My Technical Paper Presentation at ,
Munich Adhesives and Finishing
Symposium
( MKVS ) ,
( 28. – 30. October 2013 ),
at Sheraton Munchen Arabellapark Hotel , in
Munich , Germany.
On
Technical Developments in HM and HMPSA
from the Emerging Market of India
Shrikant Athavale CEO Prathith Consultants PUNE – 411038, Maharashtra , India
This is a Presentation on latest Developments
in HM and HMPSA from Emerging Market in
India.
I am going to discuss about two such
developments .
The developments that , I am going to address
are as follows.
Part One : “ Surgical tape , Water proof , with Hypo
allergic HM PSA ”
Part Two : “A Innovative method of manufacture of
PVC Insulation Tape, using HM PSA “
Let us Discuss about
Part One
now
Surgical Tape ( water proof ) ,
with
Hypo allergic HM PSA
This is a Innovative method of
manufacturing , Surgical tape ,
Water proof , with Hypo allergic
HM PSA , similar to Band Aid .
Advantages
Very light weight Film of Poly Urethane,
in Human Skin of color .
Higher production speeds due to innovative
Coating mc design.
The Product is highly cost efficient,
owing to , Lower material cost
as well as process operating Cost
and
much lower Capital investment .
Machine Design
This is a rear combination of , Water Based and Hot
melt Coating Machine.
The ease of operation of Water Based coating for
Casting a film
With online
Hot melt Adhesive coating
17
Details of Product
Construction
are as follows
PU
N Woven
Adhesive
Magnified View
PS Adhesive , Hot-Melt
Non Woven With a Top coat of
PU for smooth finish as well as
for excellent water repellence
18
The product ( Non woven Coated Surgical tape ) Is Water Proof.
19
The product ( Non woven Coated Surgical tape ) Is Breathable .
The details of the Process:
Coating pass no. 1 :
PU water Borne dispersion ( Compounded ) is coating on ,
Non Woven liner , by Kiss Roll coating method.
The Coat Wt. with help of Air Knife. This also helps to create
porosity in it.
At this stage it is supported by a silicone release liner.
The coated NW then enters the drying zone, to flash out
water , to obtain a uniform , dry film of PU , on NW + Si
liner , laminate .
A dry coat weight of approx. 10 gsm is desired and achieved.
21
Coating Machine
Coating Pass no. 2 :
The coated web then enters the second coating station .
Here the HM PSA is coated on the Non Woven , by 3 Roller
Coating method. The Coating roller is suitably designed for
Pattern coating , in order to maintain the porosity in the NW
fabric . A coat weight of approx. 18 gsm is desired and
achieved.
Now the Adhesive coated Jumbo roll is ready for further
process of , rewinding and slitting into , Rolls of required
length and width.
23
Coating Machine Diagram
24
Further Process :
Rewinding Machine:
25
Rewinding Log rolls of required length ,
from the Jumbo rolls made as above.
ID. 76 mm
1250 mm
Jumbo Roll of 1250 mm width X 500 Mtrs length
ID. 25 mm
1250 mm
Log Roll of 1250 mm width X
10 Mtrs length
26
Slicing / Slitting Machine :
ID. 25 mm
1250 mm
Log Roll of 1250 mm width X
10 Mtrs length
ID. 25mm
25mm
Finish Roll of 25 mm width X
10 Mtrs length
27
Packing Machine :
Shrink Wrapping
Box Sealing
28
Product Cost
29
Conclusion
The Invented Method of Producing
Surgical Tape by using Non Woven with
PU coating on top and , HM PSA is very
useful. It is light weight , breathable and
Water proof.
Now let us discuss about
Part Two
A Innovative method to
manufacturing
Insulation Tape , replacing
PVC Film with Cast film
using HM PSA
Cost Effective Electrical Insulation Tape ,
replacing PVC Film
This is a Innovative method of manufacturing ,
Insulation tape , by replacing PVC Film with
cast film of Radiation Vulcanized Nat rubber
latex (RVNRL) , and specially compounded
water Borne acrylic PSA , without
compromising quality.
Advantages
Very light weight Film , of Sp.Gr. below 1.0
as compared to PVC 1.3 ,
excellent conformability .
Higher production speeds due to innovative
Coating mc design.
The Product is highly cost efficient ,
owing to ,
Lower material cost
as well as
process operating Cost , and
much lesser Capital investment .
Details are as follows
The Product Construction is given
Below.
PU
Carrier
Adhesive
Magnified View
PS Adhesive , either Hot-Melt
Or Compounded Water Borne
, ( Rubber base / Acrylic )
Carrier Film , prepared by cast
method , from compounded
RVNRL
With a Top coat of PU for
smooth finish as well as for
excellent water repellence
Method of Manufacture , The Carrier Film
The carrier Film , or the Backing material , for the
purpose is manufactured by
Coating a RVNRL ( Radiation Vulcanized Natural
Rubber ) compound , made in house.
The Compound recipe is given below.
Preparation of WB Dispersion for the additive :
The Filler , antioxidant, Flame retardants , are initially,
dispersed in water using a suitable dispersing agent and
the pH is adjusted to alkaline , using liq. Ammonia
solution.
The pigment paste is available in water dispersed form.
Preparation of Coating Compound:
RVNRL is now mixed with pigment paste and
dispersion (made as above) , on a slow speed mixer.
The pH of the compound is checked and adjusted to
7-8.
Now the coating is ready for use.
The Coating or Casting is a done on a specially
designed coating machine.
This machine has number of coating stations ,
incorporated , to carry out all the coatings in a single
pass.
The details of the Process:
Coating pass no. 1 :
On the first Coating station , PU water Borne
dispersion ( Compounded ) is coating on , Silicone
Release liner , by Kiss Roll coating method.
The coated Si liner then enters the drying zone, to flash
out the solvent that is water , to obtain a uniform , dry
PU film .
A dry coat weight of approx. 10 gsm is desired and
achieved.
Coating pass no. 2 :
The coated web then enters the second coating station .
Here the RVNRL compound is coated on the same side
as PU coated earlier , by Comma Coating method. Here
also the coated Si liner then enters the Drying zone ,
similar to coating Pass no. 1
A dry coat weight of approx. 35 gsm. is desired and
achieved.
Coating Pass no. 3 :
The coated web then enters the Third coating station .
Here the HM PS Adhesive is coated on the same side as
( PU + RVNRL) coated earlier , by Roller Coating
method.
A coat weight of approx. 25 gsm. is desired and
achieved.
Now in the last phase of this coating operation , the Si
Liner is removed and rewound on separate Rewind
station no. 2 , and the adhesive coated film is rewound on
rewind station no. 1
Now the Adhesive coated Jumbo roll is ready for further
process of , rewinding and slitting into , Rolls of required
length and width.
Coating Machine Diagram
Further Process :
Rewinding Machine:
Rewinding Log rolls of required length , from
the Jumbo rolls made as above.
The Product Cost Analysis :
Conclusion
The Invented Method of Producing
Electrical Insulation Tape by using
RVNRL Film is very Cost Effective.
There is a net saving of at least 19 % ,
which is sizable by any standards.
May
I have your
Questions Please
For more Details Please Contact Shrikant Athavale CEO Prathith Consultants B 801 , Vastushree Pearl, Paud road , Kothrud PUNE – 411038, Maharashtra , India Mobile : Germany : +49 ( India ) 0091 9850242282 / 7588288204 Email : [email protected],[email protected] Website : www.psadhesive.com