ICE USA Conference sponsored by AIMCAL
|April 9, 2013||10:00am – 12:00pm|
|April 10, 2013||10:00am – 12:00pm|
|April 11, 2013||10:00am – 12:30pm|
$79 for day pass, $149 for 3-day pass.
The Technical Conference is divided into three parallel session tracks. Attendees may mix and match sessions. Papers are 30 minutes each, unless otherwise noted.
|Tuesday April 9, 2013|
|Web Coating - Methods - Room N320 A/B|
|10:00 - 10:30am||Coating Process Success Principles
Edward Cohen, Edward D. Cohen Consulting Inc.
This presentation will discuss 10 basic Success Principles that are guidelines that can be used to insure the development and manufacture of a high quality low cost web coating process. The value of these Success Principles is that they provide guidelines for efficiently developing new products and optimizing current products and processes. They will also identify hardware deficiencies, so that the overall coater manufacturing process can be modernized.
|10:30 - 11:00am||Cartridge Coaters - Design for Flexibility and Efficiency
Bob Pasquale, New Era Converting Machinery Inc.
Traditionally, coaters have been provided for a specific coating method, limiting the systems flexability and requiring significant time for clean/set up. To address this, modern coaters are being provided as cartridge systems, with interchangable coating heads that offer multiple coating methods, allowing for greater flexibility and quicker clean/set up. This presentation will cover several ways cartridge coaters can be provided, as well as the design considerations, requirements and benefits of these systems.
|11:00 - 11:30am||Bead Coating - The cutting-edge technology for coatings of functional films
Daniel Eggerath, KROENERT GmbH & CO KG
The bead coating technology becomes an interesting option for several applications. The lecture provides an overview from a machine builder stand point regarding the operating window and advantages, but also limits of this technology. Which parameters need to be analysed to qualify the bead coating method as the right application method? The theory is explained but also actual technical and practical experiences are highlighted.
|11:30 - 12:00pm||Non-Contact Precision Metered Coating
Mike Budai, ITW Dynatec
ITW Dynatec is introducing a brand new technology to the United States, but a proven technology throughout Europe. This non-contact coating method provides some unique benefits that are not capable of being done with current conventional methods: Includes solid film hot melt coatings down to 1 GSM. Provides streak-free clear coating. Ideally suited for heat-sensitive materials, will not heat-mark substrates. Ability to change coat widths and weights “on-the-fly”. Not speed limited
|Web Handling - Tension - Room N320 C/D|
|10:00 - 12:00pm||Answers to Tensioning Questions (2 hour session)
Dr. David R. Roisum, Finishing Technologies / Converting Quarterly Columnist
Timothy J. Walker, TJWalker+Associates Inc. / PFFC Contributing Editor
To many people, tension control is web handling. There are many sub-topics of web handling, but tension control is arguable the most important. There is almost nothing that you do to a web that isn’t tension dependent. Wrinkling and scratching can be turned on an off with the tension knob. Roll winding defects can be divided into too much tension and not enough tension categories. Without tension, your baggy web reveals itself to the fullest and your web guides fail to work.
In this two-hour session, the tag-team of Roisum and Walker share what you need to know to get tension control right. We won’t cover the electrical side of tension control, but we will tell you what your web and process want to avoid all the trouble that poor tensioning can cause.
Questions that will be answered in this seminar: What is the right web handling tension for a given web or process? How is tension created? When is closed-loop vs. open-loop control appropriate? What causes tension variations over time? Crossweb tension variations? Machine direction variations? What is acceptable tension variation? Why does actual tension differ from tension setpoint? What is a tension zone? How many are appropriate for a process?
|Adhesives/Adhesion - Room N320 E/F|
|10:00 - 10:30am||Novel approaches towards curing of radiation curable pressure sensitive adhesives
Benno Blickenstorfer, Collano Adhesives AG.
Radiation curable pressure sensitive hot melt adhesives have established a significant position within the pressure sensitive adhesive industry. The solvent and water free adhesive handling, the convenient and fast curing under UV radiation have proven their benefits in various label and tape applications. Developments in the area of polymers, monomers, additives and coating converting machinery enhance the tool box of the adhesive developer to cope with ever increasing demands for adhesive performance and processing efficiency. This paper presents a novel approach towards curing of radiation curable pressure sensitive adhesives as well as its technical and commercial benefits.
|10:30 - 11:00am||Effects of Cumulative Surface Treatment on Vacuum-Deposited Coating Adhesion
Rory Wolf, Enercon Industries Corporation
It is known that it is possible to improve adhesion of coatings, including metallization, by using any of a variety of surface treatments on polymer substrates. It is also known that the surface treatment can be optimized to give maximum adhesion. But if the treatment is not optimized, the adhesion will be lower. This includes being able to over-treat the surface and lose some, if not all, of the benefits of the surface treatment. The expectation has been that some of these surface treatments may be cumulative and that it is possible to over-treat the film because of the combination of more than one surface treatment. As most metallized processes are onto either oriented polypropylene (OPP) or polyethylene teraphthalate (PET) experiments were conducted on samples of each polymer type.
|11:00 - 11:30am||New Water Based Compostable Adhesive System
John Fitzgerald, BASF
In anticipation of more stringent guidelines concerning the biodegradability of the individual components of food packaging, BASF has developed water based adhesive technology that has been certified as compostable under EN 13422. This adhesive system has been run on conventional water based laminating equipment and provides bond strengths equivalent to alternate adhesive systems currently in use that have not been certified as compostable.
|11:30 - 12:00pm||Reduced Solvent and Higher Speed Application of Two Component Polyurethane Adhesives
David Vietti, Woo-Sung Bae, Linda Anderson, The Dow Chemical Company
Solvent based, two component polyurethanes are some of the oldest adhesives used for laminating flexible packaging films. Newer technologies such as solventless and advanced water based adhesives have displaced some of the solvent based products. Solvent based products are still the most widely used adhesives for many applications due to existing infrastructure to apply solvent based coatings and their long history of proven performance. Typically, solvent based adhesives are diluted to 30-40% solids to apply them on high speed laminating equipment. Application at higher concentrations has been limited because the viscosity becomes too high, the green strength too low, or the adhesive coating is uneven and gives a poor appearance. Dow has developed new solvent based adhesives which may be applied at concentrations up to 50%-55% solids. This reduces solvent usage, requires less energy for drying and allows the adhesive to be applied at higher line speeds with good optics. These developments are proven to work in some of the most demanding applications including retort packaging.
|Wednesday April 10, 2013|
|Web Coating - Curing - Room N320 A/B|
|10:00 - 10:30am||Electron Beam Technology Advancements In Package Decoration
Karl Swanson, PCT Engineered Systems
Electron beam (EB) technology has attracted the interest of packagers for its ability to generate spectacular packaging decorations. This presentation focuses on decorative innovations available using EB technology, providing real-world examples of how PCT’s BroadBeam EB 4-In-1 converting line delivers four interchangeable package enhancement operation modes: Coating, Laminating, Cold Foil Transfer, and Cast and Cure™, a patented decorative process providing high quality finish, ultra high gloss, matte and holographic images on a variety of substrates.
|10:30 - 11:00am||UV Curing for High Speed Coating Applications
Juliet Midlik, Prime UV/IR Systems
UV curing systems are often considered one of the more expensive ancillaries on a converting line, but the real factor that separates the true lifetime costs of different systems is their energy consumption, which can account for up to three quarters of total cost of ownership. This paper introduces UV solutions for minimising this overhead and their suitability for today’s challenging printing and coating applications.
|11:00 - 11:30am||Advances in UV Measurement for Better Process Control
Paul Mills & Jim Raymont, EIT Instrument Markets
Many metallizers, coaters and laminators use UV curing as part of their production process. Yet few know how well their process is performing until something goes wrong. Unlike thermal processing, where the ready access to thermocouples and other sensors keep a constant vigil on the process, UV is often a "black box". This despite the UV is often selected for high speed curing processes where the risk of undetected problems can be more severe. This presentation surveys the use of UV measurement techniques for avoding, detecting and correcting process problems. Innovations in software and hardware now make it possible to gather and compare UV measurements between different lines, and at different points in time to detect problems. The commercialization of on-line, real time sensors provide instantaneous feedback to operators on the condition of the UV cure process and avoids needless rework and scrap.
|11:30 - 12:00pm||Advantages and benefits of Ultrasonic Bonding versus Alternative Bonding Methods
Bill Lynch, Herrmann Ultrasonics
Ultrasonic bonding offers the Nonwoven and Film Converting Market both a reliable and efficient bonding process at the same time meeting and exceeding the sustainability initiative by eliminating the need for adhesive materials and high thermal heat bonding processes utilizing extreme energy consumption. Ultrasonic processing is based on the conversion of high-frequency mechanical sound waves introduced into thermoplastic materials, e.g. nonwovens fibers and film utilizing a specific amplitude and force to create sufficient frictional heat to melt the material at a given web speed. Through advancements in ultrasonic technology web speeds of over 500 meters per minute can be achieved for the bonding, laminating and embossing of various nonwoven materials used in the apparel, home furnishings, health care, engineering, industrial and consumer goods markets.
|Web Handling - Rollers - Room N320 C/D|
|10:00 - 12:00pm||Answers to Roller Design and Alignment Questions (2 hour session)
Dr. David R. Roisum, Finishing Technologies / Converting Quarterly Columnist
Timothy J. Walker, TJWalker+Associates Inc. / PFFC Contributing Editor
Rollers are the universal element of web machinery. Rollers hope they go unnoticed. But just one bad roller can shut down an entire process. A poorly designed roller can scratch, shift, wrinkle, tension, loosen, or break your web. Bad rolls can also ruin your value-creating process – coating, laminating, embossing, winding, printing, and more – turning any process from profitable to biggest bucket of your report.
In this two-hour session, the tag-team of Roisum and Walker share what you need to know to get the right roller for your process, including roller structural design, traction, air lubrication, rubber coverings, and alignment.
Questions that will be answered in this seminar: What makes one roller different from another? (structure, bearings, surface) What is web-roller traction? Why is it important to driven and idler rollers? What is the right amount of traction? What are problems of too much or too little traction? How much diameter variation is acceptable? What causes roller deflection? How much deflection is acceptable? Why is roller alignment important? What is an appropriate roller alignment specification? How are rollers aligned? How is roller alignment maintained?
|Adhesives/Adhesion - Room N320 E/F|
|10:00 - 10:30am||Technical & Regulatory Considerations for the New Entrants to the Short-Run Flexible Packaging Market
Kelly Williams, Ashland
The flexible packaging market continues to be a strong growth market globally. Disruptive technologies such as digital printing, tectonic changes in regulations and brand owner expectations relative to safe food packaging, and the trend towards shorter runs creates many opportunities for new entrants into the market. There are many technical and regulatory considerations you need before building your flexible packaging business.
|10:30 - 11:00am||UV curable PSA for industrial tapes applications
Zhaohui Sun, Ashland Performance Materials
The development of UV curable hot melt pressure sensitive adhesives (PSA) has progressed significantly over the last few years. Some UV products have similar performance attributes as solution PSA products, but without the need for expensive drying ovens and incinerators. Therefore, the applied cost of the UV hot melt PSA can be significantly lower than solution products. This is especially true for PSA applications requiring thicker films, where solution drying lines must run slowly to obtain quality coatings. This paper presents a UV curable hot melt PSAs using the technology of derivatizing acrylic polymer with UV curable functionality that permits generation of solution like performance at even high film thickness. The adhesive can be applied on conventional hot melt coaters at a temperature range of 100-120° C at reasonably high line speeds (up to ~400 fpm). A broad range of products are possible with this technology, including applications for high or low temperatures, high cohesive strength, and low surface energy (LSE) adhesion. Good cure-thru of films as thick as 10 mils (250 microns) has been validated. UV curable hot melt PSAs can be considered to be a viable alternative to solution PSAs for industrial tape applications.
|11:00 - 11:30am||Controlled Adhesion in Reactive Solution Acrylic PSAs
Dr. Eric Silverberg, Henkel Corporation
Controlling peel build and adhesion is a challenge pressure sensitive adhesives. This paper will explore the performance of a new development based on reactive resistant polymer technology and its properties as a repositionable adhesive, showing the slow build up of bond strength Behavior using standard tests as well as analytical tools will be presented.
|11:30 - 12:00pm||Combining Polypropylene With Aluminum Foil
Bruce Foster, Mica Corp.
Polypropylene is well-known for its thermal, mechanical and chemical- resistance properties. Combining polypropylene with aluminum foil for both industrial and packaging applications is a challenge. In this paper, we review some existing technologies and report on some new technology to allow converters to extrusion-coat polypropylene onto primed aluminum substrates. The same technology can also be applied to thermal-lamination of a polypropylene to a metal foil.
|Thursday April 11, 2013|
|Web Coating - Inspection - Room N320 A/B|
|10:00 - 10:30am||Film Inspection: Live Quality! - A holistic integration concept for inspection systems into the production
Oliver Hissmann, OCS Optical Control Systems GmbH
Film inspection systems are increasingly becoming a vital part of production lines. On the one hand, customers require a 100% quality control (pharmaceutical, medical, food wrappings, etc.), on the other hand, the film manufacturer needs to reduce waste and optimize their production process. At very high investment costs for production lines, the manufacturer has no objective knowledge about the quality of the films and the process. However, the holistic integration of inspection systems is a long way ("Live Quality"), because who knows the requirements of the customer and can discuss this issue aggressively? In the steel, paper and also the polymer industry this quality concept is already comprehensively (internal) standardized, but also variable in every company. Within a holistic quality approach the produced films will be monitored in the calendering or extrusion of camera systems, there are alarm limits for the machine operator and the implementation of individual critical errors are marked in-line.
Quality assurance has all the production lines using special software "in the eye" and the central metrology department can connect to systems via remote control. Here, for example, configurations can be adapted or installed at other locations around the world. Each role will have its own (standard) film grade and will, if necessary, be blocked or will be posted into the slitter department. Here, critical errors can be approached and then cut out . This quality policy has been extended by a DataLogger software that allows to sort and prepare the data according to certain criteria. All types of films that were produced within a given period, may be displayed clearly with one click, no matter on what line produced. Another central analysis software allows the reading of material, polymer and process parameters from the PDA or via an OPC interface. The data thus obtained are then correlated with the respective quality/film note and will lead to a SPC solution (statistical process control). This holistic integration of inspection systems is a long way (perhaps comparable to the introduction of an ERP system), although indispensable for the preservation of competitiveness and guaranteeing the future. In today's global world, quality is more important.
|10:30 - 11:00am||Innovative Automated Web and Sheet Inspection Systems - Vision Beyond Defect Detection
Jochen Koenig, Schenk Vision
Modern web inspection systems now deliver much more. Enabled by recent advancements in LED illumination-technology and very high speed cameras, the newest systems reach much higher image resolutions. Because of this, particularly for small defects, advanced classification becomes possible thus elevating mere detection into reliable identification of the root cause. Scan rate synchronized light switching technology, one of the most recent innovations few systems master, provides simultaneous acquisition of the sheet at multiple illumination modes with a single bank of cameras which significantly increases detection and classification performance without the traditional high cost of multiple camera banks.
|11:00 - 11:30am||New Laser-Camera Technology for On-Line, 100% Roll-To-Roll Inspection – Defect Detection, Pattern Recognition and Metrology
Timothy A. Potts, Dark Field Technologies, Inc.
Success in the production of coated and uncoated films critically depends on the ability to maximize throughput of widest web practical while maintaining pristine quality. Achieving these objectives requires high-resolution, high-speed, on-line 100% inspection tools. These tools monitor the manufacturing process, detect defects and alert the operators when the product quality deviates from acceptable limits. Operators use these tools to identify the source of the problem and take timely corrective action. Throughput, yield and quality are maximized, and scrap is minimized. Conventional RTR inspection technologies have been either flying spot laser scanners or solid state camera systems. Each technology represented unique benefits, and both technologies had significant shortcomings.
A new technology, combining solid state lasers with line scan cameras has been developed and proven on film, glass and solar PV applications. This technology represents the design convergence of laser and camera systems. Solid State Laser Reflection (SSLR) scanners deliver 20X imaging of defects, when compared to conventional systems of the same resolution. They may be used for defect detection, pattern imaging and metrology. Systems are low cost, simple to install, require no maintenance, are 100% solid state, self-aligning and consume 10X less power than conventional systems. This paper will describe SSLR technology, compare it against conventional laser scanning and camera systems and show how is can dramatically improve production rates, quality and yields for RTR processes
|11:30 - 12:00pm||Latest developments and concepts in optical web coating inspection technologies
Brian Heil, ISRA VISION
Optical inspection systems are sophisticated and reliable tools to guarantee constant quality and secure the investment in a production line. The use of new features and technologies for optical inspection systems guarantees coating companies ship 100% defect free material to a demanding, quality driven market. Latest developments in lighting and camera technologies assure complete control of the coating process, providing data analysis to improve process efficiency and avoid customer complains.
|12:00 - 12:30pm||Global defect management during the manufacturing process with vision in OPV
Dr. Michel Popovic, IN CORE Systèmes
OPV production hasn’t really started yet on a mass scale, and even if efficiency is far from reaching the same level of performances as the sillicium panels, a huge potential of applications could benefit from OPV. While measurements and inspection realized by vision can insure general layout of the cell and detection of the defects in the different layers, what solutions do manufacturers have to manage anomalies that happen during the process?
|Web Handling - Process - Room N320 C/D|
|10:00 - 10:30am||Computerized Traverse Winding for Converted Materials
Robin Ulanski, Independent Machine Company
Integrated slitting and computerized traverse winding (spooling)systems account for a growing segment of the converting industry. Traverse winding operations require the “traverse” mechanism to either laterally move the material back and forth across the spool or laterally move the spool back and forth under the fixed input of the material being spooled. The accuracy of the traverse positioning, selection of the proper traverse pattern and careful attention to tension is critical to the spooling process for converted materials
|10:30 - 11:00am||Roll-to-Roll Manufacturing Static Control Best Practices
Kelly Robinson, Electrostatic Answers
Innovations in roll-to-roll manufacturing process technologies have enabled the production of a wide variety of new products including high performance laminates, flexible electronic circuits, electronic displays, biologically active sensors, and solar cells. These products each have carefully designed surfaces that provide high value to the end product. Sensitivity to static discharges and contaminates attracted to the web by static charges demand high performance static control systems. Best practice static dissipater installations for unwinders, tension control nip rollers, corona treaters, coaters, dryers, lamination nips, and winders are designed to achieve excellent static control throughout the supply chain.
|11:00 - 11:30am||Shear Knife Overlap and Dimensional Run-Out
Dave Rumson, DR Consulting
Shear knife Overlap set-up errors and excessive knife dimensional Run-Out will negatively affect finished roll quality. This presentation discusses the results of excessive and insufficient Overlap and the importance of Run-Out control. Graphic representation and photographs help to clearly define multiple negative effects on slit edges and finished roll faces.
|11:30 - 12:00pm||Engineering Elastomeric Materials
Peter Koch, ABBA Roller
Manufacturing processes can demand a customized elastomeric material characteristics. Rubbers typically exhibit a constant force per displacement, or durometer. If the process requires something different, a dual-durometer set up is used to achieve a pseudo non-linear effect. However, this still has limitations and is bounded by the linear characteristics of the two different base elastomers. This paper outlines the options that are available through custom non-linear material compounds which can alleviate this issue. By developing an engineered elastomer one can achieve a true non-linear durometer to meet the needs of virtually any application.
|12:00 - 12:30pm||Accurate length measurement during converting
Timothy Rye, RYECO Inc
For most continuous web manufacturers, determining the accurate length for each step of the process can be a real challenge. When a roll of raw material is converted into finished goods, it is critical to know how much product there is in each roll that is shipped. It is also important to know at all times how much product is left on the unwinding roll to ensure complete sets of finished rolls. Tachometer issues, and stretch and shrinkage in the substrate can cause large inaccuracies in roll length. RYECO introduces the Length and Position Control System that uses evenly spaced code marks on a web that provides users with 100% accurate length and position information in any processed roll. The system also provides functionality for automatic stopping for sets or known defects and can display web stretch and shrinkage in real time.
|Adhesives/Adhesion - Room N320 E/F|
|10:00 - 10:30am||Emulsion Silicones and CCK - The Building Blocks for Specialty Release papers
W Michael Reed, Glatfelter
Emulsions silicones and CCK – The building blocks for specialty release papers Emulsion silicone coating as been around for a long time. Combining the versatility of emulsion coating with the diverse range of clay coated papers available, allows for the manufacturer to produce a variety a release products for use with not only adhesives, but also cast vinyls and urethanes. Emulsion silicone coatings provide the platform for designing coatings that allow for modifications to a broad range of surface properties such as gloss, release, smoothness, color and others. Emulsions provide a water based coating system allowing the coating formulator many options for combining coating additives to modify the finished product. Clay coated base papers provide a smooth, consistent surface for application of the designed coating. This paper will outline several of these combinations, highlighting the diversity of products that can be produced using emulsion silicones and clay coated papers.
|10:30 - 11:00am||Silicone Release and Pressure Sensitive Adhesives: Making the Right Selection for Label Applications
Ingrid Brase and Pete Walter, Henkel Corporation
|11:00 - 11:30am||In-line process control of silicone coatings
Vivek Komaragiri, SpecMetrix (Sensory Analytics)
An accurate new means to measure the absolute thickness of applied silicone layers on films while in-process in a non-contact and non-radioactive manner will be presented. The technique offers a real-time means to improve the accuracy and efficiency of the silicone coating process. Production data, correlation data and summary run results will be presented for wet and dry silicone film coatings, thin top coats on printed films and thin base film layers.
|11:30 - 12:00pm||Web Cleaning for Improved Adhesion
George Zuments, Web systems, Inc (WSI)
A discussion of various methods available for substrate cleaning, capabilities, benefits and advantages will be examined. Special emphasis on R2R vacuum deposition. Latest cleaning methods will also be discussed.
|12:00 - 12:30pm||Advanced On-Line Infrared Measurement Techniques of Polymer Structures
Ray Shead, NDC
Infrared measurement techniques have advanced considerably in the last 5 years to meet increased measurement demands of the biax film process. This portfolio of new capabilities includes the determination of up to six simultaneous component measurements in a coextruded structure, the measurement of true thickness, basis weight and density of cavitated, pearlized, and micro-porous battery separator films, and the measurement of thin films as light as 1 micron. New measurements of adjunct products such as barrier coatings applied either on- or off-line are also now possible. This paper will review the techniques employed and also review some actual online customer results in making these real time measurements.