Developments in on-line Gauging of Complex Extrusion Coating An - PowerPoint PPT Presentation

Developments in on-line Gauging of Complex Extrusion Coating – An update Stefan Schöneberger Session 10.4 /7629

Presentation Overview • Introduction • Complex extrusion coating process • Optimum sensor requirements • Overview of available sensor technologies • Comparison of various sensor technologies • Best choice of optimum sensor technology: HR-FSIR • Process Control; Process Tools; Process Visualization • Conclusion: Techno-Economic Benefits 7629- Schoeneberger

Introduction • Rapid growth globally in complex web coating lines • Aseptic packaging of liquid consumables – Multilayer product for barrier properties & long shelf-life – attractive packaging for consumer attention • Highly competitive Marketplace with rising raw material costs & tightening margins • Large capital investments in high-speed complex extrusion coating laminators • Increasing requirements for on-line gauging 7629- Schoeneberger

Complex Extrusion Coating Process • Product structure – Printed paperboard substrate or metallized film laminated substrate – Mono layer extrusion (outside layer, tie layer) – Multilayer co-extruded barrier coatings – Lamination: Aluminum Foil or Blown Film • Process – Extrusion Coater/Laminator – Multi coating stations (outside layer, tie-layer, inside layers) – High speed production process 7629- Schoeneberger

Optimum Sensor Requirements Ability to: • Measure true absolute thickness/basis weight of coatings of varying densities on different substrates. • Provide non-contacting measurement with low noise and fast response. • Provide high performance dynamic measurement of coatings independent of substrate variations in a high- speed production environment. 7629- Schoeneberger

Overview of on-line sensor technologies Major categories of on-line sensor technologies for complex Extrusion Coating Process are: • Nuclear Sensors • X-Ray Sensors • Full Spectrum InfraRed Sensor (High Resolution FSIR) based on Absorbance Mode (SpectraBeam) 7629- Schoeneberger

Nuclear Sensors • Based on Beta or Gamma Radiation; Subject to source decay: (PM-147;KR-85;SR-90:AM-241) • Radioactive; hence requires licensing for use and disposal • Measure Basis weight (Not thickness) • Cannot discriminate between layers in multilayer coatings • Use subtractive measurements for coat weight • Use synchronized same-spot • Use substrate-independent calibration technique (True Net Coat Algorithm) 7629- Schoeneberger

X-Ray Sensors • No licensing required. • Not subject to regulations for use at strengths below 30 keV • Measure Basis weight (Not thickness) • Cannot discriminate between layers in multilayer coatings • Composition sensitive • Use subtractive measurements for coat weight • Use synchronized same-spot • Use substrate-independent calibration technique (True Net Coat Algorithm) 7629- Schoeneberger

X-Ray & Nuclear Sensor Measurement • Both X-Ray and Beta Ray Gauges Are Total Mass Gauges • Particles will be absorbed by all mass between source and receiver • Must pay attention to dimensional (z) and air mass changes Nuclear Gauge X-Ray Gauge Isotope Pm-147 or Kr-85 Or X-Ray Tube Source Capsule Web Web Ionization Ionization Chamber Chamber All Mass is Measured Output Signal Output Signal 7629- Schoeneberger

High Resolution FSIR Sensors • Non-radioactive • IR measurement based on absorbance • Full spectrum analysis using Chemo-metrics effectively eliminates or minimizes sensitivity to additives, printing etc. • Insensitive to web or air temperature • Is an on-line spectrometer • Elliptical geometry of 6 x 25 mm design allows measurements closer to web edge, resulting in enhanced streak-detection capability and better edge control and potential less edge trims. 7629- Schoeneberger

Physics Behind IR Measurement - General Each Material Has Stronger Unique Absorption Pattern Weaker Absorption is Stronger At Certain Wavelengths Compared to Others 7629- Schoeneberger

SpectraBeam FSIR Sensor MSP Fixed Detector Array Filter Matrix Optics Full Absorption Spectrum Web Only Mass or Optics Thickness of Polymer is Measured Tuning Fork Lamp 7629- Schoeneberger

SpectraBeam Sensor I n t e Lamp Response n s i t y A b s o Material "Signature" r p t i o n S i g Full Spectrum Array n a l 7629- Schoeneberger

Chemo-metric Analysis Chemo-metric Analysis & Pattern Recognition Software Accurate Calibration for Full Spectrum Array Coatings on various substrates (Pigmented or Printed) 7629- Schoeneberger

Chemo-metric Analysis A b s Measured o Effect #1 r Standardized p (TiO 2) t Spectrum i o n Composition Effect #2 #1 (surface) Composition Residual #2 Eliminates errors caused by Surface Finish, Colorants and other Additives 7629- Schoeneberger

Measurement Technology Comparison Criteria SpectrabeamFSIR X-Ray Beta Noise Characteristics Good Good Nuclear Statistics Noise degradation over None None source decay time Tolerance to Web Flutter Best (+/- 5 mm) Good(+/- 3 mm) Fair (+/- 1 mm) Temperature Sensitivity No Yes Yes X,Y,Z Sensitivity No Yes Yes Yes Some No Composition Sensitivity Dynamic Repeatability Best Good Good Multilayer Coating Moderate High High Calibration Complexity Possible No No Polymer Discrimination Yes No No Multi-Component Measurement Exact same- spot Yes No No Minimum Yes Some Substrate effect Minimum Yes Yes Printing, Additive Effects 7629- Schoeneberger

Best Choice of Optimum Sensor Technology Based on the comparative studies of various available technologies as discussed in this presentation: High-Resolution Full Spectrum InfraRed Sensor (on-line Spectrometer) offers the best choice for the accurate dynamic measurement of multilayer coatings in complex Extrusion Coating Applications. Reflectance HR-FSIR configuration is ideal for measurements of outside layer on paper/board or metallized film laminated substrate and co-extruded inside layers on foil. 7629- Schoeneberger

Process Control • Auto Profile Control (APC) with Accelerated Thermal Response (ATR) feature helps reduce CD Variations • MD Control helps reduce Long Term Machine Direction variations • Yield Optimization Control: Target Management Control (TMC) Helps in Polymer Material Savings 7629- Schoeneberger

Process Analytical Tool • Fast Fourier Transform (FFT) Helps in reducing short term machine direction variations caused by extrusion/laminator equipment • Edge Zoom based on extended data 7629- Schoeneberger

Process Visualization • Contourview Display Suite - Contour View Display (3 Dimensional) - Blanket View Display (Topographical) 7629- Schoeneberger

Techno-Economic Benefits • Customer Results - Multiple case studies in Complex Extrusion Coating Applications: - Reduction in CD variations: 50 to 90%, typically 70% in 20 minutes from startup - Faster product change-over, typical reduction by 67% - Scrap reduction (start-ups,edge & sampling scraps): 50% - Increased edge measurement and control: Additional 2% of width 7629- Schoeneberger

Conclusion • Computer-based on-line gauging systems with optimal sensor technologies, advanced process control & process analytical tools is a powerful Process Management Tool for complex Extrusion/Laminating Processors. 7629- Schoeneberger

Thank you for your attention. Questions?