Lines for Extrusion Coating and Laminating

EXTRUSION COATING AND LAMINATING COATING LINES 2 COATING LINES COATING LINES 3

LINES FOR EXTRUSION COATING AND LAMINATING

Extrusion coating It is SML’s human centred approach, in combination with decades of experience and the constant drive for innovation, that makes the difference in and laminating this complex market segment.

solutions SML provides bespoke all-in solutions for nearly every application. That developed by involves various types of packaging materials for the food industry as well as SML are laminates for hygiene applications, for construction, for the textile industry and for the automotive sector. characterised INTRODUCTION A well thought-out design and the ultra-precise interaction of high-performance by technical components enable the creation of extrusion lamination solutions unknown to precision, the market so far. This involves, for example, innovations like extremely thin laminates with an extraordinary breathability or the development of machinery reliability and allowing the joining of materials which were considered incompatible.

easy operability. For SML, extrusion lamination does not merely consist of gluing substrates together. In combination with SML’s completely in-house developed machine control, SMILE, extrusion coating and laminating lines from SML empower manufacturers to influence the properties of end products significantly. SML’s data generation and analysis tool, bitWise provides entirely new opportunities for data driven decision making with a clear focus on the optimisation of production processes and the final product. 4 COATING LINES COATING LINES 5

LINES FOR EXTRUSION COATING AND LAMINATING

Line Description ...... 6 Extrusion Unit ...... 9 Unwinding Equipment ...... 13 ......

CONTENTS Downstream Equipment 18 Winding Systems ...... 22 FlexPack® ...... 34 Triplex Extrusion Lamination Lines ...... 38 DoubleCoat ...... 40 Woven Fabric Extrusion Coating and Laminating Lines ...... 42 Extra Wide Extrusion Coating and Laminating Lines ...... 44 Process Combinations and Integrations ...... 46 Products ...... 47 6 COATING LINES COATING LINES 7 5

2 1

11 12

4 3 7

9 6 12 10

1 RAW MATERIAL HANDLING AND DOSING 5 UNWINDING EQUIPMENT 9 PRIMER STATION

2 EXTRUDER 6 LAMINATOR 10 TRIM HANDLING SYSTEMS

3 MELT FILTRATION 7 THICKNESS MEASUREMENT 11 WINDING SYSTEMS

4 TOOL UNIT 8 CORONA TREATMENT UNIT 12 SMILE CONTROL SYSTEM 8 COATING LINES COATING LINES 9

EXTRUSION TOOL UNIT ADVANCED HEATING/COOLING SYSTEM

1 Raw material 2 Extruder handling and dosing Extrusion systems developed by SML stand for technical precision, field-tested reliability and constant innovations. It is Your Advantages SML’s gravimetric batch blenders and continuous gravimetric SML’s long-time experience in screw design in combination with Specific extruder designs for each type feeders guarantee material blending accuracy and a very simple state-of-the-art in-house testing facilities, that helps to create of raw material repeatability. Up to six components per extruder can be pro- outstanding extrusion solutions for any polymer in coating or cessed, providing a maximum of flexibility. SML’s complete dosing Superior melt quality lamination. system, as well as all the material supply vacuum pumps, filters and valves are fully integrated in the SMILE machine control CUSTOMER-SPECIFIC EXTRUDER DESIGN system. This allows the exact repeatability of recipes, making SML is offers a customer-specific extruder design for each type changes in production very fast and easy to implement at the of polymer. As a standard, a choice of screw diameters from operational level. At the same time, waste production is reduced 45mm to 220mm is available. The L/D ratio can be 28 or 33, to a minimum. whereby 33 is the preferred solution to obtain a high melt temperature and excellent mixing results even at high speeds. Your Advantages OPTIMISED ENERGY EFFICIENCY Highest material blending accuracy As a rule, the extruders are driven by energy-efficient, low-main- Up to six different components per extruder tenance, water-cooled AC motors. All extruder barrels are heated using SML’s advanced heating system. A flap, which closes SMILE control system for fast and efficient product through gravity, the escape of warm air from the system and changes retains the heat in the barrel. 10 COATING LINES COATING LINES 11

SIMPLE MANUAL FILTER FLAT DIE WITH FUME SUCTION HOOD

3 Melt filtration 4 Tool unit feedblock and flat die Effective melt filtration is a crucial issue when it comes to stable production processes and an excellent output quality. For the re- SML relies exclusively on respected partners for its feedblocks and moval of impurities, such as unmelted or cross-linked particles, flat dies. Multilayer structures require great flexibility with regard SML offers a variety of solutions. Simple manual filters can be to feedblock adjustment. Therefore, as a rule, SML utilises variable used for standard virgin coating grades, while SML usually in- geometry feedblocks and inserts that can be profiled to optimise stalls hydraulic, single-piston filters for materials requiring more the thickness tolerances of the individual layers. frequent filter changes. For special applications, i. e. when a substantial share of recycled materials is processed, continuous Hydraulic filter T-CHANNEL DIES WITH INTERNAL AND filtration systems are used. EXTERNAL DECKLING SYSTEMS

MELT PRESSURE REGULATION VALVE SML offers different die designs in line with the respective application. Extrusion coating systems need to run with various An adjustable melt pressure valve can be integrated downstream The valve can be equipped with an optional AC product widths and therefore, die deckling is required. Flat dies FUME SUCTION AS A STANDARD of the filter. This allows the adjustment of extruder backpressure, drive, which allows comfortable extruder back with a coat hanger design have good distribution characteristics, SML provides fume suction in all of its extrusion which can have a beneficial effect on shear rates. Improved pressure adjustment from the machine control but can only be deckled with external decklings. Therefore, in coating lines. As an option, an additional elec- mixing results can thus be achieved even with a low output. system. recent years, the trend has been towards T-channel dies with trostatic filtering system can be equipped with Using a melt pressure valve also helps to increase the melt internal and external decklings. The internal deckling consists of HEPA filters to clean exhaust air, minimising temperature to achieve optimised adhesion properties. individually adjustable blades. This has the positive effect of in- adverse health effects and making over-all pro- fluencing the edge bead and the neck-in of the melt curtain, which duction more eco-friendly. reduces the waste from overcoating. Profile adjustment can either Your Advantages be done with a manual or automatic die control via thermally heated bolts. Your Advantages Selection of different melt filtration systems depending Depending on the manufacturer, dies are either chrome or nickel on the material processed High-end flat dies from respected partners plated. In applications where the extrudate is corrosive, stainless Adjustable melt pressure valve downstream of the filter steel may be selected as a base material. Various types of deckling systems Motorised back pressure adjustment Manual or automatic die bolt control 12 COATING LINES COATING LINES 13

EXTRUDER CARRIAGE

Extruder carriage 5 Unwinding equipment

The extrusion units in SML’s coating and laminating lines can be RECIPE MANAGEMENT FOR Precise and reliably working unwinds are an essential part of any MODULAR SET-UP, easily moved into an offline service position, i. e. to have access COATING POSITIONS extrusion coating process. They guarantee substrate roll changes OPEN TO EXTENSIONS for die lip cleaning. SML offers two types of extruder carriages: a The extrusion units oscillate cross to line direc- up to full production speed, preventing down-times and start-up All fully automatic turret unwinds are built in a floor carriage with infloor rails and a hanging extruder platform. tion during production according to the specific waste. Depending on the structure of the products, a maximum modular design, which allows adding special The floor carriage provides perfect access to all of the installed production requirements. As the relative position of four unwinders can be installed in parallel in SML’s extrusion features to the basic machine, if needed. A sec- equipment from the top, while a hanging extruder platform offers between the die exit and the point of melt con- coating and lamination lines. ond splicing unit for bi-directional unwinding, perfect stiffness for wide coating lines. tact with the substrate is an important process integrated edge guiding or an optional constant parameter that must be altered for different SPECIFIC SOLUTIONS FOR EACH TYPE gap device for the smooth unwinding of thin, materials, the extruder carriage is adjustable in OF SUBSTRATE sensitive aluminium foil, can be installed op- all three axes. For good repeatability, the actual SML offers various types of unwinds for every requirement in pro- tionally. positions are detected, displayed and stored in duction and for any type of substrate. These can be: The unwinds in SML’s lines for coating and recipes. ¡ Simple double-station unwinds with a manual splicing unit lamination are equipped with a separate control ¡ Zero-speed splicers with thermo-welding or butt splice cabinet and their own PLC system. The local Your Advantages ¡ Fully automatic turret unwinders, shafted or shaftless control unit of the unwind is 100 % synchronised with SMILE, the comprehensive over-all Floor carriage with infloor rails for control system of the line. optimal access from the top SENSITIVE TENSION CONTROL All SML turret unwinds are equipped with a lightweight dancer roll Hanging extruder platform for best for sensitive tension control, while the substrate roll is centre-driven stiffness at wide coating lines by an AC servo motor. During splicing, the new roll is automati- Oscillating extrusion units for optimised cally synchronised with the line speed. Splicing is carried out with reel profile a driven bump roll and a pneumatically operated chopping knife. With a defined splice geometry and a position detection, the splice length is minimised.

Hanging extruder arrangement 14 COATING LINES COATING LINES 15

Unwind The turret unwind UW 1500 WS is a cost-efficient solution for Unwind The turret unwind UW 1500 SL is a shaftless unwinding the fully automatic unwinding of substrates with winding shafts. system with production speeds of up to 450 m/min UW 1500 WS UW 1500 SL and for maximum roll diameters of 1,270mm, which can It is capable of production speeds up to 350 m/min and can be used for substrates with a maximum roll diameter of 1,200mm. Splicing can be done up to be easily exchanged. full production speed. For the optimal centring of the substrate roll, winding Core clamping is done with mechanically actuated chucking heads of different shafts with a special circular adapter, in combination with sliding safety chucks, sizes. Each unwinding position is motorised in the transverse direction. It can be are used for core fixation. linked to an edge guiding system for the appropriate positioning of the substrate, The complete unwind is mounted on linear guides. An integrated edge guiding thus avoiding the need for additional web guiding equipment. Furthermore, this system ensures the correct alignment of the substrate. Therefore, no additional design facilitates easy roll handling with standard electric forklifts. web positioning equipment is required. The design enables easy roll handling with standard electric forklifts. Your Advantages Your Advantages

Fully automatic unwinding with winding shafts Fully automatic unwinding for speeds up to 450 m/min with a special Cost efficient solution for roll diameters up to 1,200mm additional web Shaftless operation using mechanically actuated chucking heads circular adapter Integrated edge guiding system guiding equipment Easy roll handling with standard electric forklifts 16 COATING LINES COATING LINES 17

The turret unwind UW 1500 SL-H is the right answer for Unwind UNWIND TYPE Double unwind UW1500 WS UW1500 SL UW1500 SL-H heavy substrates and large roll diameters. It handles widths UW 1500 SL-H Maximal mechanical up to 4,500mm and maximum roll diameters of 1,600mm. 150 m/min 350 m/min 450 m/min 600 m/min speed Splicing can be done up to full production speed. Core clamping is shaftless and employs mechanically actuated chucking heads of various sizes. Integrated Maximal substrate width 5,200mm 1,800mm 2,400mm 3,500mm lifting tables can be utilised for loading and unloading, which brings maximum Maximal mechanical 1,500mm 1,200mm 1,270mm 1,600mm roll handling flexibility in combination with minimum handling times. diameter Each unwinding position is motorised in the transverse direction and can be Core clamping shafted / shaftless shafted shaftless shaftless linked to an edge guiding system for the appropriate positioning of the substrate. For that reason, additional web guiding equipment is not necessary. Maximal roll weight 4,500kg 1,500kg 2,000kg 4,000kg

Your Advantages Unwinding direction both both both both crane / forklift / crane / forklift / Designed for heavy substrate rolls and widths up to 4,500mm Roll handling crane crane / forklift lifting table lifting table maximum roll Shaftless core clamping with mechanically actuated chucking heads handling flexibility Integrated lifting tables for fast and comfortable roll handling 18 COATING LINES COATING LINES 19

LAMINATING NIP THICKNESS MEASURING UNIT CORONA TREATMENT

6 Laminator 7 Thickness measurement

The laminator is the key component of any extrusion coating line, As a response to the differing regulations in customer countries combining all different types of substrates in one single product and specific product requirements, SML supplies automatic gaug- Your Advantages structure. SML’s laminators all have massive side frames which ing systems with infrared, X-ray or beta ray sensors. Automatic gauging systems with are directly mounted on the floor to ensure vibration-free pro- infrared, X-ray or beta ray sensors Apart from single-frame solutions with total product measure- duction. ment, SML also offers multiple frame systems for differential Single-frame solutions with total thickness measurements. All frames are synchronised to ensure product measurement PRECISE ROLL ARRANGEMENT measurements of the same spot. This is necessary to achieve a A pressing unit, consisting of a rubber roll and a steel supporting Differential measurement system for a constant coating thickness, even when the substrate thickness constant overall coating weight roll, is arranged on linear guides to precisely apply a defined has variations. pressure to the coating gap between the rubber roll and the chill roll. All of the rolls are equipped with quick change couplings in order to complete roll changes and perform product surface changes in minimum time. 8 Corona treatment unit

MINIMISED SUBSTRATE WASTE A corona treatment unit modifies the surface tension of the prod- of the corona treatment unit is fully integrated in An endless PTFE tape allows overcoating to minimise substrate uct. It can be installed upstream of the substrates, to increase the SML’s overall machine control system SMILE, waste. An adjustable stripper roll at the outlet of the unit ensures laminator with edge trimming station bonding strength, and downstream to improve printability on the making operation extremely comfortable. the consistent peel-off of the coated material from the chill roll. final product. In most of SML’s coating lines for coating and laminating, the corona treatment unit is mechanically fully integrated RECIPE MANAGEMENT FOR EXACT REPEATABILITY Your Advantages Your Advantages in the unwind side frames. This helps to shorten the web-path All parameters which have a direct impact on product properties, Massive side frames for vibration-free and to minimise the total length of the line. Corona treatment unit up- and down- are comfortably adjustable with SML’s advanced machine control production stream for specific adhesion properties system, SMILE – i. e. the position of the die or the pressing force WEB TENSION CONTROL or the chill roll temperature. For an exact repeatability, all of the Quick release equipment for easy roll Fully integrated into the unwind side changes Depending on the conductivity of the material to be treated, either frames for a short web-path settings of the laminator can be stored in recipes. ceramic or stainless steel electrodes are used. Each station can be Waste reduction with PTFE tape driven and fitted with a rubber pressing roll to avoid backside treat- Easy and simple to operate with SML’s attachment machine control system, SMILE ment and to separate and control web tension. The control system 20 COATING LINES COATING LINES 21

PRIMER STATION

9 Primer station

To enhance adhesion, it is possible to apply a liquid primer uses highly efficient equipment with adjustable coating on the pre-treated substrate surface. The primer layer is return air and optimised flow speeds. Heating transferred by a roll coating system with a gravure roll and a sources can be either electric, gas, oil or steam closed doctor chamber blade. Compared to conventional smooth – depending on customer reuqirements. roll systems, this method offers the highest precision, increased production speed and less spillage. Your Advantages

IMPROVED ENERGY EFFICIENCY Gravure roll coating system with closed doctor chamber blade The liquid is evaporated in a subsequent vertical drier and leaves a thin layer of solids on the surface, as an anchor for further pro- Highest precision, production speed cesses. Since drying is an energy-intensive process, SML only and less spillage

Energy efficient drying process

10 Trim handling systems After cutting, the trims are sucked off and can be cut into small pieces, to minimise the vol- Within SML’s extrusion coating lines, the edges of the product are ume required for storing and transportation. trimmed immediately after the laminator. Most products are wound as a mother roll, but some are slit inline into several part rolls. Your Advantages For these products which are not Edge trimming immediately after the suitable for refeeding to the extrud- laminator er, the cut trim is to be recycled off-line and therefore must be mini- Precisely working circular knife system mised. Precisely adjustable circular for optimal cutting knives with driven counter knives Waste reduction through minimised give an optimum result. edge trims 22 COATING LINES COATING LINES 23

11 Winding Over the years, SML has invested enormous amounts of Winder Reel change is done at full production speed. Winding shafts with a special cir- effort in building its own peak performance winders for cular adapter are used in combination with sliding safety chucks for core fixation. Systems various applications. W1500 WS WINDING IN GAP AND CONTACT MODE A fixpoint unit at the winder inlet separates the web and winding tension. A All these winders have a solid, vibration-dampening steel frame construction, that is lightweight dancer roll controls the winding tension, while the roll is centre driven especially designed to resist the dynamic forces generated at high production speeds. by an AC servomotor. Winding can be done in the gap or contact mode. Winders engineered by SML stand for an unequalled precision and for the best operational stability. The turret winder WINDING IN BOTH DIRECTIONS W1500 WS is Cross-cutting systems with flying or chopping knives are available for smooth roll The winders in SML’s lines for coating and lamination are equipped with a separate changes. In order to satisfy individual requirements, rolls can be wound in both control cabinet and their own PLC system. The local control unit of the winder is 100 % designed for directions by means of an optional second cutting unit. This design facilitates synchronised with SMILE, the comprehensive overall control system of the line. production speeds easy roll handling with standard electric forklifts. Operator convenience is guaranteed by a self-explanatory and easy to operate user of up to 350 m/min interface on a wide touch screen. and can be used Your Advantages for products 100 % with a maximum Especially for the production of mother rolls in the medium speed range synchronised roll diameter of Cross cutting system with flying or chopping knives with SMILE 1,200mm. Fixpoint to separate the web and winding tension 24 COATING LINES COATING LINES 25

SURFACE DRIVEN WINDING TECHNOLOGY Winder Core clamping is done without a shaft and uses mechanically actuated chucking Winder Compared with a turret winder, the winder W1800 is surface driven. The applied heads of different sizes, which can be easily exchanged. power of the contact winder motor does not have to be raised in accordance with increasing roll diameters. This permits a considerable reduction in both the installed W1500 SL The winder can be equipped for single or dual directional winding. With two W1800 motor power and the related energy consumption. For maximum flexibility, the different cutting systems available, it can be adapted to the respective customer drum winder can also be equipped with a centre drive for the shaft as an option. needs. CROSS CUTTING WITH CHOPPING OR FLYING KNIFES Depending on the application, cross-cutting is done using a guillotine or a flying knife. Both versions are equipped with a satellite unit, which orbits the contact roll as a counter support on the winding drum for optimised cutting geometry.

The turret winder AUTOMATIC SHAFT AND REEL HANDLING SYSTEM W1500 SL is The drum winder This winder is operated with winding shafts. An automatic shaft and reel handling designed for W1800 is for system is available as an option to ease the handling of heavy rolls and shafts. production speeds Your Advantages large widths of Your Advantages of up to 450 m/min up to 4,500mm and maximum Shaftless winding system for higher production speeds and maximum roll Designed for heavy product rolls and diameters up to 1,800mm roll diameters of Two different cutting systems available diameters of Surface driven, with minimal energy consumption 1,270mm. Dual direction winding 1,800mm. Draw unit to separate the web and winding tension 26 COATING LINES COATING LINES 27

NO CORE PREPARATION NECESSARY The winder W2000 robotic is designed for the winding of laminates in a wide Compared to all other winding systems, this type of winder requires an extremely thickness range. It is equipped with an ultra-lightweight dancer roll for sensitive low floor space and installed motor power. Nevertheless, it can wind up to Winder tension control and can be operated in the gap or contact mode. A satellite roll Winder 1,500mm diameter rolls with a perfect hardness from the inner core till the outer optimises the entrance angle of the film to the roll, which minimises the air en- layer. W2000 trapment. A strong guillotine knife is used for cross-cutting. The film is fixed onto W100 the new winding core with a belt cage and compressed air nozzles. As a result, FOCUS ON THICK AND REINFORCED PRODUCTS robotic core preparation is unnecessary. The strong cross-cutting unit cuts even very thick and reinforced products, such INLINE-SLITTING as container bag or reinforced fabrics. The complete winder can be oscillated, which enables the winding of products that tend to create rings or edge build. The winder W2000 The winder 2000 robotic is optimal for inline slitting, since there is no turret rotation robotic is the standard during change-over. The inline-slitting process can be carried out either with or SIMPLE AND EFFECTIVE LOADING without bleed trims. horizontal sliding The unloading of finished rolls is done with a hydraulic lifting system. After the FULLY INTEGRATED ROLL AND SHAFT HANDLING preparation of the new winding core with a double sided adhesive tape, the winder for the inline- The finished roll and the winding shaft are transported onto a moveable lifting feeding of the new winding shaft into the winder can be done with the simple, slitting of rolls. table by an overhead robot, which pulls the slit rolls from the clamped shaft. The W100 is a but very effective loading system without physical stress. Owing to the principle of a horizontal Your Advantages surface winder Your Advantages winding position movement, the roll and ideal for the remains in an optimum winding posi- Horizontal sliding winder for inline-slitting For the winding of big diameter rolls with a perfect hardness tion until the very last moment before winding of big cross-cutting, thus guaranteeing a Perfect roll quality due to optimised winding position diameter mother Ideal concept for minimal floor space perfect winding quality up to the last layer of the roll. Especially designed for winding in a wide thickness range rolls. Winder oscillation for products with edge built-ups, as an option 28 COATING LINES COATING LINES 29

WINDER TYPE W1500 WS W1500 SL W1800 W2000 W100

Maximal mechanical 350 m/min 450 m/min 450 m/min 600 m/min 150 m/min speed

Maximal winding width 1,800mm 2,400mm 4,800mm 2,900mm 2,400mm

Inline slitting No No Yes Yes No

Maximal mechanical 980 or 1,200mm 1,270mm 1,800mm 1,500mm diameter 1,500mm

Maximal roll weight 1,500kg 2,000kg 4,000kg 2,500kg 2,500kg

top wound Winding direction both both top inside top inside inside

Winding tension 50 - 750N 50 - 750N 50 – 3,500N 30 – 300N 50 – 1,200N

Contact roll pressure 100 – 1,800N 100 – 1,800N 50 – 3,500N 50 – 500N 100 – 3,000N

Roll handling manual manual automatic fully automatic semi-automatic 30 COATING LINES COATING LINES 31

OPEN FOR CUSTOMISATION Developed in close consistency with the hardware components of SML’s extrusion lines, SMILE is highly customisable. It is SML’s flexibility that offers a wide range of opportunities if customer-specific solutions are required.

SOFTWARE 100 % DEVELOPED IN-HOUSE Above all, it is SML’s long-standing in-house competence in the field of automatisation and machine control that provides loads of innovative functions tailored to specific customer requirements. In-house developed, state-of-the-art and dynamic controller systems always allow running SYSTEMATISED QUALITY CONTROL the machines at their very best performance- In close interaction with SML’s data collection and analysis system level – considering both economic and environ- bitWise, SMILE is an efficient tool to keep output quality stable and mental aspects. All of SMILE’s software solutions to optimise output properties. are developed by SML technicians. Last but ¡ Formula recipe system to copy production parameters not least, it is SML’s concentrated know-how in ¡ Documentation and detailed reporting of production processes any aspect of automation, that helps to create

E-CONTAINER ¡ Automatised alarm functions via e-mail or text message for quick the extrusion solutions of tomorrow. debugging 12 control system INTERCONNECTIVITY AND THIRD-PARTY INTEGRATION SMILE SOFTWARE FEATURES SMILE has open interfaces that allow the web-based data exchange SMILE is SML’s generic machine control and operation concept. OPTIMISED PRODUCTION EFFICIENCY with third-party machines and systems. Central control station system for all production processes It stands for all-encompassing automatisation, providing machine One key purpose of SMILE is the increase in the ¡ Open to interconnecting with systems like Enterprise Resource control systems with the highest usability in combination with Overall Equipment Effectiveness (OEE) through Planning (ERP), Quality Assurance (QA) or SML’s data analysis tool Full interconnectivity – global UPC-UA, outstanding capacities for profound process management and optimised production processes. bitWise programmed on HTML5, open interface monitoring. to other machines and systems ¡ Based on open standards like HTML5 and UPC-UA ¡ Optimised use of raw materials, preventing The end-to-end integration of third-party systems, overall line ¡ Complete end-to-end process control beyond SML extrusion lines waste Remote access for operators and service effectiveness, operator-friendliness as well as tailor-made and teams – worldwide via the internet, from ¡ Faster start-up of production flexible software solutions are the key elements of SMILE. INTEGRATED ALL-IN-ONE CONCEPT any PC, laptop or most smartphones ¡ Minimised times for product change-overs – It is SMILE’s all-in-one concept that helps to create completely new SMILE is developed as a whole in-house and is integrated one customisable assistant for product changes Multi-client / multi user capability – simul- hundred percent in SML’s extrusion lines. It is the highly precise, types of extrusion solutions, making one single operator-friendly taneous access for different type of users, centralised control and synchronisation of all components in an step out of the most complex production processes. The control of simple assignment of permissions extrusion system, which is blazing the way to new manufacturing temperatures, speeds and pressures on SML extrusion lines is highly centralised. All of the line modules and motors are perfectly Highest comfortability – visualisation of all concepts as well as delivering product properties, line efficiency production processes on a wide screen and output volumes. interconnected and synchronised with each other. Worldwide possibility of remote update for INTUITIVE MACHINE CONTROL CONCEPT CENTRAL CONTROL STATION SYSTEM customisation and technical support SMILE is an integral part of SML’s coherent and user-friendly over- SMILE’s central control station system allows the management of all line concept; machine control and operation is highly intuitive all of the production processes from the wide touch screen attached to the line. As SMILE is web-based, all of the production and and self-explanatory: SMILE HARDWARE FEATURES maintenance processes can be entirely remote controlled, i.e. from ¡ A central control station system for the highest operating com- a PC or even a smartphone. The system is fully multi-client and The hardware components of SMILE are fort and the visualisation of all processes multi-user capable, different types of users can log-in simultaneously. supplied by B&R Industrial Automation ¡ Reduced training efforts and error rates at operator level, less Control panel GmbH, a member of the ABB group, a personnel required global leader in automation. ¡ Remote control, remote update and remote service for minimised maintenance-costs, multi-client / multi-user capability 32 COATING LINES COATING LINES 33

MANAGEMENT DASHBOARD

data analytics

bitWise is SML’s digital transformation solution for extrusion lines. It MAXIMISING OUTPUT ON-PREMISE SOLUTION breathes life into the buzzword “Industry 4.0”. bitWise provides for Data recorded, aggregated and visualised by bitWise helps to raise bitWise is a 100 % on-premise solution. Your a wide range of entirely new opportunities for data driven decisions overall line utilisation and deliver a faster return on investment (ROI). data stays in your company, on dedicated and secured hardware, no cloud services required. with a clear focus on the optimisation of production processes and ¡ Discovering hidden or unused output capacities the final product. Completely developed in-house, it incorporates ¡ Preventing downtimes by detecting potential problems at an early CUSTOMISATION AND RETRO-FIT SML’s decades of experience in automation with the latest tech- stage As with most technologies developed by SML, nologies in data analytics and visualisation. ¡ Minimising maintenance times through optimised scheduling and bitWise is highly customisable. bitWise can be structured access to documentation and service support IN-DEPTH PROCESS INSIGHTS retro-fitted to many existing SML extrusion lines SML extrusion lines are equipped with hundreds of data-generating MINIMISING PRODUCTION COSTS optimising production processes, cutting costs, raising the OEE and ROI of existing investments. sensors. Following the principle of “stop guessing – start knowing”, bitWise is the central tool to measure and visualise all production- bitWise collects, records and visualises this data up to 10 times per related costs. It forms a strong and reliable basis for the continuous OPEN FOR VERTICAL INTEGRATION second. This gives manufacturers a 360 degree in-depth view of all cost-optimisation of production processes. of the details involved in a production process, both in the present Extrusion lines are a key part in a wider produc- and in the past. ¡ Detailed monitoring and reporting of energy and raw material tion chain. For end-to-end optimisation, bitWise consumption supports data exchange and vertical integration OPTIMISING QUALITY ¡ In-depth optimising, tracking and reporting of Overall Equipment with third-party systems, e.g. Manufacturing bitWise is a powerful tool to optimise any aspect of the production Effectiveness (OEE) Execution Systems (MES), Enterprise Resource process with a direct effect on product quality. ¡ Full end-to-end cost transparency through third-party integration Planning (ERP) or Quality Assurance (QA).

¡ In-depth monitoring of all quality-related process parameters, allowing quick corrective action ¡ Comprehensive tracking and documenting of product quality ¡ Making quality reproducible 34 COATING LINES COATING LINES 35

FlexPack® – the modular line concept for different configurations

TANDEM CONFIGURATION

STANDARD CONFIGURATION FlexPack ®

Extrusion Coating MODULAR LINE SET-UP precisely manages the interaction among each of FlexPack’s mod- Your Advantages FlexPack’s main characteristic is its compact and modular concept. ules, enabling the smooth processing of the most different materials and Laminating It guarantees thoroughly safe, cost-effective and user-friendly pro- while considerably boosting the overall-performance of the whole Wide application area – from flexible duction while delivering extraordinary product qualities. FlexPack’s line. According to SML’s general human centred approach, SMILE packaging to applications in the automotive sector Line modular set-up facilitates the subsequent positioning of a second is intuitive and easy to operate. laminator, creating highly complex laminate structures in one single Modular and compact line set-up BOPP, BOPET, paper, aluminium foil, production step. Furthermore, this line concept allows a high degree Substrates metallised film, barrier film, nonwoven, etc. Excellent price/performance ratio of customisation to meet the most specific customer requirements. flexible packaging, tooth paste tubes, Products The name FlexPack stands PROCESSING VARIOUS TYPES OF PRODUCTS technical applications for an elaborated, well-proven SML’s FlexPack lines are typically equipped with automatic turret FlexPack 1500 700 – 1,350mm Substrate width coating and laminating line unwinds and a turret rewind as a standard. They facilitate the pro- FlexPack 1800 800 – 1,650mm cessing of various products that contain substrates such as paper, concept for a wide range of Extrusion materials LDPE, PP, EAA, EMA, EVA, ionomers.... film, aluminium foil, nonwovens and others. applications – ranging from Coating weight 9 - 50 g/sqm (depending on the product) flexible packaging to textiles, INTUITIVE MACHINE OPERATION Coating layers 3-layer (optional 5-layer) and from construction to FlexPack’s coherent line concept is completed by SML’s compre- 350 m/min winding shafts Maximal line speed automotive. hensive control system SMILE. Developed entirely in-house, SMILE 450 m/min shaftless 36 COATING LINES COATING LINES 37

UNWINDING EQUIPMENT COATING UNIT

FlexPack’s fully automatic turret unwinds offer automatic splicing at ¡ Chill roll, Ø 800mm full operating speed, for constant production conditions. An option- ¡ Rubberised pressing roll, Ø 200mm al constant gap device is provided for highly sensitive substrates, ¡ Steel supporting roll, Ø 250mm such as aluminium foils, allowing a smooth peel-off from the roll. ¡ Quick-change equipment for each roll ¡ Adjustable stripper roll at the chill roll outlet ¡ Adjustable PTFE belt attachment for over- Maximal substrate diameter 1,270mm coating Web tension 30 - 600N Core fixation winding shafts (shaftless optional) THICKNESS MEASURING SYSTEM Frame with beta sensor for maximum product 3-inch, 6-inch (other dimensions Core diameter on request) flexibility. Additional frames for differential thickness measuring as an option. Unwinding direction both directions possible EDGE TRIM HANDLING CORONA TREATMENT ¡ Shear cut system with circular knives and a A driven, ceramic treatment roll is equipped with a rubberised press- driven counter-knife, mounted at the exit of ing roll for web tension control. Ceramic electrodes are available for the coating unit. the treatment of conductive and non-conductive substrates. ¡ Edge trim suction system with blower, Venturi system, pre-cutter and sound absorber. PRIMER COATING ¡ Edge trim can either be collected in a big To increase adhesion, SML offers a gravure roll system with a bag or container, or passed to a compactor. chamber doctor blade for anchor-coating, when co-extrusion is not sufficient. The vertical dryer has movable hoods for a minimum WINDERS space requirement. A driven fixpoint roll with a rubberised pressing For its FlexPack lines, SML suggests its wind- roll offers exact web tension control. The fixpoint roll can be water- ers W1500 WS or W1500 SL. These are fully cooled optionally. automatic turret winders with a roll change at full operating speed for constant production EXTRUSION conditions. Extruder carriage with a floor level track-system, motorised 3-axis movement and an adjustable die oscillation function. Maximal winding 1,200mm WS ¡ Gravimetric batch dosing system with 4 components diameter (1,270mm SL) (optional 6 components) Winding tension 50 - 750N ¡ Main extruder: Ø 90/33 L/D winding shafts Core fixation ¡ Side extruder: Ø 60/33 L/D (shaftless optional) ¡ Specially designed screws are installed for the polymers used in 3-inch, 6-inch (other Core diameter coating applications dimensions on request) ¡ An advanced heating system on the barrel reduces the energy Winding direction both directions possible consumption Cutting device flying knife or chopping knife

TOOL UNIT, FEEDBLOCK AND FLAT DIE Winding mode contact or gap Compact housing with a piston-type manual filter and integrated manual melt pressure regulation valve.

¡ 3-layer feedblock with variable geometry ¡ T-die with manual or automatic die bolt adjustment ¡ EBR-deckling system (adjustable internal and external deckling) ¡ Removable die splitter for easy die cleaning ¡ Fume exhaust 38 COATING LINES COATING LINES 39

UNWINDING UNIT #1 (BOARD): STATION #3 (DECOR): ¡ Fully automatic turret unwind with shaftless operation, ¡ Batch dosing system bi-directional unwinding ¡ Extruder 105/33, max. 500 kg/h ¡ Maximum reel diameter 1,600mm ¡ Hydraulic melt filter and motorised melt ¡ Maximum load, in-floor reel loading trolley 3,500kg pressure valve ¡ Automatic Cloeren EBR V die with internal CORONA #1: and external deckling ¡ For treating paper from unwind #1 ¡ 3-roll laminator with chill roll diamenter ¡ Single-sided treatment 1,000mm

FLAME TREATMENT: EDGE TRIMMING: ¡ For treating board from unwind #1 ¡ 3-shear cut systems with driven counter- ¡ Treatment on both sides knife for trimming both side edges

UNWINDING UNIT #2: THICKNESS MEASURING SYSTEM: ¡ Fully automatic turret unwind with shaftless operation for ¡ 4-frame system with Kr85 sensor working bi-directional winding in differential measuring mode ¡ Maximum reel diameter 1,270mm ¡ Maximum load 2,000kg WINDING UNIT: ¡ Crane system for reels ¡ Fully automatic drum winder W1800 ¡ Unidirectional winding CORONA #2: ¡ Maximum winding diameter 1,800mm ¡ For treating aluminium foil from unwind #2 ¡ Maximum load 4,000kg ¡ Single-sided treatment ¡ Handling system for winding shafts and reels

STATION #1 (LAMINATE): ¡ Batch dosing system ¡ Extruder 135/33, max. 750 kg/h ¡ Hydraulic melt filter and motorised melt pressure valve PROCESSING THIN PAPER AND PAPERBOARD ¡ Automatic Cloeren EBR V die with internal and external The Triplex extrusion lamination line strikes a reasonable balance Triplex deckling between very sensitive and fast-responding tension control in low ¡ 3-roll laminator with chill roll diameter of 1,000mm tension areas and a robust, long-lasting design for materials like rigid cardboard. In contrast to most other lines in this market segment, CORONA #3: SML’s Triplex line processes thin paper as well as rigid paperboard Extrusion ¡ For the treatment of material upstream of laminator #2 at an equally high quality. Lamination Line ¡ Single-sided treatment PRECISELY CONTROLLED PROCESSES STATION #2 (INSIDE): The standout technical attribute of the new Triplex line is the precise ¡ Batch dosing system interaction between different machine units, managed by SML’s ¡ Extruder 90/33, max. 400 kg/h central machine control system, SMILE. SML develops its auto- ¡ Extruder 90/33, max. 400 kg/h The Triplex extrusion lamination mation and machine control systems completely in-house. Triplex’ ¡ Extruder 75/33, max. 250 kg/h Your Advantages line is a completely new line state-of-the art tension control, which communicates between the ¡ Hydraulic melt filter and motorised melt pressure valve concept for aseptic board different PLCs, drives and measuring cells within microseconds, is Antiseptic board packaging of a ¡ 3-layer feedblock with variable geometry high quality one of the best examples of SML’s capacities in this field. packaging. The line is designed ¡ Automatic Cloeren EBR V die with internal and external to produce various types of deckling Optimised product change over - READY FOR HEAVY LOADS low waste board/aluminium composites in ¡ 3-roll laminator with chill roll diameter of 1,000mm The general line set-up of the Triplex extrusion lamination line makes Durable machine design and one simple and cost-effective waste-free changes of materials easy and fast. SML’s fully automat- CORONA #4: comfortable operation process. The application areas ic drum winder, W1800, is fitted with an automatic reel and shaft ¡ For treatment of paper upstream of the laminator range from classical beverage handling system. It supports the winding of heavy product rolls up ¡ Single-sided treatment cartons to pouches. to 4 tons. 40 COATING LINES COATING LINES 41

DoubleCoat

SML’s New and Patented Sequential JOINING OF INCOMPATIBLE MATERIALS MINIMISED COATING THICKNESS Your Advantages Coating Process DoubleCoat combines extrusion coating with hot melt lamination. The new method has considerable effects on the thickness of That allows the conjunction of materials which were considered coatings. For TPE on a PP nonwoven, a minimum coating layer Massive machine frame to withstand incompatible so far, for example a TPU or TPE coating layer on PP thickness of 7μm can be achieved. This corresponds with roughly a high web tensions nonwoven spunbonds. A good matching between the substrate, mere quarter of the current average for such coatings. An excellent DoubleCoat is SML’s new and Well-proven for a wide range of adhesive and extruded membrane is the basis for the creation of product quality is guaranteed, as the thin coating layer’s adhesion to different applications patented sequential coating products with unequalled features. the substrate is perfect and no pinholes occur. process for the production of Tailor-made machine configurations extremely thin, breathable THE ADVANTAGES OF THE “DOUBLECOAT” INCREASED PRODUCT BREATHABILITY products with outstanding PROCESS AT A GLANCE: Enhanced breathability is a central feature of SML’s DoubleCoat product properties. Application ¡ Reduced coating layer thickness technology, as the coating thickness has a significant effect on the areas up to now, are sanitary ¡ Material savings and hence lower costs water vapour transmission rate (WVTR). articles, functional clothing and ¡ Strong adhesion ¡ Improved breathability products for the construction ¡ High water column industry. ¡ Enhanced mechanical properties 42 COATING LINES COATING LINES 43

SUBSTRATE TREATMENT PERFORATION UNIT SML’s woven fabric extrusion coating lines are equipped with a Residual air can be exhausted by means of a corona treatment station with a silicone treatment roll and stainless micro-perforation system, which makes subse- steel electrodes. An optional cleaning system is available for con- quent bag filling easier and raises the attainable taminated substrates. A preheating system with two heating rolls production speed. increases the bonding strength during the coating process and flat- tens out the substrate. EDGE TRIM The entire cutting system is mounted on linear guides. An optical sensor detects the edge of the product and tracks the complete cutting process, and as a result only the overcoat is trimmed off. This is fed back directly to the extruder.

EXTRUSION A hanging extruder arrangement with an edge trim re-feeding system ensures minimum waste and optimum efficiency. With a continuous melt filter system, downtimes for cleaning are reduced.

WINDER The recommended winding system for this ap- Woven fabric plication is the surface winder W100. It is simple, robust and perfectly suited to the winding of tubular products. To avoid bullhorns, the com- Woven Fabric TECHNICAL DATA plete winder W100 can oscillate and be moved off centre for the production of small tubular Substrates woven fabric Extrusion Coating fabric bags. Maximal flat product width 2,200mm Lines 2,200mm, single-sided coating Maximal tubular product width 750mm, double-sided coating COATING UNIT SML has gained vast experience Extrusion materials LDPE, PP An integrated reversing triangle facilitates the coating of tubular fabrics on both sides, in a single production step. in manufacturing coating lines for Coating weight 15 - 80 g/sqm a variety of fabric types. These Maximal operating speed 150 m/min lines are especially engineered for rough ambient conditions and UNWINDING well-known for their robust and Double unwinding units with a semi-automatic splice function. operator-friendly design. Typical Maximal substrate diameter 1,500mm applications include tarpaulins, Web tension 700N container liners, big bags, sacks, Core fixation winding shafts tents and woven bags laminated 4-inches, 6-inches, 8-inches Core diameter with printed BOPP film. (other dimensions on request) 44 COATING LINES COATING LINES 45

woven fabric, paper, nonwovens, Substrates grids, etc.

tarpaulins, steel wrap, wood wrap, roofing membranes, tents, Products landfill liner, geo membranes, carpets, truck covers,scaffold sheeting, technical laminates, etc. Product width up to 5,300mm Extrusion materials LDPE, PP, EAA, EMA, EVA, TPE 15 - 80 or 80 - 600 g/sqm, Coating weight others on request Extrusion layer mono or co-extrusion Maximal operating speed 250 m/min

UNWINDING SUBSTRATE TREATMENT For these types of machines, SML can provide either fully auto- Possible treatment methods are corona treat- matic turret unwinds for roll changes up to the full operating ment or flame treatment. Since substrates, such speed, or semi-automatic double unwinds. as woven fabrics, are often contaminated with dust, they need to be cleaned before in-line Maximal substrate diameter 1,200mm (optional 1,500mm) treatment. Web tension up to 1,600N EXTRUSION Core fixation shaftless or winding shafts SML provides high-performance extruders to 6-inches, 8-inches Core diameter run at the optimum production speed. For spe- (other dimensions on request) cial applications, SML also offers solutions with twin-screw extruders. SML favours hanging extruder arrangements to accommodate wide flat Extra wide dies, as their stability is much higher. COATING UNIT The wider a line gets, the more effort needs to be invested to avoid the bending of the rollers. Because the specifications for this type of line are usually quite Extra Wide SML’s wide lines are usually fitted with big unique, extra wide coating and laminating lines are completely diameter rollers in combination with calculated Extrusion Coating customised. SML has successfully installed such wide lines for a bending compensations to achieve a constant variety of applications – i.e. products for landfills, green-houses, pressing nip over the whole product width. and Laminating sun-shades as well as tarpaulins and reel-wraps.

Lines Based on its experience in this field, SML is always ready to develop WINDER perfectly fitted machines for very specific requirements. Winders for extra wide lines need to be able to handle rolls with big diameters and several tons The coating of wide products of weight. SML typically offers drum winders for has been one of the core these types of applications. Inline-slitting for part competencies of SML for bobbins is available as an option. decades. One characteristic all these lines have in common Your Advantages

is a very massive machine Massive machine frame to withstand high web tensions frame to withstand the high web tensions and to avoid Well-proven for a wide range of different applications vibrations. Tailor-made machine configurations 46 COATING LINES COATING LINES 47

HIGHEST QUALITY PRODUCTS

Combinations

Process It is obvious to combine the substantial know-how derived from these different operations to build up integrated production lines.

Combinations and Individual substrates, which are required in a laminated structure Integrations are often produced using the cast or calendering method. In order to save production costs, SML merges the fabrication of the substrate and the lamination process in one single extrusion lamination line.

Typical examples of this type of combination include production lines for asymmetric PA/PE barrier films and inline PET/PE lamination for sealable PET-trays.

Your Advantages SML offers high-performance machinery for all major flat Cutting production costs die extrusion processes, such Streamlining manufacturing processes as cast film, sheet calendering Integration with machinery from external manufacturers and extrusion coating. NOTES: SML - Head Office SML Maschinengesellschaft mbH Gewerbepark Ost 32 4846 Redlham, Austria Phone: +43 7673 90999 0 E-mail: [email protected] www.sml.at

SML - Machinery Far East Sdn Bhd (1029958-P) 1201 Block B, Menara Amcorp No.18 Jalan Persiaran Barat 46050 Petaling Jaya Selangor Darul Ehsan, Selangor, Malaysia Phone: +60 3 7955 9098 Fax: +60 3 7955 9981 E-mail: [email protected]

SML - Moscow Office Ogorodny proezd, 5 Building 6, office 504 127254 Moscow Russia Phone: +7 495 618 8007 Fax: +7 495 619 5961 E-mail: [email protected]

SML - Beijing Office Unit 1410, Landmark Tower No. 8 North Dongsanhuan Road Chaoyang District 100004 Beijing, P.R. of China Phone: +86 10 6590 0946 Fax: +86 10 6590 0949 E-mail: [email protected]

SML - North America Service Inc. Suite 204 85 Eastern Avenue Gloucester MA 01930 USA Phone: + 1 978 281 0560 E-mail: [email protected]

ANALYSES I DEVELOPMENT PRE-TESTED PERFORMANCE I DELIVERY ON TIME SERVICE SUPPORT I CUSTOMER SATISFACTION COATING LINES

www.sml.at

The contents of this brochure are only intended for informational purposes. They are not to be considered as an offer with legal effect. CG-1019-01-A-E