the latest developments in on- line measurement …...the latest developments in on-line measurement...

NDC Technologies Proprietary & Confidential Information. Document Reference Number

The Latest Developments in On-line Measurement and Control for

Film Extrusion & Coating Applications

NDC Technologies Proprietary & Confidential Information. Document Reference Number NDC Technologies Proprietary & Confidential Information. Document Reference Number SHEAD 2016

NDC Business Focus

High Value Measurement & Control Solutions for raw & intermediate materials used in manufacturing of consumer goods

Robust stable measurements, unaffected by the environment, fit for process control

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Measurement TechnologiesNIR, Gamma Backscatter, Beta Transmission, X-Ray Backscatter, Transmission

X-ray Fluorescence Microwave, UV Fluorescence, Laser Calliper, Laser diameter Ultrasonics, X-ray Thickness, Width and Flatness

Food & Bulk On line and At line IR

measurement solutionsfor composition analysis

Web - Packaging Film thickness, coat weight,

moisture, scanning profile measurementdisplay & control systems

Cable & Tube Diameter, speed,

length, ovality, wall thickness

NDC Technologies Businesses

Metals Thickness, width,

flatness and coating weight

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Measured by Commitment

►Measurement & control Systems

►10,000 Systems installed worldwide:

►Measuring thickness, basis weight, coating weight and barrier layers for:

Converting Paper Nonwovens Extrusion Flexible Packaging Rubber & PVC Calendering

NDC Web Solutions


• 1940’s – start of the nuclear era [Manhattan Project (1942 to 1946).

• 1951 first nuclear energy generation

• 1948 Tracerlab (USA) invented and sold the 1st on-line basis weight sensor; a Krypton 85 beta transmission gauge.

• 1965 NDC was founded by a former employee of Tracerlab (Mr Fishman) who invented and marketed the gamma backscatter sensor

A very Brief History of the Gauging Industry



An advert you are unlikely to see today!

September 1949

Indeed you are more likely to see these signs


• Measurex founded in 1969 -> very influential and significant player within the history of our industry bringing out the first computer based systems.

• Alfrey & Schrenk developed multilayer film technology in the 60’s. Early 70’s Brun developed 1st NIR sensor to measure barrier layers. Only in mid 80’s did these films commercially take off. NIR development grew from there.

• Egan (part of Davis Standard) filed the 1st autodie patent (1972). But it was EDI/Welexwho in 1974 went commercial with the air cooled bolt heater concept (LFE was the gauge partner).

• 1995 the worlds first 10.4m film line (BOPP) was commissioned.

• 2016 the worlds first 6.3m CPP lines was commissioned



Manufacturing Considerations

Quality Variation without

Automatic Control

Quality Variation with

Automatic Control

Target before optimization

Target Shift to Reduce Raw

Material Consumption

Target after optimization

Lower Quality Limit

Production Increase %

Product Change Time 10-30%

Start Up Time 10-30%

MD/CD Scrap Reduction 30-50%

Downstream Savings %

Reduced Scrap due to: SlittingQuality rejectsRegrindDowngradeCustomer returns

10-20% of machine direction & profile scrap

Quality Improvements %

MD Spread Reduction 30-50%

CD Spread Reduction 50-80%

Material Savings %

Weight or Thickness Down Gauging

1-5%


Achieving Optimum Results with Gauging

Application-matched Measurements & Controls ǀ No Surprises ǀ & Reliable

Accuracy Control CapabilityRepeatable Measurements

Effective Controls

Intuitive OS

Doc. results/Confidence

Management Decisions

ROI

UptimeSupport/trainingTCOAcceptance

ContdResults


Consider - TCO

In Korea buying a system with a radiation sensor

Initial purchase cost $X

Cost of ownership: Importation licenseMonthly Radiation Safety Administration

Fee (per person)Source exchange/disposal fee + shipping

TCO after 10-years = $X

So total cost of the system = $2X

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X X

XX

XX

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Low repeatabilityLow accuracy

High repeatabilityHigh accurate

High repeatabilityLow accurate

Low repeatabilityHigh accuracy

XX X

XXX

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Consider – Application Matched Solutions


Speciality Films & Flexible Packaging

Parameter Requirements

Product Quality Minimal quality variationFlat roll structureRuns efficiently through conversionMeets customer specifications

Process Minimum raw material use Performance Fast start up

Fast grade changeMinimum scrapFast problem identification


Web Gauging Requirements

Item ExpectationsItem Expectations

Measurement Accurate, repeatable measurementMeasurement sensitivity <0.1 micronsAccurate die bolt mappingNon-contacting measurementNon-nuclear measurement

Profile High streak resolution <5mm Resolution

Scan Speed Fast scan up to 650mm/second

Controls Robust control strategies

HMI Interface Provide an effective process interface


Introducing FilmPro


Accurate Measurements: Introducing FilmPro

One gauge provides superior measurement across a wide range of films Efficient optical design for best precision New modular Fringe Suppression Optics (FSO) for thin, clear films Multilayer discrimination for up to 6 components Measures:

Clear, pigmented and some black tinted films Weight and thickness of voided, microporous and breathable films Oil content in microporous film


IR Measurement Discrimination

LDPE, HDPE, LLDPEEVA*, PP EVOH PET

Polyamides (PA) Surlyn™ PS

Polyethylene

Polyester

100

0

50

1.5 3.02.0 Wavelength (micrometres)

2.5

%Tr

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Weight

Insight into Short Term Machine Direction Variation

The Fast Fourier Transform Package (FFT) can be used to pinpoint high-frequency disturbances from out-of-round rolls, bad bearings and material surging

This FFT display identifies a dominant thickness disturbance every 1.8secs, or 1.99m, which was found to be an out-of-round roll

Thickness

Density


Black Stretch Film CD sample

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CPE black stretch film

LabFilmpro


FilmPro Measurement Accuracy

Thin, Clear PET Voided PET

y = 1x + 0.036R² = 0.9997

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Blen

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Thickness (um)

TFG-Y 2114 (GN937) vs SIOS reference values Thin clear BOPP

BOPP 0-30um

Linear (BOPP 0-30um)

Thin Film PP

Thin, Clear PETy = 1.0039x + 0.218

R² = 0.9995

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Unca

libra

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Thickness (um)

TFG-Y 2114 (GN937) vs SIOS reference valueThin clear and filled PP and PE

BOPP clear

Linear (BOPP clear)

BOPP Filled & Clear Thin, Clear PA

PE Film Stretch Blown

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FG71

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Thickness (SIOS) /um

PE film (stretch, blown, biax)

Dolci & Interplast black PE

refuse sacks

clear,blue & green PE

white PE

Black Stretch CD

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Lab

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New 3024 alg

CPE Black Stretch Film

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Dolci black PE

Dolci semi-clear

Dolci pale

Dolci medium

Dolci dark

Interplast black PE


FilmPro Summary

Fast, accurate thickness measurement for film, sheet and coated products

Measurements include thickness, mass, moisture, density and oil content

Safe, reliable and more accurate than other sensor technologies

Pre-selected wavelengths are based on sound spectroscopy and chemical/physical rationale:• Most applications require only 3-4

component wavelengths with additional reference wavelengths


Coating & Laminating Applications

Flexible Packaging Coated / Laminated Papers

Coated Paperboard

Packaging Laminates Pouches Multi-wall bags

Industrial grade papers Release liners Adhesive tapes & labels Photographic papers Crystal & powder

packaging NCR, CB, CF & CFB Labels

Bleached board Food packaging

– Liquid Packaging– Cup Stock


Common Coating & Laminating Structures

NDC IR technology provides measurement visibility into the base, coating and laminating structures– Extruded sheet and films (clear or pigmented) and coatings:

• PE, PP, PA, BOPP, PET etc.– Co-extrusion layer thickness:

• PE, PA, EVOH, PP, Surlyn and other polymers where spectra do not overlap. Continuous multi-layer measurement for up to six components Near and mid-IR measurement capability

Board

PE

BoardPEFoilIonomerPE

Tie

PE

PE

PETieEVOHTie

Tie

Option

NDC710S

NDC710SNDC710SNDC710S

NDC710S


NDC710S Infrared Backscatter SensorBackscatter sensor for measuring thin to thick organic

coatings and moisture:

– Clear & pigmented coatings– Moisture in paper, textiles and nonwovens– Able to discriminate up to 6 multi-layer coatings

Coatings on paper, board, textiles, polymer films and other scattering substrates:

Water or solvent-based Impregnation Solvent-less Barrier coatings Wax dip Lacquers Impregnation Hot melt Polymer extrusions


NDC710S Infrared Backscatter Sensor

RPS09

Custom-made filters:-Up to 10 filters handle a broad range of IR measurement applications -6 simultaneous component measurement

High-speed filter wheel:-8000rpm for fast measurement response- 7.5msec measurement rate

Brushless DC motor:-5 year warranty

IR source:-Off-axis collecting mirror for efficient source focussing - 20W Low heat generation source -5 year source warranty

Window Contamination Monitor:-Checks dust and dirt build up and scattered light from contamination -Detects powders, haze and condensation

Environmentally designed: -IP 65 sealed sensor enclosure

Coating Films

Sintered Air Purge:-Keeps optical path clean

Segmented mirror: -High-efficiency segmented mirror -Improves pass-line insensitivity

Near & Mid IR measurement capability: -Detectors can measure wavelengths from 1 to 5μ

Measurement beam: -27mm wide beam -10mm beam for high-resolution APC applications

Reference detector:-Used for baseline correction -Compensates for optical and electrical changes


NDC710S Direct Coat Weight Measurement The following coatings are measured with the –CH

band: Label stock Wax barriers on paper Polymer extrusion on paper/foils:

• Sugar wraps• Sacking • Packaging• Aseptic cartons

Cold seal adhesives on paper/films Wallpaper PVC plastisol coatings on paper UV Cured lacquers on paper Acrylic coatings on paper pre-metallizing Epoxy resin coatings (carbon fiber applications)


NDC SR710S Infrared Backscatter Sensor Designed to measure the thickness of clear coatings

on shiny or reflective surfaces

Lacquer coat weights from 0.5-25gm2

Ultra thin coatings from 20-1000mg/m2

Applications include: Clear and lightly pigmented thin organic lacquer

coatings, adhesive coatings. Wax on aluminum or steel and thin water-based

coatings.


NDC SR710S Coating & Laminating ApplicationsFlexible packaging:

– Vinyl, acrylic, epoxy, polyester, nitrocellulose & lacquers Can stock:

– Vinyl lacquers and lube coatings on aluminumAir conditioning foil:

– Water based coatings on foilsMetallized packaging:

– Lacquers on metallized surfaces and di-isocyanateadhesives in laminating

PE/Surlyn coatings:– Aluminium (aseptic packaging)

Cigarette– Foil laminated to paper

Protective/heat seal lacquers: – Aluminum (yoghurt tops etc.)

RPS09


Thin Coatings Measurement:Dealing with Optical Fringe Interference

With shiny substrates, two strong reflections are captured by the gauge; one off the primary surface, with no absorption data, and the second off the substrate surface, which contains the needed absorption information

The two signals combine with a phase shift. If they are in phase, the gauge signal is stronger; out of phase, and the signal is weaker; this creates measurement errors

The phase shift / intensity depends on the coating thickness and refractive index Thin, clear coatings are the most problematic between 1 and 25 microns

Reflected intensity = RI Incident Light

Reflected intensity = R2

Thickness = d

Extra path length taken by the incident light

Coating

Foil or Shiny Substrate


Interference Suppression Using Polarized Infrared Light at the Brewster Angle

Foil or Shiny Substrate

Polarized incident light at the Brewster angle

57O

R1R2

At the Brewster angle, R1 becomes zero and prevents optical interference

The Brewster angle is a function of the refractive index of the coating

0O

Angle of Incidence

1.0

0,9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

10o0o 20o 30o 40o 50o 60o 70o 80o 90o

Reflectance

57oa

bc

Curves a and c represent the two planes of polarized light Curve b represents unpolarized light At the Brewster angle, one plane of

polarized light (curve c) is not reflected by the coating surface This totally eliminates optical interference

effects


NDC SR710S Infrared Backscatter Sensor

Sintered Air Purge:-Keeps optical path clean

Window Contamination Monitor:-Checks dust and dirt build up and scattered light from contamination -Detects powders, haze and condensation

Brushless DC motor:-5 year warranty

Custom-made filters:-Up to 10 filters handle a broad range of IR measurement applications -6 simultaneous component measurement

Measurement beam: -25wide beam -10mm beam for high resolution APC applications- Presented to the product at the Brewster angle

IR source:-Off-axis collecting mirror for efficient source focussing -20W low heat generation source -5 year source warranty

High-speed filter wheel:-8000rpm for fast measurement response with 7.5msec measurement rate

Reference Detector:- Monitors and compensates for source output

Steering Mirror:- Achieves the required Brewster angle

Polarizer


SlimTrak Scanner


OptiMike OM190HP Sensor Specifications

Measurement Range: 50 to 5000 microns

Measurement Backing Roll: High-performance stainless steel

Reproducibility ± 2-sigma : ± 0.5 microns

Accuracy ± 2-sigma : ± 5.0 microns

Response Time 10msec

100% Streak Response 1.6 mm

Measurement Resolution 0.10 microns

Maximum Sheet Temperature: 50°C

Maximum Sheet Width: 2500mm

Roll Wrap: 1mm product: 64o

5mm product: 85o


Thank you

the latest developments in on- line measurement …...the latest developments in on-line measurement...

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