TAPPI 11th European PLACE Conference, Athens 2007 Online Quality Control of Polymers and Extruded Films Oliver Hissmann 1
Contents � Introduction � Online Quality Control in Polymer Plants Technology, Benefits, Online Lab, Close Loop Concept � Web Inspection in Film Extrusion Technology, Benefits, Integration � Interrelationships and Correlation � Practical Examples � Summary 2
Online „Closed Loop Control“-Concept Additives Production Process Raw material Sampling Feedback On-line Quality Assurance Data (opt. measuring technique) Determination of the Process computer process parameters 3
Principal of Online Quality Control Production of Polymer Pellets Pellet Transport System Pellet Sampling and Transport Film Extrusion Pellet Preprocessing Blown Film / Cast Film Dedusting / Drying Measurements on Extruded Films Measurements on Pellets Gloss Measurement Gel Counter Pellets Color Measurement Thickness Measurement Haze Measurement Pellets and Powder Inspection Polymer Analysis by FTIR Spectroscopy Pellets Throughput Measurement Pellets Size and Shape Distribution Melt Index 4
Benefits of Online Control � Process Control (Optimisation, capacity, cleaning, waste) � Product (better quality, customer satisfaction/relation, less claims, more competitive products) 5
Online Measurement of Pellets Measurements on Pellets Pellets Color Measurement PCM Measurement of LAB Color Values and Yellowness Index Pellets and Powder Inspection PS 25C, PS 25, PS 2 PT 2 Detection and Evaluation of Impurities in Pellets and Powder Pellets Throughput Measurement PTM Weight Measurement of the inspected Pellets over the time Pellets Size and Shape Distribution PSSD Measurement of Size and Shape of the Pellets Detection of Twin, Triple and Multiple Pellets 6
Pellet Scan System Hopper CCD-Camera Lighting unit Pellet stream 7
Pellet Scan System 8
Pellet Size & Shape Distribution Hopper Pellet stream CCD-Camera Lighting unit 9
Pellet Size & Shape Distribution 10
Pellet Size & Shape Distribution 11
Pellet Colour Measurement visible light color measuring device visible light 12
Online Measurement on Extruded Films Film Extrusion Blown Film Cast Film Measurements on Extruded Films Gel Counter Polymer Analysis by MID-IR Spectroscopy Detection and Evaluation of Measurement of Additive Contents and Physical Properties Gels, Fish Eyes, Black Specs by IR-Light Transmission Through Extruded Films Gloss Measurement Haze Measurement OHM Measurement of Gloss of Extruded Films Measurement of Haze and Transmission of Extruded Films Thickness Measurement TMD Measurement of Films Thickness 13
Online Quality Control 14
Online Integrated Measurement Solution 15
Online Integrated Measurement Solution 16
Online Gel Count 17
Online Gel Count 18
Defect Types � Gels � Black Specs � Contaminations 19
Web Inspection in Film Extrusion 100 % Optical Control of the Web � Photo of every defect � Position of every defect � Database Interface � Reports � Alarms 20
Benefits of Web Inspection � Process Control (Optimisation, capacity, cleaning, waste) � Raw Material (Optimisation material + recipe, control material) � Product (better quality, customer satisfaction/relation, less claims, more competitive products) 21
Origin of Defects in Extrusion � Extrusion Line (screw geometry / dead zones) � Resin (contamination, recipe) � Production Process (extruder temperatures, screen change) 22
Defect Types in Film Extrusion � Gels � Black Specs � Contaminations � Die Lines � Insects � Lamination Defects � Oil Stains � Fish Eyes � etc. 23
Web Inspection System Embedded Multiple Camera Solution 24
Embedded Solution Technology � High Speed CCD Line Scan Cameras 80 – 160 MHz, 512 – 8192 Pixel � Embedded PC with High Speed Framegrabber � Windows XP Server (network) � Exact information on defects within the web (mosaics, position, alarms, protocols, storage) 25
Quality Reports / Alarming � Single Defect � Trend Defects (20 gels per m²) � Slit Defects � Repeating Defect � Gel Shower / Cluster � Roll Defects 26
Rolling Map / Die Defect 27
Time History (Gel Level) 28
Mosaic View 29
3-D Defect Analysis 30
Lane Distribution 31
Die Defect 32
Calander Defect 33
Alarms / Repeaters 34
Teach-In Function - Fly 35
Teach-In Function – Oil Stain 36
Teach-In Function - Gel 37
Teach-In Function – Black Spec 38
Inspection Systems 39
Inspection Systems 40
Closed Frame 41
Interrelationship and Correlation Example � Online Compound Control (Gel Analysis) � Oracle Database Integration � Decision for Film Extrusion Quality (Grading) � 100 % Web Inspection in Cast Line (Diaper Breathable Film) 42
Online Container for Plant Control (Example) 43
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Gel Shower 46
Online Anticipation of Plant Shut Down Start injection cleaning agent Plant shut down 47
Online Transition Control Stop injection cleaning agent Stop extruder rinsing Start extruder cleaning 48
Online Control of Extruder Start Up Extruder startup after plant restart, start extruder cleaning Stop injection cleaning agent Stop extruder rinsing 49
Summary � Close Loop Online Control (Process + Grading) is today‘s Standard in Polymer Plants � 100 % Web Inspection in Film Extrusion � Different Defect Types, but close Interrelation � Working Together avoids Problems and improves Film Quality 50
Thank You very much for Your Attention ! 51
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