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No or low cost Extrusion Coating Improvements
Lou PifferSenior Sales Engineer – Davis-Standard, LLCPaper #6.1
No or low cost e/c improvements Lou Piffer
Performance – Labor related• Staffing – Liaison• Complacency – Old line/new line• Organized labor
No or low cost e/c improvements Lou Piffer
Organized Labor – A success story• 600 FPM avg. to 950 – 1000 FPM 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
4.5”, 30L/D ExtruderScrew: Single Stage, MixingMaterial: 7MI LDPE
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
)
No or low cost e/c improvements Lou Piffer
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
)
No or low cost e/c improvements Lou Piffer
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)
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
Performance – other issues• Output
– Screw– Motor
• Ancillary systems (trim, blowers, etc)• Edge Weave
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 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 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• Simple change – composite shafts• Greater change – automatic system
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
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
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage– Resin Type
No or low cost e/c improvements Lou Piffer
Availability• Internal deckle dies inefficiencies
– Cleaning of lands– Leakage– Resin type– 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
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
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
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
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
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
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
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
Stretching and Wrinkling• After unwind• General alignment – wrinkling source• New drives?
No or low cost e/c improvements Lou Piffer
Thank YouPRESENTED BY
Lou PifferSenior Sales EngineerDavis-Standard [email protected]
Please remember to turn in your evaluation sheet...