz Appointed to the Committee on Acoustics of the Polish Academy of Sciences

We are pleased to announce that Dr. Agnieszka Bicz, Member of the Management Board of PBP OPTEL Sp. z o.o. and expert in ultrasonic techniques and non-destructive testing (NDT), has been appointed as a member of the Ultrasound, Underwater and Medical Acoustics Section of the Committee on Acoustics of the Polish Academy of Sciences (PAN) for the 2026 to 2028 term.

This appointment is a significant scientific and professional distinction, recognizing Dr. Bicz’s long-standing contribution to the development of ultrasonics, applied acoustics, and advanced ultrasonic measurement systems.

For over three decades, ultrasonics and non-destructive testing have been at the core of her professional work, from early-stage research and development to the design of high-precision ultrasonic systems and real industrial implementations.

At PBP OPTEL, this experience directly supports the company’s mission: to bridge advanced scientific knowledge with practical industrial engineering and to deliver reliable ultrasonic technologies for research, industry, and non-destructive evaluation.

We sincerely congratulate Agnieszka Bicz on this appointment and are proud that her expertise will contribute to the work of the Committee on Acoustics of the Polish Academy of Sciences.

PBP OPTEL continues to advance ultrasonic technology, applied acoustics, and NDT solutions for demanding scientific and industrial applications

19/05/2026

I am deeply honored and proud to share a significant milestone in my professional journey.

I have been appointed as a member of the Ultrasound, Underwater and Medical Acoustics Section of the Committee on Acoustics of the Polish Academy of Sciences (PAN) for the 2026–2028 term.

For over three decades, ultrasonics and non-destructive testing (NDT) have been more than just a career. They have been my greatest professional passion.

From early-stage R&D and designing high-precision ultrasonic systems to real-world industrial implementations, this field has shaped how I approach science and engineering.

This appointment is both a privilege and an exciting opportunity to help bridge the gap between academic excellence and practical industrial engineering.

My sincere thanks to the Committee on Acoustics of the Polish Academy of Sciences for their trust.

I look forward to collaborating with distinguished colleagues and continuing to push the boundaries of acoustic technology and innovation.

dr inż. Agnieszka Bicz

08/05/2026

Before AI can find a defect,
someone has to capture the signal.

Before automation.
Before dashboards.
Before “smart inspection.”

There is physics.

A pulse. An echo.
A material that answers in microseconds.
This is where ultrasonic engineering really begins.

Not in the final report.
Not in the software screenshot.
Not in the pass/fail decision.

It begins much earlier:
At the transducer.
At the first echo.

At the moment when weak data either becomes useful, or becomes noise.

Because if the signal is poor,
no algorithm can make it true.

For over 35 years, at PBP OPTEL, we’ve followed one rule:

Better data first. Smarter interpretation second.

Whether it’s medical research or heavy industrial NDT, the lesson remains:

AI can help classify.

Automation can help scale.

But everything starts with the signal.

Physics doesn’t care about buzzwords.

It rewards those who listen carefully.

What is the one engineering principle you still trust more than any trend?

06/05/2026

Quality control doesn’t end on the surface.

Sometimes the real defect is hidden inside.

Before the panel looks wrong.
Before the customer complains.
Before waste becomes visible.

In particle boards, MDF, HDF and OSB, delaminations, blows and internal inconsistencies may remain invisible from the outside.

But ultrasound can listen deeper.

That is exactly why **UPU 3000, Ultrasonic Camera** was developed by **PBP OPTEL Sp. z o.o.** for **GreCon**.

An advanced ultrasonic system for non-destructive inspection of wood-based panel materials.

Inline.
Real-time.
At transport speeds of up to **250 m/min**.

It detects what the eye cannot see.
It supports thickness and gap monitoring.
It uses natural panel gaps for automatic zeroing and sensor condition monitoring.

For us, UPU 3000 is more than a measurement system.

It proves that our ultrasonic engineering is ready for demanding, high-speed, automated industrial lines around the world.

Because modern quality control is not only about finding defects.

It is about understanding the process early enough to act.

Physics doesn’t change.

We just get better at listening.

05/05/2026

The most expensive defect is not the one you detect.

It is the one that keeps moving down the production line.

Random sample testing tells you what happened to a sample.

In-line inspection tells you what is happening to the process.

In rod manufacturing, this difference matters, especially in automotive, aerospace, steel processing and nuclear applications, where material integrity becomes a safety-critical parameter.

That is why OPTEL developed **OpRod v3.1**: a multi-channel ultrasonic system for **100% in-line rod inspection during production**.

The challenge?

Production is not a laboratory.

The rod moves.
It vibrates.
The surface echo shifts.
And the system must distinguish a real discontinuity from process noise.

This is where **REL1 relative gates** make the difference.

Instead of keeping defect detection gates fixed in time, OpRod allows them to follow the reference surface echo of the rod.

So when the material moves, the detection logic stays aligned with the real ultrasonic signal, not with an ideal, static setup.

And with ultrasonic signal sampling up to **100 MHz**, the system works with a very fine time resolution, corresponding to a theoretical defect positioning step of approximately **0.0295 mm** in steel.

**What OpRod v3.1 enables:**

✅ 16 ultrasonic channels
✅ external and internal flaw detection
✅ reduced false alarms
✅ real-time rod cross-section visualization
✅ alarm history and traceability
✅ integration with PLC, MES/ERP and rejection systems
✅ data archiving for Industry 4.0 production environments

In modern manufacturing, NDT is no longer just a final quality check.

It is becoming part of process control.

Because the goal is not only to find defects.

The goal is to stop defective material before it moves further down the value chain.

That is where ultrasonic inspection becomes production intelligence.

23/04/2026

A pressure cylinder is only “safe” until the day nobody checks it properly.

That is why inspection frequency is not just a technical parameter.

It is a safety issue.

In the European gas sector, inaccurate tare weight identification is estimated to generate around €1.2 billion in losses every year for SMEs.

But the real problem goes beyond economics.

When cylinder integrity is uncertain, safety, traceability, and operational reliability are all at risk.

That is exactly the challenge addressed by the EU-funded TARE-IT project, which developed a hybrid non-contact NDT approach for:

🔹 tare identification
🔹 corrosion detection
🔹 screening during the filling process

The system combined:

▪️ Laser ultrasonics
▪️ EMAT
▪️ Air-coupled testing

Why does this matter?

Because traditional inspection intervals of 5 to 10 years are not enough for assets operating under constant pressure, repeated handling, and demanding field conditions.

A solution capable of checking cylinders during filling, without couplant, and even through paint or oxidation changes the logic completely.

It shifts inspection from an occasional control step to something far more valuable:
an embedded safety function of the process itself.

That is the moment when advanced ultrasonics stop being just a laboratory capability
and start becoming a real industrial advantage.

Potential impact:

✅ Higher operational productivity
✅ Fewer losses linked to tare weight errors
✅ More frequent integrity screening
✅ Improved safety across the full cylinder lifecycle
✅ Greater efficiency for gas SMEs
✅ Protection of high-tech competence and jobs in Europe

At PBP OPTEL Sp. z o.o., we were proud to contribute to work that showed how hybrid ultrasonic systems can solve real industrial problems, where accuracy, scalability, and safety all matter at once.

Because in industry, assumptions are expensive.

Verification is what creates safety.

Adres

Jerzego Kowalskiego 5
Wroclaw
52-428

Godziny Otwarcia

Poniedziałek	08:00 - 17:00
Wtorek	08:00 - 17:00
Środa	08:00 - 17:00
Czwartek	08:00 - 17:00
Piątek	08:00 - 17:00
Sobota	10:00 - 14:00

Strona Internetowa

https://www.optel.eu/

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