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No or low cost e/c improvements Lou Piffer
No or low cost Extrusion Coating Improvements
Lou PifferTappi India ConferenceSenior Sales Engineer – Davis-Standard, LLC
No or low cost e/c improvements Lou Piffer
Challenges in Extrusion Coating
No or low cost e/c improvements Lou Piffer
•Single pass or Tandem machine
•Reverse print BOPP / BOPET laminated to CPP / LDPE
•Trends in Emerging Markets up to 300MPM
•Trend in North America and Europe up to 750MPM
Flexible LaminationsSingle or MultipleExtruder Carriage
No or low cost e/c improvements Lou Piffer
Stand-up pouch
MetallizedFilm 20 mic/20 mic
ADH/PE Coex
10 micron Foil
20 mic PE
Unwind
No or low cost e/c improvements Lou Piffer
2-Color gravure printing with dry bond laminator combined with coating or laminating in-line.
Printing/Coat Combination Line
Winder Gauge Foil Unwind Ext Coating Foam Unwind 2-Color Printer/Laminator Main Unwind
FilmFilmPrint
FilmPrint
EAA
Foil
PaperPaperPrint
PaperPrint
EAA
Foil
FilmFilmPrint
Adhesive
Foam
Foam
FilmPrint
EAA
Foil
FoamAdhesive
1st Pass
Foil
EAA
FilmPrint
EVA
2nd Pass
No or low cost e/c improvements Lou Piffer
Thermal Lamination Film Line
Direction of Web
40µ BOPPPEI Primer
Corona
40µ BOPP
LDPE or EVA
Ozone
PEI Primer
Corona
40µ BOPP
EVA
LDPE or EVA
Ozone
PEI Primer
Corona
40µ BOPP
Corona
EVA
LDPE or EVA
Ozone
PEI Primer
Corona
40µ BOPP
No or low cost e/c improvements Lou Piffer
Toothpaste Tube
110µ PE Film
20µ Foil20µ/20µPE/EAA Coex
20µ/20µEAA/LLD Coex
110µ Film
No or low cost e/c improvements Lou Piffer
Aseptic Structure
Paper25 mic PE
Lamination
6 – 7 mic foil
25 mic PE
Cover coat50 micron PE
Inside layer
No or low cost e/c improvements Lou Piffer
Effectiveness• Performance • Availability• Quality
No or low cost e/c improvements Lou Piffer
What they really want!
No or low cost e/c improvements Lou Piffer
Performance
The need for speed!
No or low cost e/c improvements Lou Piffer
Performance – Labor related• Staffing – Liaison
No or low cost e/c improvements Lou Piffer
The value of employees!
No or low cost e/c improvements Lou Piffer
Performance – Labor related• Staffing – Liaison• Complacency – Old line/new line• Labor relations
No or low cost e/c improvements Lou Piffer
A labor success story
• 200 MPM avg. to 300 MPM avg.• Revenue increase plant wide of 60%
–“Folklore of the floor”–“Re-evaluate your assumptions”–“Increase training” – Inter-connectiveness–“Keep good supervisors”–Alignment–Operators do gapping of dies
No or low cost e/c improvements Lou Piffer
Performance – other issues• Output
– Screw– Motor
No or low cost e/c improvements Lou Piffer
0
50
100
150
200
250
300
350
400
450
0 50 100 150 200 250SCREW SPEED (RPM)
OU
TPU
T R
ATE
(KG
/HR
)4.5”, 30L/D ExtruderScrew: Single Stage, MixingMaterial: 7MI LDPE
No or low cost e/c improvements Lou Piffer
310
312
314
316
318
320
322
324
0 50 100 150 200 250SCREW SPEED (RPM)
MEL
T TE
MPE
RA
TUR
E (C
)
4.5”, 30L/D ExtruderScrew: Single Stage, MixingMaterial: 7MI LDPE
No or low cost e/c improvements Lou Piffer
0
20
40
60
80
100
120
0 50 100 150 200 250SCREW SPEED (RPM)
POW
ER C
ON
SUM
PTIO
N (K
W)
4.5”, 30L/D ExtruderScrew: Single Stage, MixingMaterial: 7MI LDPE
No or low cost e/c improvements Lou Piffer
Performance – other issues• Output
– Screw– Motor
• Ancillary systems (trim, blowers, etc)
No or low cost e/c improvements Lou Piffer
Corona treater blower
No or low cost e/c improvements Lou Piffer
Trim Pick-up
No or low cost e/c improvements Lou Piffer
Trim Pick-up
No or low cost e/c improvements Lou Piffer
Performance – other issues• Output
– Screw– Motor
• Ancillary systems (trim, blowers, etc)• Edge Weave
No or low cost e/c improvements Lou Piffer
Edge Instability is the Limitation
No or low cost e/c improvements Lou Piffer
Edge Instability is the Limitation
No or low cost e/c improvements Lou Piffer
Edge weave issues• ID die set correctly?
No or low cost e/c improvements Lou Piffer
Series 50 Internal Deckles
No or low cost e/c improvements Lou Piffer
Relative Positions of Internal Blades Influence Edge Bead Size and Shape
No or low cost e/c improvements Lou Piffer
Edge Instability is the Limitation
No or low cost e/c improvements Lou Piffer
Restabilizing the Edge
No or low cost e/c improvements Lou Piffer
Further Edge Reduction
No or low cost e/c improvements Lou Piffer
Edge weave issues
ID die set correctly?
• Running too thin?• Can you change the melt index?
No or low cost e/c improvements Lou Piffer
Performance – other issues• Output
– Screw– Motor
• Ancillary systems (trim, blowers, etc)• Edge weave• Stripping problems
No or low cost e/c improvements Lou Piffer
Temperature Distribution Around Chill Roll
0 360
100
200
300
400
500
0
600
30 60 90 120 150 180 210 240 270 300 33Round Chill Roll [°]
°C °F
38
94
150
204
260
316
s u b s t r a t e (pre-heated)p l a s t i c
90°F
web melt
600°F
100°F 80°F
120°F200°Fspeed 260m/min
800 ft/min
22 mil
Water
316°C
Contact time 0.24 sec.
shell = 12 mm (0.5”)
75°F
plastic stripping temperature
No or low cost e/c improvements Lou Piffer
Stripping problems• Increase chill roll diameter • Increase pump/rotary unions/piping• Increase surface roughness• Air condition building • Air condition laminator area• See if finish is smoothing out over time
No or low cost e/c improvements Lou Piffer
Performance – other issues
• Output – Screw– Motor
• Ancillary systems (trim, blowers, etc)• Edge weave• Stripping problems• Roll Handling
No or low cost e/c improvements Lou Piffer
Roll Handling
No or low cost e/c improvements Lou Piffer
Roll Handling• Simple change – composite shafts• Greater change – automatic system
No or low cost e/c improvements Lou Piffer
Availability
Waste is a waste!
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands
No or low cost e/c improvements Lou Piffer
External Deckle Die - Cleaning
No or low cost e/c improvements Lou Piffer
External Deckle Die - Cleaning
No or low cost e/c improvements Lou Piffer
Internal Deckle Die - Cleaning
9.5MM (3/8”)
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage
No or low cost e/c improvements Lou Piffer
External-Only Deckles
• Disadvantage: External-only deckles increase edge bead size and create stagnation areas within the die flow channel.
No or low cost e/c improvements Lou Piffer
Leakage
No or low cost e/c improvements Lou Piffer
Leakage
No or low cost e/c improvements Lou Piffer
Internal Deckle Die - Cleaning
9.5MM (3/8”)
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage
• Material Left on the Core
No or low cost e/c improvements Lou Piffer
Material Left on the Core
No or low cost e/c improvements Lou Piffer
Material left on the core• Present day – encoder/drive = 2 wraps• Yesterday – sonar = 1/8” – ¼” left• Years ago – contact device – ¼” left• Always there – operator – 2 wraps to ¼”+
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage– Resin type
• Material left on core• Obsolescence
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage– Resin type
• Material left on core• Obsolescence• More recipe variables = less down time
•
No or low cost e/c improvements Lou Piffer
Controls – Recipe driven• New width adjustment for unwind/winder• Slitter positioning• Deckle width• Edge guide positioning• Treater width• Valve stem
No or low cost e/c improvements Lou Piffer
Motorized spindle adjustment• Unwinds and winders automatically adjust to new recipe
web width.• Lead screw RPM read by encoder
No or low cost e/c improvements Lou Piffer
Motorized slitter positioning• Servo drives move slitter assemblies to recipe
determined positions• Trim extraction system mounted to the motorized base
to follow slitter assembly• Position feedback to control system
No or low cost e/c improvements Lou Piffer
65.0 [1651]WEB MAX.
38.0 [965]WEB MIN.
No or low cost e/c improvements Lou Piffer
Motorized Deckles• Deckle position provided in recipe with motorized
movement coordinated with control cycle.• Programmed closure of deckles for startup and moving
online and offline• Position feedback to the line control
No or low cost e/c improvements Lou Piffer
No or low cost e/c improvements Lou Piffer
Motorized Guide Sensor
• Motorized sensors positioned to recipe dependent position
• Position feedback to the line control
No or low cost e/c improvements Lou Piffer
No or low cost e/c improvements Lou Piffer
Motorized Treater Adjustment• Flame treater motorized deckle and gap adjustment.
Info is placed in recipe• Power or treatment level is recipe driven with feedback• Exhaust system uses AC variable drive to adjust to line
speed
No or low cost e/c improvements Lou Piffer
No or low cost e/c improvements Lou Piffer
Motorized Valve Stem• Position of valve stem adjusted through motor• Valve stem position can be placed in pressure PID
control loop.
No or low cost e/c improvements Lou Piffer
Motorized Adapters
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage– Resin type
• Material left on core• Obsolescence• More recipe variables = less downtime• Transfers and splices
No or low cost e/c improvements Lou Piffer
Quality
Quality is King!
No or low cost e/c improvements Lou Piffer
Quality• Melt
– Screw
No or low cost e/c improvements Lou Piffer
Old Screw
No or low cost e/c improvements Lou Piffer
Quality• Melt
– Screw– Water Circulation System
No or low cost e/c improvements Lou Piffer
Feed Section• Cast iron jacketed• Initial point where resin is
introduced• Space between gear box and
resin feeding point
No or low cost e/c improvements Lou Piffer
Quality• Melt
– Screw– Water Circulation System– Adapter
No or low cost e/c improvements Lou Piffer
screw
movable valve
melt channel
pressure sensor
screen pack
Valved Adapter
No or low cost e/c improvements Lou Piffer
Quality• Melt
– Screw– Water Circulation System– Adapter
• Stretching and Wrinkling
No or low cost e/c improvements Lou Piffer
Stretching and Wrinkling• Few tension isolation points can create stretching issues
No or low cost e/c improvements Lou Piffer
Tandem Line – Tension Isolation
No or low cost e/c improvements Lou Piffer
Stretching and Wrinkling• After unwind• Idlers in Drives• General alignment – wrinkling source• New drives?
No or low cost e/c improvements Lou Piffer
Thank YouPRESENTED BY
Lou PifferSenior Sales EngineerDavis-Standard LLCpifferl@bc-egan.com
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