Film Machine runs at high speeds.
Press Release Summary:
Large, 4 meter, cast film line processes industrial pallet stretch-wrap film at speeds from 1,470 to 1,960 ft/min, with outputs between 5,500 and 6,200 lb/hour. Faster cycle times eliminate off-line rewinding for hand wrap, and single roll handling system simplifies winding logistics. Process control system incorporates automatic die-control software and provides management reporting and recipe system with remote access for maintenance and monitoring purposes.
Original Press Release:
Davis-Standard Develops One of the World's Largest, Most Advanced Film Lines
(Erkrath, Germany)-Davis-Standard recently developed the industry's most advanced 4-meter cast film line for processing industrial pallet stretch wrap film. The five-layer system is capable of processing speeds ranging from 450 to 600 m/min (1,470 to 1,960 ft/min) with outputs between 2,500 and 2,800 kg/hour (5,500 to 6,200 lb/hour). The line, which was sold to a customer in Spain, is currently running 17-micron LLDPE stretch film at 500 m/min (1,640 ft/min) at Davis-Standard's systems test facility in Erkrath, Germany. The two primary processing advantages of the new system include faster cycle times that eliminate off-line rewinding for hand wrap, and a single roll handling system that simplifies winding logistics by providing automated core loading as well as automatic unloading of all finished rolls to the same side of the winder. Following is a summary of the line's key components.
o Extruders - The extruder configuration features one 4 1/2-inch (115 mm) 30:1 extruder for processing the cling layer, two 6-inch (150 mm) 30:1 extruders for processing the bulk layers, and one 4 1/2-inch (115 mm) 30:1 extruder for processing the slip layer. A fifth extruder with a 2 1/2-inch (60 mm) diameter provides side encapsulation. Davis-Standard divided extrusion for the bulk layer into two extruders rather than one 8-inch (200 mm) extruder because company research showed that the 6- inch (150 mm) size optimizes screw designs for these materials. Also, the feedblock configuration allows the extrusion of five-layer film from the four extruders. Typical cling, bulk and slip layer ratios are 20%-60%-20% and 15%-70%-15%.
o Lamella Feedblock - The ER-WE-PA five-layer, four-extruder lamella feedblock is equipped to process metallocene blends and to retrofit two additional extruders for processing added layers as dictated by the market.
o Automatic Die - The line features an ER-WE-PA 310A 4,600 mm (180-inch) automatic die with an encapsulated flow channel, developed in collaboration by Davis-Standard's process engineers in Erkrath and Somerville, N.J.
o Chill Roll Unit - This unit features one chill roll and one post-cooling roll with dimensions that allow for an increased cooling capacity. The unit's water delta "T" allows for entry and exit temperatures of less than 3°C (37.4°F).
o Winder - The 2-by 2-meter twin, turret winder offers single roll handling for each winder half, a compact design and new shaft clamping technology. The identical winder halves feature short winding shafts with clamped bearings at both ends to minimize vibration problems due to the natural shaft resonance. Each winder can cut and change winding position in less than one second, half the time of competitive models. Winder cycle time, including core and roll handling, is less than one minute making it possible to produce shorter rolls without rewinding off- line.
o Process Control System with Integrated Gravimetric System - The ER-WE-PA EXACT-S process control system used to operate the line incorporates the company's proprietary automatic die control software and provides a management reporting and recipe system with remote access capability for maintenance and monitoring purposes. The ER-WE-PA Gradex enhanced gravimetric dosing and metering system provides automatic screw speed control and is fully integrated into the EXACT system.
o In-line Recycling/Gravimetric System - The line has been equipped with a fully integrated scrap reclaim system for in-line recycling. Agglomerate is fed through the line's gravimetric control system back to the extruders.
Additionally, the new line is equipped with a double chamber vacuum box, high performance edge pinning, an oscillation frame and randomizer, a new generation bleed trim slit exhaust, and AC vector drives for extruders and line control. For more information about this new cast film technology, contact Chris Barton at Davis-Standard's facility in Erkrath, Germany, at chris.barton@davis-standard.de.
