confined flame confined flame … flame confined flame treatment: the process treatment: the process...
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2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20061
CONFINED FLAME CONFINED FLAME TREATMENT: THE PROCESS TREATMENT: THE PROCESS
AND ITS APPLICATIONSAND ITS APPLICATIONS
Stefano MancinelliesseCI SRL Process Engineer
esse CIflame treaters®
Via Flaminia Ternana no.386
05035 – Narni (TR) - ITALY
www.essecinet.com
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20062
SUMMARYSUMMARY
1.Brief introduction to flexible packaging
2.Web surface treatment techniques
3.Confined flame treatment characteristics
5.Confined flame treatment applications
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20063
1.1.11 FLEXIBLE PACKAGINGFLEXIBLE PACKAGING“Flexible packaging is a packaging having an
internal pressure in dynamic balance with total external pressure”
Flexible packaging advantages vs. inflexible one:
l Lower weight;
l Infrangible;
l Cheaper transportation;
l Lower storage overall dimensions;
l Lower production energy cost;
l More effective product promotion;
l Processed by FFS machines.
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20064
1.1.22 FLEXIBLE PACKAGINGFLEXIBLE PACKAGING
Process of Extrusion:
q Flat films;q Blown films.
Films finishing:q Stretching;
q Thermal stabilization;
q Surfaces modifications;
q Metallization and coating.
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20065
1.1.33 FLEXIBLE PACKAGINGFLEXIBLE PACKAGING
Typical production process of a metallized BOPP film
Surface
TreatmentMetallization
Printing
and
Laminating
EXTRUSION MDO, TDO
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20066
2.2.11 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
In order to increase the attitude of polymerous films to be printed, coated, lacquered, metallized, several techniques can be used. The most common are the followings:
q PRIMING q CORONA TREATMENT;q COLD PLASMA TREATMENT;q HOT PLASMA (FLAME) TREATMENT.
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20067
2.2.22 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUESq C-H link breaking vs. C-C link breaking;q OH > O > H >> HO2
RH+OH Þ R°+H2O; Initiating stepRH+H Þ R°+H2
R°+OH Þ ROH;
R°+HO2 Þ ROOH; Propagating stepR°+O2 Þ ROO;R°+H2O2 Þ ROO+OHR°+O Þ RO
R°+H Þ RH; Terminating step
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20068
2.2.33 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
b-scission reaction:
-C-C-C- Þ -C=O + C
ô
O
O Þ alkoxy radicals RO° Þ LMWOM.
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 20069
2.2.44 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
qO/C RATIOq IMWOM vs. LMWOM
INCREASED SURFACE ENERGY
ü Chain Scission behaviourü “Aging” behaviourü Metallizing barrier effect & Improved surface
properties
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200610
2.2.55 WEB SURFACE TREATMENT WEB SURFACE TREATMENT
TECHNIQUESTECHNIQUES
Pin-holes formation
Ozone production
Difficulties in hoods position optimization
Not selective
Not uniform
Not repeatable
Poor treatment at higher speeds
Backside treatment
Film treated surface aspect at high trt
Heat distributed to the surrounding room
Room conditions influence on flame yield
Std. FLAME TREATMENT
CORONA TREATMENT COLD PLASMA TREATMENT
High Depth of treatment
Production of LMWOM
Cannot be used on common BOPP film widths
Poor treatment levels
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200611
2.2.66 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200612
2.2.77 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
Lambda value vs. Room Temperature
at different relative humidity values.Natural Gas combustion (d=0.59).
Stoichiometric at 20°C; H% = 0
0,4
0,5
0,6
0,7
0,8
0,9
1
1,1
0 20 40 60 80 100
Room Temperature [°C]
Lam
bd
a v
alu
e
RH 0%
RH 25%
RH 50%
RH 75%
RH 100%
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200613
2.2.88 WEB SURFACE WEB SURFACE TREATMENT TECHNIQUESTREATMENT TECHNIQUES
Thickness meter device measurements vs. lab ones
y = 6E-06x2 - 0,0042x + 18,776
R2 = 0,8407
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
TD coordinate [cm]
Thickness
[ m]
]
Lab values Thickness meter values
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200614
3.13.1 CONFINED FLAME TREATMENT CONFINED FLAME TREATMENT
CHARACTERISTICSCHARACTERISTICS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200615
3.3.22 CONFINED FLAME CONFINED FLAME
TREATMENT CHARACTERISTICSTREATMENT CHARACTERISTICS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200616
3.3.33 CONFINED FLAME CONFINED FLAME
TREATMENT CHARACTERISTICSTREATMENT CHARACTERISTICS
Bottom Burner version
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200617
3.3.44 CONFINED FLAME CONFINED FLAME
TREATMENT CHARACTERISTICSTREATMENT CHARACTERISTICS
Top Burner version
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200618
3.3.55 CONFINED FLAME CONFINED FLAME
TREATMENT CHARACTERISTICSTREATMENT CHARACTERISTICS
Confined flame treatment advantages:
q Higher surface quality at higher treatment levels;
q Improved after treatment web surface properties;
q No radiating heat to the surrounding room;
q Access easiness to the burner body;
q Possibility to control the combustion room conditions;
q Possibility to add inert gases to the combustion area.
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200619
3.3.66 CONFINED FLAME CONFINED FLAME
TREATMENT CHARACTERISTICSTREATMENT CHARACTERISTICS
FLAME SPEED Mallard-LeChatelier Theory
SL ~ (b ´ RR)1/2
b=Thermal Diffusivity=l/rcp
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200620
4.4.11 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200621
4.4.22 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200622
4.4.33 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Upstream hood - Exhaust gases temperatures at different speed and
mixture flow values
40
60
80
100
120
140
160
180
40 50 60 70 80 90 100 110 120
Mixture flow [Nmc/h]
Exhaust
s te
mpera
ture
[°C]
speed 100 m/min
speed 300 m/min
speed 500 m/min
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200623
4.4.44 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Downstream hood - Exhaust gases temperatures at different speed and
mixture flow values
50
100
150
200
250
40 50 60 70 80 90 100 110 120
Mixture flow [Nmc/h]
Exhaust temperature
[°C]
speed 100 m/min
speed 300 m/min
speed 500 m/min
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200624
4.4.55 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Energy to the exhausts
Energy to the treater roll
40 - 45%
Energy to the web (1%)
15 - 20%
COMBUSTION ENERGY
STANDARD FLAME TREATMENT DISTRIBUTION ENERGY MAP
40 - 45%
Energy to the burner
STANDARD FLAME
TREATMENT PROCESS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200625
4.4.66 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Energy to the exhausts
Energy to the treater roll
35 - 40%
Energy to the web (1%)
10 - 15%
COMBUSTION ENERGY
CONFINED FLAME TREATMENT DISTRIBUTION ENERGY MAP
50 - 55%
Energy to the burner
CONFINED FLAME
TREATMENT PROCESS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200626
4.4.77 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
•• • •Anti -blocking particles
Layer “C” – Heat Seal
Layer “A” – Al deposition receptive
Layer “B” –PP Structural
Al layer (deposition under vacuum)
•
A) Metallized Coex films
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200627
4.4.88 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Mixture flow per web
meter [Ncm/(h m)]
Air Gap [mm]
Line Speed [m/min]
Treatment Roll
Temperature [°C]
STANDARD FLAME
TREATMENT
CONFINED FLAME
TREATMENT
70,5
5,0
45
3,8
1.020
30
277
Mixture lambda value 1.020
27
335
Treatment level
[dynes/cm] 46/48 60
STANDARD VS. CONFINED FLAME TREATMENT PARAMETERS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200628
4.4.99 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
108
235
176
82
320
229
0
50
100
150
200
250
300
350
1
Metallized film properties: Confined vs. Standard flame treatment
OTR [cc/day, dry 22.8°C]
Transversal Rexam [g/cm]
Longitudinal Rexam[g/cm]
OTR [cc/mq day, dry 22.8°C]
Transversal Rexam [g/cm]
Longitudinal Rexam [g/cm]
STANDARD FLAME
TREATMENT
CONFINED FLAME
TREATMENT
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200629
4.4.1010 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
0,68
0,44
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
1
Metallized Film WVTR: Confined vs.Standard Flame Treatment
WVTR [g/mq day; 37.8°C, 100%RH]
WVTR [g/mq day; 37.8°C, 100%RH]
Standard
Flame
Treatment
Confined
Flame
Treatment
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200630
4.4.1111 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Metallized BOPP film aging curves
30
35
40
45
50
55
60
65
70
0 5 10 15 20 25 30 35 40 45
Days after treatment
Tre
atm
ent
leve
l [d
ynes/
cm]
Confined Flame Treatment
Standard Flame Treatment
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200631
4.4.1212 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONSB) White Opaque films / Synthetic Paper
Mixture flow per web
meter [Ncm/(h m)]
Air Gap [mm]
Line Speed [m/min]
Treatment Roll
Temperature [°C]
STANDARD FLAME
TREATMENT
CONFINED FLAME
TREATMENT
62,5
4,0
40
3,5
1.020
18
260
Mixture lambda value 1.020
20
250
Treatment level
[dynes/cm] 40/42 46/48
STANDARD VS. CONFINED FLAME TREATMENT PARAMETERS
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200632
4.4.1313 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
106
129 132
182
0
20
40
60
80
100
120
140
160
180
200
Sealing Strength [g/cm]
1
Confined vs. Standard Flame treatment on white opaque films:
sealing strength
SIT 105°C
SIT 115°C
SIT 105°C
SIT 115°C
Standard Flame
Treatment
Confined Flame
Treatment
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200633
4.4.1414 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
Confined vs. Standard Flame Treatment: aging curves
30
32
34
36
38
40
42
44
46
48
50
0 10 20 30 40 50 60
Days after treatment
Tre
atm
ent
leve
l [d
ynes/
cm]
Standard Flame Treatment
Confined Flame Treatment
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200634
4.4.1515 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
121°C
+3°C
122°C
+4°C
124°C
+6°C
114°C
0°C
116°C
+2°C
112°C
0°C
SIT-Delta T[°C]
NNNNNNFilm aspect
(stripes)
424448484852Dynes/cm
181820252525Roll Temp.[°C]
300300300280280300Speed [m/min]
810820820795795812T Jono [°C]
3.53.53.83.53.53.2Gap [mm]
333342323227Mixt. [m3/h*m]
654321
C) Sealable Coex films
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200635
4.4.1616 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
189,4
261,5
0,0
50,0
100,0
150,0
200,0
250,0
300,0
1
Confined vs. Standard Flame Treatment: sealing strength
Standard Flame Treatment
Confined Flame Treatment
SIT: 122°C;
46 dynes/cm
SIT: 116°C;
50 dynes/cm
Sealing Strength [g/inch]
2006 AIMCAL Fall Technical Conference Peppermill Resort, Reno, NV - October 22 - 25, 200636
4.4.1717 CONFINED FLAME CONFINED FLAME
TREATMENT APPLICATIONSTREATMENT APPLICATIONS
CONFINED FLAME TREATMENT PROCESS ADVANTAGES
q Higher treatment levels with improved web surface properties;
q Improved final properties on metallized, white opaque and sealable treated films;
q No corrugation/deformations on white opaque films;
q Simple system to run;q Costs-saving technology;q Room friendly technology .