No or low cost Extrusion Coating Improvements Lou Piffer Senior - - PowerPoint PPT Presentation

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No or low cost Extrusion Coating Improvements Lou Piffer Senior - - PowerPoint PPT Presentation

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No or low cost Extrusion Coating Improvements Lou Piffer Senior Sales Engineer Davis-Standard, LLC Paper #6.1 Effectiveness Performance Availability Quality No or low cost e/c improvements Lou Piffer What they really want!

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No or low cost Extrusion Coating Improvements

Lou Piffer Senior Sales Engineer – Davis-Standard, LLC Paper #6.1

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No or low cost e/c improvements Lou Piffer

Effectiveness

  • Performance
  • Availability
  • Quality
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No or low cost e/c improvements Lou Piffer

What they really want!

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Performance – Labor related

  • Staffing – Liaison
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The value of employees!

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Performance – Labor related

  • Staffing – Liaison
  • Complacency – Old line/new line
  • Organized labor
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Performance The need for Speed!

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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

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Performance – other issues

  • Output

– Screw – Motor

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4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE

50 100 150 200 250 300 350 400 450 50 100 150 200 250 SCREW SPEED (RPM) OUTPUT RATE (KG/HR)

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4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE

310 312 314 316 318 320 322 324 50 100 150 200 250 SCREW SPEED (RPM) MELT TEMPERATURE (C)

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No or low cost e/c improvements Lou Piffer

4.5”, 30L/D Extruder Screw: Single Stage, Mixing Material: 7MI LDPE

20 40 60 80 100 120 50 100 150 200 250 SCREW SPEED (RPM) POWER CONSUMPTION (KW)

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Performance – other issues

  • Output

– Screw – Motor

  • Ancillary systems (trim, blowers, etc)
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Corona treater blower

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Trim Pick-up

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Trim Pick-up

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Performance – other issues

  • Output

– Screw – Motor

  • Ancillary systems (trim, blowers, etc)
  • Edge Weave
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Edge Instability is the Limitation

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Edge Instability is the Limitation

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Edge Instability is the Limitation

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Edge weave issues

  • ID die set correctly?
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Series 50 Internal Deckles

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Relative Positions of Internal Blades Influence Edge Bead Size and Shape

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Edge Instability is the Limitation

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Restabilizing the Edge

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Further Edge Reduction

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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?
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No or low cost e/c improvements Lou Piffer

Performance – other issues

  • Output

– Screw – Motor

  • Ancillary systems (trim, blowers, etc)
  • Edge weave
  • Stripping problems
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No or low cost e/c improvements Lou Piffer

Temperature Distribution Around Chill Roll

360 100 200 300 400 500 600 30 60 90 120 150 180 210 240 270 300 33 Round 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°F 200°F speed 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

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Stripping problems

  • Increase chill roll diameter
  • Increase surface roughness
  • Air condition building
  • Air condition laminator area
  • See if finish is smoothing out over time
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Performance – other issues

  • Output

– Screw – Motor

  • Ancillary systems (trim, blowers, etc)
  • Edge weave
  • Stripping problems
  • Roll Handling
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No or low cost e/c improvements Lou Piffer

Roll Handling

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Roll Handling

  • Simple change – composite shafts
  • Greater change – automatic system
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Availability Waste is a waste!

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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands

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External Deckle Die - Cleaning

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External Deckle Die - Cleaning

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Internal Deckle Die - Cleaning

9.5MM (3/8”)

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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage

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External-Only Deckles

  • Disadvantage: External-only deckles increase edge bead size

and create stagnation areas within the die flow channel.

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Leakage

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Leakage

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Internal Deckle Die - Cleaning

9.5MM (3/8”)

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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage – Resin Type

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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage – Resin type – Material Left on the Core

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Material Left on the Core

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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”+
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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage – Resin type

  • Material left on core
  • Obsolescence
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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage – Resin type

  • Material left on core
  • Obsolescence
  • More recipe variables = less down time
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Controls – Recipe driven

  • New width adjustment for unwind/winder
  • Slitter positioning
  • Deckle width
  • Edge guide positioning
  • Treater width
  • Valve stem
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Motorized spindle adjustment

  • Unwinds and winders automatically adjust to new recipe

web width.

  • Lead screw RPM read by encoder
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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
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65.0 [1651] WEB MAX. 38.0 [965] WEB MIN.
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Motorized Deckles

  • Deckle position provided in recipe with motorized

movement coordinated with control cycle.

  • Programmed closure of deckles for startup and moving
  • nline and offline
  • Position feedback to the line control
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Motorized Guide Sensor

  • Motorized sensors positioned to recipe dependent

position

  • Position feedback to the line control
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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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Motorized Valve Stem

  • Position of valve stem adjusted through motor
  • Valve stem position can be placed in pressure PID

control loop.

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Motorized Adapters

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Availability

  • Internal deckle dies inefficiencies

– Cleaning of lands – Leakage – Resin type

  • Material left on core
  • Obsolescence
  • More recipe variables = less downtime
  • Transfers and splices
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Quality Quality is King!

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Quality

  • Melt

– Screw

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Old Screw

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Quality

  • Melt

– Screw – Water Circulation System

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Feed Section

  • Cast iron jacketed
  • Initial point where resin is

introduced

  • Space between gear box and

resin feeding point

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Quality

  • Melt

– Screw – Water Circulation System – Adapter

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screw movable valve melt channel pressure sensor screen pack

Valved Adapter

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Quality

  • Melt

– Screw – Water Circulation System – Adapter

  • Stretching and Wrinkling
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Stretching and Wrinkling

  • Few tension isolation points can create stretching issues
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Tandem Line – Tension Isolation

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Stretching and Wrinkling

  • After unwind
  • General alignment – wrinkling source
  • New drives?
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Thank You

PRESENTED BY

Lou Piffer Senior Sales Engineer

Davis-Standard LLC pifferl@bc-egan.com

Please remember to turn in your evaluation sheet...