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! 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 • Organized labor No or low cost e/c improvements Lou Piffer
Performance The need for Speed! No or low cost e/c improvements Lou Piffer
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 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 OUTPUT RATE (KG/HR) 350 300 250 200 150 100 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 MELT TEMPERATURE (C) 320 318 316 314 312 310 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 120 POWER CONSUMPTION (KW) 100 80 60 40 20 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 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 316 600 316°C Contact time 0.24 sec. 260 500 web 22 mil melt shell = 12 mm (0.5”) 204 400 200°F 600°F 120°F Water speed 260m/min 150 300 800 ft/min 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 0 Round Chill Roll [°] No or low cost e/c improvements 0 30 60 90 120 150 180 210 240 270 300 33 Lou Piffer 360
Stripping problems • Increase chill roll diameter • 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 – Resin Type No or low cost e/c improvements Lou Piffer
Availability • Internal deckle dies inefficiencies – Cleaning of lands – Leakage – Resin type – 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
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