No or low cost Extrusion Coating Improvements · 2009-12-02 · No or low cost e/c improvements Lou Piffer Temperature Distribution Around Chill Roll 0 360 100 200 300 400 500 0 600

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


Challenges in Extrusion Coating


•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


Stand-up pouch

MetallizedFilm 20 mic/20 mic

ADH/PE Coex

10 micron Foil

20 mic PE

Unwind


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


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


Toothpaste Tube

110µ PE Film

20µ Foil20µ/20µPE/EAA Coex

20µ/20µEAA/LLD Coex

110µ Film


Aseptic Structure

Paper25 mic PE

Lamination

6 – 7 mic foil

25 mic PE

Cover coat50 micron PE

Inside layer


Effectiveness• Performance • Availability• Quality


What they really want!


Performance

The need for speed!


Performance – Labor related• Staffing – Liaison


The value of employees!


Performance – Labor related• Staffing – Liaison• Complacency – Old line/new line• Labor relations


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


Performance – other issues• Output

– Screw– Motor


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


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


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



– Screw– Motor

• Ancillary systems (trim, blowers, etc)


Corona treater blower


Trim Pick-up


Trim Pick-up



– Screw– Motor

• Ancillary systems (trim, blowers, etc)• Edge Weave


Edge Instability is the Limitation




Edge weave issues• ID die set correctly?


Series 50 Internal Deckles


Relative Positions of Internal Blades Influence Edge Bead Size and Shape




Restabilizing the Edge


Further Edge Reduction


Edge weave issues

ID die set correctly?

• Running too thin?• Can you change the melt index?



– Screw– Motor

• Ancillary systems (trim, blowers, etc)• Edge weave• Stripping problems


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


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


Performance – other issues

• Output – Screw– Motor

• Ancillary systems (trim, blowers, etc)• Edge weave• Stripping problems• Roll Handling


Roll Handling


Roll Handling• Simple change – composite shafts• Greater change – automatic system


Availability

Waste is a waste!


Availability• Internal deckle dies inefficiencies

– Cleaning of lands


External Deckle Die - Cleaning


External Deckle Die - Cleaning


Internal Deckle Die - Cleaning

9.5MM (3/8”)



– Cleaning of lands– Leakage


External-Only Deckles

• Disadvantage: External-only deckles increase edge bead size and create stagnation areas within the die flow channel.


Leakage


Leakage


Internal Deckle Die - Cleaning

9.5MM (3/8”)







• Material Left on the Core


Material Left on the Core


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”+



– Cleaning of lands– Leakage– Resin type

• Material left on core• Obsolescence




• Material left on core• Obsolescence• More recipe variables = less down time

•


Controls – Recipe driven• New width adjustment for unwind/winder• Slitter positioning• Deckle width• Edge guide positioning• Treater width• Valve stem


Motorized spindle adjustment• Unwinds and winders automatically adjust to new recipe

web width.• Lead screw RPM read by encoder


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


65.0 [1651]WEB MAX.

38.0 [965]WEB MIN.


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



Motorized Guide Sensor

• Motorized sensors positioned to recipe dependent position

• Position feedback to the line control



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



Motorized Valve Stem• Position of valve stem adjusted through motor• Valve stem position can be placed in pressure PID

control loop.


Motorized Adapters




• Material left on core• Obsolescence• More recipe variables = less downtime• Transfers and splices


Quality

Quality is King!


Quality• Melt

– Screw


Old Screw


Quality• Melt

– Screw– Water Circulation System


Feed Section• Cast iron jacketed• Initial point where resin is

introduced• Space between gear box and

resin feeding point


Quality• Melt

– Screw– Water Circulation System– Adapter


screw

movable valve

melt channel

pressure sensor

screen pack

Valved Adapter


Quality• Melt

– Screw– Water Circulation System– Adapter

• Stretching and Wrinkling


Stretching and Wrinkling• Few tension isolation points can create stretching issues


Tandem Line – Tension Isolation


Stretching and Wrinkling• After unwind• Idlers in Drives• General alignment – wrinkling source• New drives?


Thank YouPRESENTED BY

Lou PifferSenior Sales EngineerDavis-Standard [email protected]

Documents

No or low cost Extrusion Coating Improvements · 2009-12-02 · No or low cost e/c improvements Lou Piffer Temperature Distribution Around Chill Roll 0 360 100 200 300 400 500 0 600