No Or Low Cost Extrusion Coating Improvements

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No or low cost Extrusion Coating Improvements Lou Piffer Tappi India Conference Senior 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 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 No or low cost e/c improvements Lou Piffer Stand-up pouch Unwind Metallized Film 20 mic PE 10 micron Foil 20 mic/20 mic ADH/PE Coex No or low cost e/c improvements Lou Piffer Printing/Coat Combination Line Winder Gauge Foil Unwind Ext Coating Foam Unwind 2-Color Printer/Laminator Main Unwind Foil 2-Color gravure printing with dry bond laminator combined with coating or laminating in-line. EAA Film Film Film Print Print Foil EAA Paper Paper Paper Print Print Foil EAA Foam Foam Adhesive Film Print Adhesive Film Foam Print 1st Pass EVA Foil EAA No or Film low cost e/c improvements 2nd Pass Print Lou Piffer Film Thermal Lamination Film Line Corona EVA LDPE or EVA PEI Primer 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 No or low cost e/c improvements Lou Piffer 40µ BOPP Toothpaste Tube 110µ PE Film 20µ/20µ PE/EAA Coex 20µ Foil 20µ/20µ EAA/LLD Coex No or low cost e/c improvements Lou Piffer 110µ Film Aseptic Structure Paper 25 mic PE 25 mic PE Cover coat Lamination 50 micron PE Inside layer 6 – 7 mic foil 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 4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE 450 OUTPUT RATE (KG/HR) 400 350 300 250 200 150 100 50 0 0 50 100 150 SCREW SPEED (RPM) No or low cost e/c improvements Lou Piffer 200 250 4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE MELT TEMPERATURE (C) 324 322 320 318 316 314 312 310 0 50 100 150 SCREW (RPM) No or low cost e/c SPEED improvements Lou Piffer 200 250 POWER CONSUMPTION (KW) 4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE 120 100 80 60 40 20 0 0 50 100 150 SCREW SPEED (RPM) No or low cost e/c improvements Lou Piffer 200 250 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 °C 316 °F 600 316°C Contact time 0.24 sec. 260 web 22 mil 500 melt shell = 12 mm (0.5”) 204 150 200°F speed 260m/min 800 ft/min 600°F Water 300 75°F 100°F 94 80°F 90°F s u b s t r a t e (pre-heated) plastic 38 Round Chill Roll [°] 0 120°F 30 60 90 150 200 100 plastic stripping temperature 0 No or low cost e/c improvements Lou Piffer 120 400 180 210 240 270 300 360 33 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 38.0 [965] WEB MIN. 65.0 [1651] WEB MAX. 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 Valved Adapter pressure sensor movable valve screw melt channel No or low cost e/c improvements Lou Piffer screen pack 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 You PRESENTED BY Lou Piffer Senior Sales Engineer Davis-Standard LLC [email protected] No or low cost e/c improvements Lou Piffer