2009 PLACE Conference November 10-13, 2009

Mubai and New Dehli, India

New On-Line Measurement and Control of Multilayer Blown Films

Presented by: Name Mr. Vinay Verma Title Regional Sales Manager Company Thermo Fisher Scientific

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Agenda

Problem statement

Review the original paper

Latest developments

Future Investigations

Questions

2008 PLACE Conference September 14-17, 2008

Portsmouth, VA

New Blown Film Measurement and Control

Presented by: Name Marty Lauginiger Title Regional Sales Manager Company Thermo Fisher Scientific

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Application

High performance multilayer Blown Film lines• Medical Films• High Performance Packaging• Barrier films

Can distinguish between inner/outer layers and barrier layers inan A/B/C/B/A structure

Should be used where the bubble is not split for winding on multiple winders

Measures through the layflat (two plies)

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Typical Blown Film Line

Diagram Courtesy of Alpha Marathn

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Line Pictures

Miller Blown Film Line

Carnevalli Blown Film Lines

Octagon Blown Film Die

Contact Gauge on Collapsing Frame

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Problem Statement

For Multilayer Barrier FilmsWith the oscillating frame, difficult to map the measurement data back to the individual die or air nozzle

Understanding and compensating for the natural twist angle between the die and the “frost” line (NO PENS!)

Don’t know how much of each polymer is being used

Don’t understand the material distribution

Total measurement on the bubble with gamma backscatter or capacitance is too slow for effective control

On the bubble solutions contact the bubble

Getting a line under process control takes too long, creating excessive scrap and reduces overall production time

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System Configuration

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Why is our Solution Unique?

FSIR provides material discrimination of key layers

Scans the collapsed tube (double layflat) and distinguishes between top and bottom

• Splitting the tube is not necessary

APC uses PI (Proportional-Integral) control on an annular die• Actuators can be Viscosity Heaters or Air Nozzles

Rotational speed of the collapsing frame is measured using a high resolution quadrature encoder

• Accuracy is maintained via a reference input every rotation, at the home position

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The Solution - Sensor

Full Spectrum Infrared (FSIR)

• Simultaneous software based analysis of a complete near infrared spectral range

• Discriminate between multiple components• Report individual layer thickness as well as overall thickness

Non nuclear

Invented the technology

• >20 years of providing FSIR technology to our customers to better understand therefore control their process

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The Physics Behind IR Measurement - General

Absorption is stronger at certain wavelengths compared to others

Each material has unique absorption pattern

EVOH

weaker

STRONGER

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FSIR Material Spectra

Absorbance spectra increases with increased weight

PE Surlyn PE and Surlyn

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The Solution - Controls

21Plus! Operating SystemData Mapping:

• Film measured as a collapsed tube

• Speed:• Bubble rotational speed measured at the collapsing frame• Haul Off Speed is measured at the winder or other convenient location

• Distance from the rotational point to the measurement point is entered

• Monitored by the digital tachometer• Rotational data is saved along with corresponding

measurement point position during each scan of the collapsed tube

• Automatic twist angle determination reduces start-up time

Photo Courtesy: Macro Engineering

Photo Courtesy: Gloucester Engineering

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Data Mapping Technique

Start with the collapsed bubble in a “layflat” position with the first data setData set rotates, due to tower/top nip oscillation, creating the second data setThe process continues, creating a set of simultaneous equations from which to refine the die mapping therefore improving material controlStarts resolving within 1 minute or 4 scans of the web

A CB D E

J HI G F

J BA C D

I GH F E

1ST Iteration

2ST Iteration

V XW Y Z

V XW Y Z

=A+J =C+H=B+I =D+G =E+F

=J+I =B+G=A+H =C+F =D+E

Bubble

Collapsed Bubble in “Layflat” Condition

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The Solution

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Results

Case Study: Poorly Centered Die

Before: 12% After: 4.7%

** Results based on an Oakland offline lab profiler with resolution of 5000+ points across the web

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Results – Auto Die

Before: 3.0% (2σ)

After 45 Min: 1.3% (2σ)

5 Mil (127 μm) Barrier Film

>50% reduction in CD spread in ~45 minutes

DATA ORIGINALLY PRESENTED AT TAPPI PLACE

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Results – Auto Die

After 35 Min: 2.7% (2σ)

After 65 Min: 0.9% (2σ)

Start: 3.7% (2σ)

DATA ORIGINALLY PRESENTED AT TAPPI PLACE

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Air Ring

Situation: Upgrade of an auto Air Ring on an existing manual annular die

End Product: 3 different, 5 layer medical flexible package films with annual resin consumption of ~2,000 tons

Applied the same mapping measurement and control algorithms as with the heated automated annual die

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Customer Results – Air Ring

>75% reduction in CD spread in ~25 minutes

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The Value

50-70% reduction in CD variations

60% reduction in time for product change-overs and restarts

50% scrap reduction at winder• Additional scrap reduction in downstream operations

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Future Investigations

Does the FSIR technology provide better uniformity over the traditional total thickness measurement combined with gravimetric resin monitoring?

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Summary

New revolutionary solution for high performance, multilayer blown film lines

Proprietary mapping algorithm controlling critical barrier layer films

• Includes dynamic twist angle compensation

Much faster measurement feedback and control as compared to conventional designs

• ~45 minutes for viscosity heater• ~25 minutes for air nozzle

Typical CD reduction of > 50%

Does not require splitting the bubble onto two winders• Measures and distinguishes top and bottom plies of layflat

Have systems running at both end user and OEM sites

Offers significant annual resin, scrap, and time savings

Thank You

PRESENTED BY

Name Mr. Vinay VermaTitle Regional Sales MangerCompany Thermo Fisher Scientific

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QUESTIONS??