No Or Low Cost Extrusion Coating Improvements
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 10 micron 20 mic PE 20 mic/20 mic Film Foil 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 EAA Film Film Film bond laminator combined with Print Print coating or laminating in-line. Foil EAA Paper Paper Paper Print Print
Foil EAA Foam Foam Adhesive Adhesive Film Film Film Foam Print Print 1st Pass
EVA Foil EAA No or low cost e/c improvements Film 2nd Pass Print Lou Piffer 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
No or low cost e/c improvements Lou Piffer Toothpaste Tube
110µ PE 20µ/20µ 20µ Foil 20µ/20µ 110µ Film Film PE/EAA Coex EAA/LLD Coex
No or low cost e/c improvements Lou Piffer Aseptic Structure
25 mic PE 25 mic PE Paper 50 micron PE Lamination Cover coat 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
450 400 350 300 250 200 150 100 OUTPUT RATE (KG/HR) 50 0 0 50 100 150 200 250 SCREW SPEED (RPM)
No or low cost e/c improvements Lou Piffer 4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE
324
322
320
318
316
314
MELT TEMPERATURE (C) TEMPERATURE MELT 312
310 0 50 100 150 200 250
No or lowSCREW cost e/c SPEEDimprovements (RPM) Lou Piffer 4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE
120
100
80
60
40
20
POWER CONSUMPTION (KW) CONSUMPTION POWER 0 0 50 100 150 200 250 SCREW SPEED (RPM)
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 °C °F 316 316°C 600 Contact time 0.24 sec. 260 500 web 22 mil melt shell = 12 mm (0.5”)
204 400 200°F 600°F 120°F speed 260m/min Water 150 800 ft/min 300 75°F 100°F 80°F 94 200 90°F s u b s t r a t e (pre-heated) 38 p l a s t i c 100 plastic stripping temperature Round Chill Roll [°] 0 No or low cost e/c improvements 0 30 60 90 120 150Lou Piffer 180 210 240 270 300 36330 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 screen pack 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 You
PRESENTED BY Lou Piffer Senior Sales Engineer Davis-Standard LLC [email protected]
No or low cost e/c improvements Lou Piffer