tappi place conference 2005

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ISBN: 978-1-61738-880-4 TAPPI PLACE Conference 2005 Las Vegas, Nevada, USA 25-29 September 2005 Volume 1 of 2

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Page 1: TAPPI PLACE Conference 2005

ISBN: 978-1-61738-880-4

TAPPI PLACE Conference 2005

Las Vegas, Nevada, USA 25-29 September 2005

Volume 1 of 2

Page 2: TAPPI PLACE Conference 2005

Printed from e-media with permission by:

Curran Associates, Inc. 57 Morehouse Lane

Red Hook, NY 12571

Some format issues inherent in the e-media version may also appear in this print version. Copyright© (2005) by the TAPPI Press All rights reserved. Printed by Curran Associates, Inc. (2010) For permission requests, please contact the TAPPI Press at the address below. TAPPI Press 15 Technology Parkway South Norcross, Georgia 30092 Phone: (800) 332-8686 Fax: (770) 209-7206 [email protected] Additional copies of this publication are available from: Curran Associates, Inc. 57 Morehouse Lane Red Hook, NY 12571 USA Phone: 845-758-0400 Fax: 845-758-2634 Email: [email protected] Web: www.proceedings.com

Page 3: TAPPI PLACE Conference 2005

TABLE OF CONTENTS

Volume 1

SESSION 1: PLENARY SESSION Optimization By Integrating Engineering and Business Models ....................................................................................... 1

David R. Roisum

SESSION 2: STRUCTURE OPTIMIZATION Understanding Why Adhesion in Extrusion Coating Decreases With Diminishing Coating Thickness, Part I: Penetration of Porous Substrates ........................................................................................................................... 38

Barry A. Morris

How Sealant Film Choice Can Affect a Laminated Structure's Properties .................................................................... 61David G. Timm

Using Primers in Combination With Adhesive Tie-Layer Resins or Their Blends to Make Structures With Unique Performance .................................................................................................................................................. 87

Richard B. Allen

SESSION 3: PROCESS OPTIMIZATION Intertial Measurement of Roller Parallelism-A New Approach to Solving an Old Problem....................................... 112

Sebastian Busch

Application of 3D Flow Simulation Towards Blown Film Die Optimization................................................................ 115John Perdikoulias, Jiri Vlcek, Jiri Svabik

How to Improve Cross-Machine Drying Profiles ............................................................................................................ 134William R. Henry

SESSION 4: BUILDING BETTER BARRIER A New Family of sHDPE Polymers for Enhanced Moisture Barrier Performance ..................................................... 151

Norman D. Aubee, Sarah Marshall, Patrick Lam

Topas® Cyclic Olefin Copolymers in Food Packaging-High Aroma Barrier Combined With Low Extractables........................................................................................................................................................................ 173

Randy D. Jester

Adding Oxygen Barrier to Adhesive Laminations .......................................................................................................... 184Jessica C. Bodine

SESSION 6: ADDITIVES; UNDERSTANDINGS AND APPLICATIONS Polymer Processing Additives and Melt Fracture in Blown Film: Die Geometry Considerations ............................. 197

Paul Neumann

The Influence of Process Aids on Zig-Zag Type of Interfacial Instabilities in Film Blowing Multi-Layer Flows ........................................................................................................................................................................ 217

Martin Zatloukal, Johan De Witte

The Use of Calcium Carbonate in Polyolefins Offers Significant Improvement in Productivity................................ 225James E. Cara, Lane G. Shaw, Michael Roussel, Allen R. Guy

Discolaration Resistant Polyolefins: Part IV; Gamma Irradiated LLDPE Film.......................................................... 237Roswell E. King III

Page 4: TAPPI PLACE Conference 2005

SESSION 7: PRODUCTIVITY DEVELOPMENTS – MACHINERY DESIGNS TO IMPROVE EFFICIENCY Automatic Servo Postioned Air Knife Systems for Optimal Cast Film Quenching ..................................................... 264

Beth M. Wells, Fred Suppon

Improving Productivity with Automated Slitter Positioning ......................................................................................... 274Bryan Zimmerman

Benefits of Automatic Computer Positioning Systems ................................................................................................... 281David A. Rumson

Benefits of New Technology Ionizers for Web Handling................................................................................................ 289Scott Shelton

Fully-Integrated Multi-Station Static Control System With Web Charge Verification .............................................. 301Mark Blitshteyn

Improving Production Efficiency of Flexible Film Printing Lines by the Print Control and Changeover Benefits of Gearless C.I. Presses.................................................................................................................. 316

Thomas J. Jacques

SESSION 8: ADVANCEMENTS IN RETORT PACKAGING Introduction to Retort Pouch Technology ....................................................................................................................... 338

W. Scott Whiteside

Retort Flexible Pouches: Selecting a Co-Packer ............................................................................................................. 347Winson Kutte

The Effects of Retort Conditions on Clear High Barrier Laminated Structures ......................................................... 355Thomas R. Mueller

PVDC Barrier Concepts for Demanding Coextrusion and Lamination Applications ................................................. 378Valérie Renard, Steve Jenkins

SESSION 9: ADDITIVES – UNDERSTANDINGS AND APPLICATIONS Polymeric Nanocomposites Enabled by Controlled Architecture Materials ................................................................ 392

James Nelson, Ryan E. Marx, John W. Longabach, Terri A. Shefelbine, Myles L. Brostrom, Mary I. Buckett

Improving the Gas-Fading Performance of Polyethylene Film Resins by Addressing the Over-Oxidation of Phenolic Antioxidants ................................................................................................................................. 397

T. Tikuisis, L. Ellis, S. Chisholm

Proprietary Engineering Resins as Additives to Polypropylene .................................................................................... 434Thomas Hartle, Robert McKay, Geoffrey Riding, Todd Washburn

High Clarity Masterbatch ................................................................................................................................................. 450Prakash R. Patel

Advances in Polymer Processing Additives (PPA) .......................................................................................................... 460Claude Lavallée

SESSION 10: PRODUCTIVITY DEVELOPMENTS – MACHINERY DESIGNS TO IMPROVE EFFICIENCY More Than Defect Detection – The Real Value of Web Inspection ............................................................................... 483

Brian Heil

Non-Nuclear Gauging Alternatives Offer Enhanced Performance with Simplified Use ............................................. 499Hector E. Marchand

New Die Designs and Advancements in Automatic Die Controls for Improved Efficiencies in Film Production .......................................................................................................................................................................... 522

James F. Foederer

Challenges of High Speed Splicing ................................................................................................................................... 532Donald L. Teich, Richard S. Tetro

Advancements in Melt Fracture Elimination Technology.............................................................................................. 549Rafael J. Castillo

Page 5: TAPPI PLACE Conference 2005

SESSION 11: SELECT TOPICS Viscoelastic Coextrusion Flow Modeling by Advanced Constitutive Equations: The Influence of the Die Design on Interfacial Instabilities .............................................................................................................................. 563

Jiri Vlcek, Martin Zatloukal, Petr Saha, Michael T. Martyn

Flame Plasma Surface Treating System Applied to a High Speed Coating Line ......................................................... 578Dom Medina, Joseph D. Digiacomo

Printing on Metalized Polymer-Papaerboard Compounds: Improvement of Adhesion by Optimized Flame Plasma Pre-Treatment ........................................................................................................................................... 591

Werner Eckert

Future European Regulations on Adhesives for Food Contact Articles........................................................................ 596Hermann K. Onusseit

Volume 2

High Clarity Linear Low Density Polyethylene for Packaging Applications................................................................ 635

Amy B. Hitchcock

SESSION 12: SURFACE TREATING FOR FLEXOGRAPHY (SPONSORED BY FTA) Do All Substrates Need Surface Treatment? ................................................................................................................... 649

Steve Utschig

Total Package Integrity-Test Methods and Protocols for Confirmation of Shelf-Life of Flexible Packages ............................................................................................................................................................................. 654

Michelle Stevens

Surface Activation Systems for Optimizing Adhesion to Polymers ............................................................................... 662Rory A. Wolf

New Printing Adhesion Improvements Using Atmospheric Plasma Glow Discharge Technology ............................. 667Rory A. Wolf

SESSION 13: COST REDUCTION AND EFFICIENCY IMPROVEMENT Economic Analysis of On-Line Gauging for Coating/Laminating Process ................................................................... 684

Tan Srinivasan

Reducing Resin Waste in Polymer Processing and Converting Operations ................................................................. 691Natti S. Rao

An Optimized and Integrated Supply Chain Planning Arcitecture for Paper and Film Manufacturers................... 710Bart Van De Velde

Getting Something for Nothing......................................................................................................................................... 723Louis W. Piffer

SESSION 14: UTILIZING METALLIZED FILMS TO RETAIN PACKAGE INTEGRITY DURING TRANSPORT Barrier Testing and Comparison in Pouch Packaging Structures ................................................................................ 749

Bill Minnich

Effects of Converting Operations on the Barrier Levels of Metallized Films............................................................... 756Thomas J. Dunn, Eric Jordan

Advances in Ultra High Barrier (UHB) and Enhanced Sealant (ES) Technology for Bi-Oriented Polypropylene (BOPP) Film ............................................................................................................................................. 767

Sal Pellingra

High Barrier Advancements in Metallized Films............................................................................................................ 773Dante F. Ferrari, Jim Lush

Page 6: TAPPI PLACE Conference 2005

SESSION 15: HOW SUBSTRATES EFFECT HIGH QUALITY GRAPHICS (SPONSORED BY FTA) Evaluating, Monitoring and Controlling the Flexographic Printing Process ............................................................... 789

Cordes Porcher

Substrate Effects on High Quality Graphics-Controlling Ink Volume=High Quality ................................................. 790Mike Huey

Detecting and Managing Print Defects-A Comparison of Quality Control Strategies and Tools ............................... 797John D. Thome

How Substrates Affect High Quality Graphics-The Converters Perspective ............................................................... 805Jason Scroggs

SESSION 16: TEST METHODS AND MATERIAL CHARACTERIZATIONS Polyethylene Coextruded Blown Film: Layer Arrangement and Gloss ........................................................................ 812

Kathleen McCormick, P. Tas

Thermal Analysis of Primers and Coatings as a Prediction Model ............................................................................... 830Robert Hammond

Infrared Analysis of Single and Multilayer Films in the Production Area ................................................................... 855Scott T. Cobranchi, Sandy Rintoul, Nina Tani

Reducing Variability in Dart Measurement Associated With Dart Head Wear .......................................................... 873Mark Weber, Gil Arnould, Jason Benoit

SESSION 17: MATERIALS SELECTION AND OPTIMIZATION First Principles Cause of Melt Fracture in LLDPE ........................................................................................................ 888

David J. Smith, Mike Andrews

Processability and Film Performance of Single Site sLLDPE/LDPE Blends................................................................ 925Trevor Swabey, Sarah Marshall, P. Tas

Cost Reduction Using Performance Products - A Case Study ....................................................................................... 947P. Tas, Lan T. Nguyen

The Effect of Material Selection in Feed-Black Coextrusion of a Three Layer Film ................................................... 971Jiri Svabik, Walter Kopytko, Martin Zatloukal, Jiri Vlcek

SESSION 18: UV/EB COATING AND ADHESIVES Applications of Novel Photo-Curing Oligomer Resins: Generation Two...................................................................... 984

Michael L. Gould, Robert B. Fechter, Sridevi Narayan-Sarathy, Matthew S. Sheridan, Thomas Marino, Alex Mejiritski, Dustin Martin

Choosing the Right Cure Mechanism for UV Curable Laminating Adhesives ............................................................ 995Deborah Smith

Optimizing Application Properties of EB Curable Laminating Adhesives for Flexible Packaging.......................... 1015Stephen C. Lapin

SESSION 19: TEST METHODS AND MATERIAL CHARACTERIZATIONS Polyolefin Microstructure Characterization Using 3D-GPC-TREF ........................................................................... 1031

Wallace W. Yau

Monitoring of Rheological Indicators of LDPE ............................................................................................................ 1046Claes Oveby, Per-Åke Clevenhag

Use Process Control Valves as Rheometers to Predict and Control Polyethylene Molecular Weight and Molecular Weight Distribution ............................................................................................................................... 1061

William Todd, Jean Merrick-Mack, Chad M. Airhart

SESSION 20: MATERIALS SELECTION AND OPTIMIZATION Performance Films from Single Site Bimodal sLLDPE Resins.................................................................................... 1079

Shivendra Goyal, M. Boparai

Page 7: TAPPI PLACE Conference 2005

Metallocene LLDPE Films for Heavy Duty Sack Applications ................................................................................... 1102David M. Fiscus

Novel High Performance Collation Shrink Film ........................................................................................................... 1127Richard W. Halle, David R. Weisinger, Philipp Becker, Donna Davis

SESSION 21: UV/EB COATINGS AND ADHESIVES Heat Management Methodology for Successful UV Printing on Film Substrates...................................................... 1140

David A. Samide, Erich Midlik

Influence of Electron Beam on Some Polymeric Substrates Used in Flexible Packaging .......................................... 1164Imtiaz J. Rangwalla

SESSION 22: FOIL APPLICATIONS AND ADVANCEMENTS Advanced Aluminum Foil Products for Packaging Applications ................................................................................ 1180

Mel Ball

The Impact of Foil Pinholes and Flex Cracks on the Moisture and Oxygen Barrier of Flexible Packaging ......................................................................................................................................................................... 1195

Lee J. Murray

Saturation Phenomena in Conjunction With Corona Treatment on Different Substrates ....................................... 1213Ralf Weber

SESSION 23: FILM PROPERTY OPTIMIZATION THROUGH ORIENTATION Effects of Machine Direction Orientation (MDO) on the Moisture and Oxygen Barrier Properties of HMW-PE Films ............................................................................................................................................................... 1225

D. Ryan Breese

The Effect of Orientation on MD-Tear of HMW-HDPE Films ................................................................................... 1234Harry Mavridis, Ayush Bafna, Jean Merrick-Mack

Author Index