No or low cost Extrusion Coating Improvements

Transcription

1 No or low cost Extrusion Coating Improvements Tappi India Conference Senior Sales Engineer Davis-Standard, LLC

2 Challenges in Extrusion Coating

3 Flexible Laminations Single or Multiple Extruder Carriage 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

4 Stand-up pouch Unwind Metallized Film 20 mic PE 10 micron Foil 20 mic/20 mic ADH/PE Coex

5 Printing/Coat Combination Line Winder Gauge Foil Unwind Ext Coating Foam Unwind 2-Color Printer/Laminator Main Unwind 2-Color gravure printing with dry bond laminator combined with coating or laminating in-line. Foil EAA Film Print Foil Film Print Film EAA Paper Print Paper Print Paper Foil EAA Foam Adhesive Foam Adhesive Film Print Foam 1 st Pass Film Print Film EVA Foil EAA No or Film low cost e/c improvements Print 2nd Pass

6 Thermal Lamination Film Line Corona EVA LDPE or EVA PEI Primer 40µ BOPP EVA LDPE or EVA Ozone Corona LDPE or EVA Ozone PEI Primer 40µ BOPP Ozone PEI Primer Corona PEI Primer Corona 40µ BOPP Corona 40µ BOPP 40µ BOPP Direction of Web

7 Toothpaste Tube 110µ PE Film 20µ/20µ PE/EAA Coex 20µ Foil 20µ/20µ EAA/LLD Coex 110µ Film

8 Aseptic Structure Paper 25 mic PE Cover coat 25 mic PE Lamination 6 7 mic foil 50 micron PE Inside layer

9 Effectiveness Performance Availability Quality

10 What they really want!

11 Performance The need for speed!

12 Performance Labor related Staffing Liaison

13 The value of employees!

14 Performance Labor related Staffing Liaison Complacency Old line/new line Labor relations

15 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

16 Performance other issues Output Screw Motor

17 4.5, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE 450 OUTPUT RATE (KG/HR) SCREW SPEED (RPM)

18 4.5, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE 324 MELT TEMPERATURE (C) SCREW SPEED (RPM)

19 4.5, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE POWER CONSUMPTION (KW) SCREW SPEED (RPM)

20 Performance other issues Output Screw Motor Ancillary systems (trim, blowers, etc)

21 Corona treater blower

22 Trim Pick-up

23 Trim Pick-up

24 Performance other issues Output Screw Motor Ancillary systems (trim, blowers, etc) Edge Weave

25 Edge Instability is the Limitation

26 Edge Instability is the Limitation

27 Edge weave issues ID die set correctly?

28 Series 50 Internal Deckles

29 Relative Positions of Internal Blades Influence Edge Bead Size and Shape

30 Edge Instability is the Limitation

31 Restabilizing the Edge

32 Further Edge Reduction

33 Edge weave issues ID die set correctly? Running too thin? Can you change the melt index?

34 Performance other issues Output Screw Motor Ancillary systems (trim, blowers, etc) Edge weave Stripping problems

35 C Temperature Distribution Around Chill Roll web 22 mil 200 F speed 260m/min 800 ft/min Round Chill Roll [ ] 316 C F 600 Contact time 0.24 sec. 500 melt shell = 12 mm (0.5 ) 600 F Water 75 F 120 F 100 F 80 F 90 F s u b s t r a t e (pre-heated) p l a s t i c plastic stripping temperature

36 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

37 Performance other issues Output Screw Motor Ancillary systems (trim, blowers, etc) Edge weave Stripping problems Roll Handling

38 Roll Handling

39 Roll Handling Simple change composite shafts Greater change automatic system

40 Availability Waste is a waste!

41 Availability Internal deckle dies inefficiencies Cleaning of lands

42 External Deckle Die - Cleaning

43 External Deckle Die - Cleaning

44 Internal Deckle Die - Cleaning 9.5MM (3/8 )

45 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage

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

47 Leakage

48 Leakage

49 Internal Deckle Die - Cleaning 9.5MM (3/8 )

50 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage

51 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage Material Left on the Core

52 Material Left on the Core

53 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 +

54 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage Resin type Material left on core Obsolescence

55 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage Resin type Material left on core Obsolescence More recipe variables = less down time

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

57 Motorized spindle adjustment Unwinds and winders automatically adjust to new recipe web width. Lead screw RPM read by encoder

58 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

59 38.0 [965] WEB MIN [1651] WEB MAX.

60 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

61

62 Motorized Guide Sensor Motorized sensors positioned to recipe dependent position Position feedback to the line control

63

64 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

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66 Motorized Valve Stem Position of valve stem adjusted through motor Valve stem position can be placed in pressure PID control loop.

67 Motorized Adapters

68 Availability Internal deckle dies inefficiencies Cleaning of lands Leakage Resin type Material left on core Obsolescence More recipe variables = less downtime Transfers and splices

69 Quality Quality is King!

70 Quality Melt Screw

71 Old Screw

72 Quality Melt Screw Water Circulation System

73 Feed Section Cast iron jacketed Initial point where resin is introduced Space between gear box and resin feeding point

74 Quality Melt Screw Water Circulation System Adapter

75 Valved Adapter pressure sensor movable valve screw melt channel screen pack

76 Quality Melt Screw Water Circulation System Adapter Stretching and Wrinkling

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

78 Tandem Line Tension Isolation

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

80 Thank You PRESENTED BY Senior Sales Engineer Davis-Standard LLC