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Manufacturing Flexible Packaging

E-BookEPUBDRM AdobeE-Book
304 Seiten
Englisch
Elsevier Science & Techn.erschienen am04.09.2014
Efficiently and profitably delivering quality flexible packaging to the marketplace requires designing and manufacturing products that are both 'fit-to-use' and 'fit-to-make'. The engineering function in a flexible packaging enterprise must attend to these dual design challenges.

Flexible Packaging discusses the basic processes used to manufacture flexible packaging products, including rotogravure printing, flexographic printing, adhesive lamination, extrusion lamination/coating; and finishing/slitting. These processes are then related to the machines used to practice them, emphasising the basics of machines' control systems , and options to minimize wasted time and materials between production jobs.

Raw materials are also considered, including the three basic forms: Rollstock (paper, foil, plastic films); Resin; and Wets (inks, varnishes, primers). Guidance is provided on both material selection, and on adding value through enhancement or modification of the materials' physical features.

A 'measures' section covers both primary material features - such as tensile, elongation, modulus and elastic and plastic regions - and secondary quality characteristics such as seal and bond strengths, coefficient of friction, oxygen barrier and moisture vapour barrier.

Helps engineers improve existing raw material selection and manufacturing processes for manufacturing functional flexible packaging materials.
Covers all aspects of delivering high value packaging to the customer - from the raw materials, to the methods of processing them, the machines used to do it, and the measures required to gauge the characteristics of the product.
Helps engineers to minimize waste and unproductive time in production.mehr
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Produkt

KlappentextEfficiently and profitably delivering quality flexible packaging to the marketplace requires designing and manufacturing products that are both 'fit-to-use' and 'fit-to-make'. The engineering function in a flexible packaging enterprise must attend to these dual design challenges.

Flexible Packaging discusses the basic processes used to manufacture flexible packaging products, including rotogravure printing, flexographic printing, adhesive lamination, extrusion lamination/coating; and finishing/slitting. These processes are then related to the machines used to practice them, emphasising the basics of machines' control systems , and options to minimize wasted time and materials between production jobs.

Raw materials are also considered, including the three basic forms: Rollstock (paper, foil, plastic films); Resin; and Wets (inks, varnishes, primers). Guidance is provided on both material selection, and on adding value through enhancement or modification of the materials' physical features.

A 'measures' section covers both primary material features - such as tensile, elongation, modulus and elastic and plastic regions - and secondary quality characteristics such as seal and bond strengths, coefficient of friction, oxygen barrier and moisture vapour barrier.

Helps engineers improve existing raw material selection and manufacturing processes for manufacturing functional flexible packaging materials.
Covers all aspects of delivering high value packaging to the customer - from the raw materials, to the methods of processing them, the machines used to do it, and the measures required to gauge the characteristics of the product.
Helps engineers to minimize waste and unproductive time in production.
Details
Weitere ISBN/GTIN9780323265058
ProduktartE-Book
EinbandartE-Book
FormatEPUB
Format HinweisDRM Adobe
Erscheinungsjahr2014
Erscheinungsdatum04.09.2014
Seiten304 Seiten
SpracheEnglisch
IllustrationenApprox. 105 illustrations
Artikel-Nr.2991526
Rubriken
Genre9200

Inhalt/Kritik

Inhaltsverzeichnis
1;Front Cover;1
2;Manufacturing Flexible Packaging;4
3;Copyright Page;5
4;Contents;6
5;Introduction;14
5.1;Background;15
5.2;Reference;17
6;1 Basics of Web Processes;18
6.1;Web Tension;19
6.2;Web Winding;20
6.3;Cross-Web Variation;22
6.4;Web Dimensional Analysis;26
6.4.1;Industry Units of Measure;26
6.4.2;Web Length Estimation;28
6.4.3;Roll Rewind Designation;29
7;2 Rotogravure Printing;30
7.1;Gravure Process;31
7.2;Gravure Cylinders;31
7.3;Halftone Image Reproduction;33
7.4;Ink Metering;37
7.5;Gravure Process Innovation;39
7.6;Cylinder Cost and Cycle Time;40
7.6.1;Work Practices;41
7.7;Reference;42
8;3 Flexographic Printing;44
8.1;The Flexo Process;45
8.1.1;Numerical Color Space;45
8.1.2;Flexo Ink Metering;49
8.1.3;Flexo Halftone Printing (Process Printing);50
8.1.4;Flexo Process Innovation;52
8.2;Reference;54
9;4 Adhesive Lamination;56
9.1;Adhesive Laminating Process;58
9.2;Adhesive Lamination Strength;60
9.3;Other Coating Processes;61
9.4;Adhesive Laminating Innovation;62
9.5;Reference;64
10;5 Extrusion Lamination and Coating;66
10.1;Extrusion Laminating Process;66
10.1.1;Promoting Adhesion: Melt Curtain;69
10.1.2;Promoting Adhesion: Substrate;71
10.2;Extrusion Coating Process;72
10.3;Extrusion Laminating Innovation;74
10.4;References;76
11;6 Finishing and Slitting;78
11.1;Communicating Slit Roll Requirements;78
11.2;Slitting Options;82
11.3;Rewind Options;82
11.4;References;86
12;7 In-Line Processes;88
12.1;Equipment Requirements;88
12.2;Operational Considerations;90
12.2.1;Availability;90
12.2.2;Performance;91
12.2.3;Quality;91
12.3;Success Criteria;91
13;8 OEE Effectiveness;94
13.1;Overall Equipment Effectiveness;96
13.2;Availability;98
13.3;Performance;98
13.4;Quality;100
13.5;OEE Calculation;100
13.6;References;102
14;9 Efficiency and Cost Accounting;104
14.1;Efficiency;105
14.1.1;Material Waste;107
14.1.2;Time Waste;109
14.2;Cost Accounting;110
14.2.1;Minimum Order Size;115
14.3;References;118
15;10 Basics of Control Systems;120
15.1;Distributed Control Systems;120
15.2;Data Inputs;122
15.3;Process Feedback;123
15.3.1;Open-Loop Control System;123
15.3.2;Closed-Loop Control System;124
15.3.3;PID Controls;125
15.4;References;127
16;11 Rotogravure Presses;128
16.1;Press Components;128
16.1.1;Ink Viscosity;130
16.1.2;Electrostatic Assist;131
16.1.3;Image Monitoring;131
17;12 Flexographic Presses;134
17.1;Press Components;134
17.1.1;Plate Cylinder Pressure;135
17.1.2;Plates, Mounting Tape, and Plate Sleeves;137
17.1.3;Drying Technology;138
17.2;Reference;139
18;13 Adhesive Laminators;140
18.1;Dry Bond Laminators;140
18.2;Solventless Laminators;142
18.3;Online Coating Measurement;142
19;14 Flexible Packaging Extrusion Coating/Laminating Line;144
19.1;Line Configuration;146
19.2;Gauge Measurement and Control;146
20;15 Slitters;150
21;16 Preventative Maintenance versus Available Production Time;154
21.1;Availability;154
21.2;Preventative Maintenance;155
21.3;Calibration;156
21.4;Actual Operating Time;157
22;17 Setup/Cleanup versus Scheduled Production Time;160
22.1;Performance;160
22.2;Setup and Cleanup;160
22.3;Decreased Speeds and Minor Stoppages;162
22.4;Increased Speeds;163
23;18 Saleable Product versus Product Produced;166
23.1;Quality;166
23.2;Reference;171
24;19 Paper;172
24.1;Paper Dimensioning;172
24.2;Paper Grades;173
24.3;Paper Coatings;175
24.4;Paper for Flexible Packaging;176
24.5;References;177
25;20 Foil;178
25.1;Production;178
25.2;Converting;180
25.3;Commercial Trends;181
25.4;References;182
26;21 Unoriented Plastic Films;184
26.1;Flexible Films;184
26.1.1;Cast;186
26.1.2;Tubular;187
26.2;General Film Property Effects;189
26.3;References;192
27;22 Oriented Plastic Films;194
27.1;Film Orientation;195
27.2;Oriented Film Applications;197
27.2.1;Cast (Tenter);197
27.2.2;Tubular (Bubble);199
27.3;Special Oriented Film Effects;200
27.4;References;202
28;23 Bulk Polyolefin Resins;204
28.1;Polymer Structure;204
28.2;Functional Description;206
28.2.1;Intrinsic Material Characteristics;207
28.3;Value Provided;211
28.4;Forms Used;212
28.5;Reference;213
29;24 Specialty Sealant and Adhesive Resins and Additives;214
29.1;Polymer Structure;215
29.1.1;Alpha-Olefin Comonomers;216
29.2;Additives;217
29.3;Functional Advantages;218
29.3.1;Ethylene Vinyl Acetate;219
29.3.2;Ethylene Methyl Acrylate;219
29.3.3;Ethylene Acrylic Acid;220
29.3.4;Ionomer;220
29.3.5;Alpha-Olefin Copolymers (LLDPE and mLLDPE);221
30;25 Barrier Resins;224
30.1;Barrier Kinetics;224
30.2;Polyvinylidene Chloride;231
30.3;Ethylene Vinyl Alcohol;232
30.4;Nylon;233
30.5;Coextrusion;233
30.6;References;234
31;26 Inks;236
31.1;Ink Vehicles;236
31.2;Ink Pigments;238
31.3;Ink Curing;239
31.4;Ink Selection;240
31.5;References;242
32;27 Overprint Varnishes and Coatings;244
32.1;Overprint Varnish;244
32.2;Coating Integrity;245
32.3;Vacuum Deposition;246
32.4;Reference;249
33;28 Adhesives;250
33.1;Polyurethane Adhesives;251
33.2;Acrylic-Based Adhesives;253
33.3;Energy-Cured Adhesives;254
33.4;References;255
34;29 Primers;256
34.1;Polyethylene Imide Primers;256
34.2;Ethylene Acrylic Acid Copolymer Primers;258
34.3;Other Primers;259
34.4;Primer Selection;259
34.5;Reference;260
35;30 Conditioning;262
35.1;Standard Conditioning;263
35.2;Special Conditioning;264
35.3;References;265
36;31 Intrinsic Material Properties;268
36.1;Standards;270
36.2;Intrinsic Property Influences;270
36.3;Case Study: Intrinsic Property Influences;272
37;32 Secondary Quality Characteristics;276
37.1;Containment Integrity Characteristics;281
37.2;Protection/Preservation Characteristics;283
37.3;Transportation Integrity Characteristics;289
37.4;Communication Integrity Characteristics;291
37.5;Flexible Packaging Material Specifications;291
37.6;References;293
38;Index;294mehr
Leseprobe

1
Basics of Web Processes


This chapter summarizes common components of web-based processes. These processes involve long thin strips ("webs") of various materials rolled onto a cylindrical core with length approximately equal to the width of the stip. The rolls will later be unwound for their eventual use. The mechanics of winding and unwinding observe very basic principles of physics. Tension, nip pressure, and torque are the physical forces used to control webs during various manufacturing processes. Understanding specific flexible packaging manufacturing processes requires at least a semiquantitative appreciation of the meaning and interactions of these forces. Industry measures including "yield" and "basis weight" must also be understood for further study of flexible packaging manufacturing.

Keywords

Cross-web variation; dimensional analysis; down web variation; nip pressure; rewind designation; roll length estimation; torque units of measure; web tension; web winding

Chapter Outline


Web Tension 2

Web Winding 3

Cross-Web Variation 5

Web Dimensional Analysis 9

Industry Units of Measure 9

Web Length Estimation 11

Roll Rewind Designation 12


Essentially all flexible packaging converting processes involve rolls of web materials (thin materials, manufactured and processed in the form of a continuous, flexible strip). The full length of the strip represents the "machine direction" and its width, the "cross direction". Equipment pulls material from the roll and then modifies it in some way that increases its suitability for use as a package. If the eventual fit-for-use packaging material requires several converting processes, the equipment will rewind the modified material into roll form again. The basic flexible packaging converting processes are printing, laminating, and slitting. The modifications at each stage are generically called "value-adding" processes and they form the basis for converters' selling margins over their costs of purchased raw material.

Web handling in general reflects a dynamic, but otherwise simple, model of Newton's laws of motion:


1. Any object in a state of uniform motion tends to remain in that state of motion unless an external force is applied to it.

2. Force applied to a material accelerates it in direct proportion to its mass; the direction of acceleration is the same as that of the applied force.

3. For every action there is an equal and opposite reaction.


These and related "laws" of classical mechanics make web handling a model system for mechanical engineering science to understand and control web processes. The physical and mathematical relationships developed by this science to describe and design web processes involve several sophisticated concepts. This chapter can only highlight some of the powerful insights of the science when designing and operating web handling equipment, but the interested reader can find more detailed sources in the further reading chapter.1
Web Tension

"Pulling" a web off an unwinding roll and rolling it onto a rewinding one presents major mechanical issues. A force must be applied to the unwinding web. The general term for this force is called "tension." Tension in web converting is often expressed in terms of "pounds per linear inch (PLI)." The units reflect the actual force pulling the web divided by its width (without regard to the thickness of the web material). Web process conditions typically report only this value. To better understand the physical effects of tension on a material, its "tensile stress" must be recognized. Instead of force per unit width, this measure addresses force per unit area, "pounds per inch2." This value relates directly to laboratory measures of tensile properties, an "Intrinsic Property" of the web material (Chapter 31).2

Tension applied to a web may not only pull it off the unwind roll, but also stretch it, or even break it (depending on the web's tensile properties). Flexible plastic films in particular have tensile and elongation properties that can result in diversion of some of the applied unwind force to stretching the film (Figure 1.1). When cross-web length variation (called "bagginess") is present, the stretching force can sometimes "pull out" the bagginess, so that the web appears to lie in a flat plane to observers as well as to the mechanics of the value-adding processes.


Figure 1.1 Distortion of plastic film in response to applied force. Force is applied to web at an unwind, the web resists, the roll turns, releasing web, at the same time the web itself deforms and reshapes.

In addition to moving the web through the equipment to the unwind, tension on the web helps to resist side to side movement, to reduce drooping ("catenary" effect) in horizontal spans between supports, and to establish friction against rollers along the web path and in the rewinding roll itself.
Web Winding

The rewind roll of a web process represents a protective means of storing the web for subsequent use in converting or at an end user. Consideration of the winding step itself reveals many of the additional mechanical considerations critical to successful web processes. Consistent winding of an excellent roll involves three critical factors at the rewind: Tension of the web as it wraps onto the roll; Nip pressure of drum or roller that presses down on the winding web; Torque of the rotating roll as it winds more web material onto itself. Controlling various combinations of "T N T" factors at different points along the whole web process provides the essence of its design and operation. Tension was described above. Torque is simply a "turning" force, which is the one acting in a clockwise or counterclockwise, rather than a linear direction. Nip represents a point along the process at which two rollers contact the web at the same time. One or both of these rollers are "driven," that is, having torque applied to them (using a DC motor, a fluid motor, or a slip clutch). Surface friction between the roll(s) and web's surface controls the web's speed, lateral position, tension, etc.

Excellence for web winding (called "good roll formation") implies an overall cylindrical shape (i.e., circular cross-section), lateral alignment of web edges on both sides (i.e., even from core to top of roll), and centered placement on the core. Because the roll itself represents a convenient interim storage state for the web, it must of course be "unwindable." "Blocked" is the term used to describe the condition in which one wrap of the web on a roll adheres to an adjacent one. Blocking prevents unwinding and often tears the web. Block-prone webs require a thin layer of air between wraps of a roll, generally referred to as winding a "soft" roll. Tensile and surface properties of the web mean different TNT combinations provide optimum roll formation for a particular web. Three types of winding processes can adapt to the range of properties anticipated in a particular industry:


1. Center winding: a rotating rewind shaft turns the core that holds the winding roll in order to apply a tension to the web.

2. Surface winding: rotating drum(s) on the surface of the winding roll apply tension to the web.

3. Center-surface winding: both rotating rewind shaft and rotating drum apply a tension to the web.


Table 1.1 summarizes how these winding processes apply the TNT factors to webs.


Table 1.1

Comparison of Winding Processes

Generic winding type Torque Gap Torque-gap Nip present Lay on roller ½ driven drum rollers Driven lay on roller Torque applied to Spindle shaft Drum roller(s) Spindle/drum roller Web tension source Torque from spindle Nip with drum(s) Nip lay on roller Roll hardness control Tension and nip Nip at drum Torque from spindle Roll hardness range Softer Harder Softer Typical web Plastic films Inelastic materials ↑slip and ↑diameter


All along web processes, TNT factors control movement of the web through the overall process. Many value-adding steps themselves represent nip points (e.g., applying inks, adhesives; laminating webs to one another). The combination of friction, adhesion, and lubrication between a web and any roller surfaces is called "traction." Traction between a web and a roller along the process can transfer some of the web's energy to the roller and cause it to rotate if the roller is properly lubricated. Traction at a nip changes the tension of the web relative to the force between nip rollers, the...
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