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