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Online Quality Control of Polymers and Extruded Films Oliver - - PowerPoint PPT Presentation
Online Quality Control of Polymers and Extruded Films Oliver - - PowerPoint PPT Presentation
TAPPI 11th European PLACE Conference, Athens 2007 Online Quality Control of Polymers and Extruded Films Oliver Hissmann 1 Contents Introduction Online Quality Control in Polymer Plants Technology, Benefits, Online Lab, Close Loop
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Online „Closed Loop Control“-Concept
Sampling Feedback Raw material Additives
Process
Production On-line Quality Assurance Process computer Determination of the process parameters Data (opt. measuring technique)
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Principal of Online Quality Control
Gloss Measurement Gel Counter Thickness Measurement Haze Measurement Polymer Analysis by FTIR Spectroscopy Measurements on Extruded Films Film Extrusion
Blown Film / Cast Film
Pellets Color Measurement Pellets and Powder Inspection Pellets Throughput Measurement Pellets Size and Shape Distribution Melt Index Measurements on Pellets Pellet Preprocessing
Dedusting / Drying
Pellet Transport System
Pellet Sampling and Transport
Production of Polymer Pellets
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Benefits of Online Control
Process Control
(Optimisation, capacity, cleaning, waste)
Product
(better quality, customer satisfaction/relation, less claims, more competitive products)
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Pellets Color Measurement
PCM Measurement of LAB Color Values and Yellowness Index
Pellets and Powder Inspection
PS 25C, PS 25, PS 2 PT 2 Detection and Evaluation of Impurities in Pellets and Powder
Pellets Throughput Measurement
PTM Weight Measurement of the inspected Pellets
- ver the time
Pellets Size and Shape Distribution
PSSD Measurement of Size and Shape of the Pellets Detection of Twin, Triple and Multiple Pellets
Measurements on Pellets
Online Measurement of Pellets
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Pellet Scan System
CCD-Camera Lighting unit Hopper Pellet stream
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Pellet Scan System
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Pellet Size & Shape Distribution
Lighting unit Hopper Pellet stream CCD-Camera
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Pellet Size & Shape Distribution
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Pellet Size & Shape Distribution
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Pellet Colour Measurement
visible light color measuring device visible light
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Online Measurement on Extruded Films
Gel Counter
Detection and Evaluation of Gels, Fish Eyes, Black Specs
Polymer Analysis by MID-IR Spectroscopy
Measurement of Additive Contents and Physical Properties by IR-Light Transmission Through Extruded Films
Gloss Measurement
Measurement of Gloss of Extruded Films
Haze Measurement
OHM Measurement of Haze and Transmission
- f Extruded Films
Thickness Measurement
TMD Measurement of Films Thickness
Measurements on Extruded Films Film Extrusion
Blown Film Cast Film
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Online Quality Control
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Online Integrated Measurement Solution
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Online Integrated Measurement Solution
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Online Gel Count
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Online Gel Count
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Defect Types
Gels Black Specs Contaminations
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Web Inspection in Film Extrusion
100 % Optical Control of the Web
Photo of every defect Position of every defect Database Interface Reports Alarms
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Benefits of Web Inspection
Process Control
(Optimisation, capacity, cleaning, waste)
Raw Material
(Optimisation material + recipe, control material)
Product
(better quality, customer satisfaction/relation, less claims, more competitive products)
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Origin of Defects in Extrusion
Extrusion Line (screw geometry / dead zones) Resin (contamination, recipe) Production Process (extruder temperatures, screen change)
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Defect Types in Film Extrusion
Gels Black Specs Contaminations Die Lines Insects Lamination Defects Oil Stains Fish Eyes etc.
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Web Inspection System
Embedded Multiple Camera Solution
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Embedded Solution Technology
High Speed CCD Line Scan Cameras 80 – 160 MHz, 512 – 8192 Pixel Embedded PC with High Speed Framegrabber Windows XP Server (network) Exact information on defects within the web (mosaics, position, alarms, protocols, storage)
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Quality Reports / Alarming
Single Defect Trend Defects (20 gels per m²) Slit Defects Repeating Defect Gel Shower / Cluster Roll Defects
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Rolling Map / Die Defect
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Time History (Gel Level)
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Mosaic View
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3-D Defect Analysis
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Lane Distribution
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Die Defect
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Calander Defect
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Alarms / Repeaters
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Teach-In Function - Fly
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Teach-In Function – Oil Stain
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Teach-In Function - Gel
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Teach-In Function – Black Spec
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Inspection Systems
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Inspection Systems
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Closed Frame
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Interrelationship and Correlation Example
Online Compound Control (Gel Analysis) Oracle Database Integration Decision for Film Extrusion Quality (Grading) 100 % Web Inspection in Cast Line (Diaper Breathable Film)
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Online Container for Plant Control (Example)
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Gel Shower
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Online Anticipation of Plant Shut Down
Start injection cleaning agent Plant shut down
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Online Transition Control
Start extruder cleaning
Stop injection cleaning agent Stop extruder rinsing
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Online Control of Extruder Start Up
Extruder startup after plant restart, start extruder cleaning
Stop injection cleaning agent Stop extruder rinsing
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Summary
Close Loop Online Control (Process + Grading) is today‘s Standard in Polymer Plants 100 % Web Inspection in Film Extrusion Different Defect Types, but close Interrelation Working Together avoids Problems and improves Film Quality
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