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ICE USA Conference sponsored by AIMCAL


ICE USA 2015 will feature the most comprehensive educational program in the converting industry. AIMCAL will once again sponsor the ICE USA Conference offering an array of technical sessions featuring key insights from some of the industry’s leading experts. The robust conference program features nearly forty educational sessions designed to provide converting professionals with knowledge they can use to enhance their companies’ performance and productivity.

Each day will begin with a thought-provoking keynote presentation which is free to all registered ICE USA attendees. The keynote presentation will be followed by three concurrent 2-hour technical sessions (one in each track) led by well-known industry experts.

The sessions are scheduled from 10am to noon, providing attendees ample time to visit the show floor and experience converting technology in action.

Conference Schedule

February 10, 2015 10:00am – 12:00pm
February 11, 2015 10:00am – 12:00pm
February 12, 2015 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.

Tuesday, February 10, 2015
Coating Quality
10:00 - 10:30am How Automatic Metrology Systems Help to Increase Product Quality While Saving Production Costs and Time
Jochen Koenig, Schenk Vision

Automatic optical inspection systems (AOI) for in-line quality control are applied in various steps of film production. They help to identify defective areas which avoids delivery of scrap inferior material to be delivered to customers. AOI systems can detect local defects as well as large area irregularities in film properties (e.g. coating thickness, opacity/reflectance, …). Feeding back the AOI results will keep the production within the defined process window, resulting in higher yield and shorter production time.

10:30 - 11:00am Solutions for all coating industries: Advanced optical coating inspection for maximum quality
Jeff Potter, ISRA Vision

Polyethylene-coated liquid cardboard, lithium-ion foil, banded cigarette paper and siliconized film are only a few examples of products demanding optical quality inspection to ensure shipments of flawless rolls.

ISRA offers a diverse portfolio of optical coating inspection solutions that cover all processes. Users will benefit from a significant improvement in quality very early within the processing steps. Using innovative technologies, the systems provide 100% quality control e.g. for adhesive, special and PE coatings and coated paper. Additional features like edge inspection and coating monitoring lead the way to a high-quality, maximum efficient production.

Furthermore ISRA offers tools to optimize the production to generate additional benefits by increasing the overall processing efficiency with slit-optimization or rewind controller. The inspection solutions guarantee constant quality with defined standards and enables customer to reach their quality goals.

11:00 - 11:30am On-line Coating Weight Measurement
Ted Schnackertz, NDC Infrared Engineering

The requirement for increased functionality in films and coated web products results in more complex and costly structures. Layers and coatings are getting thinner, production runs are shorter and line speeds are increasing. To meet this requirement and remain competitive requires an efficient process able to run within specification from the start to finish of a run. This cannot be accomplished with periodic lab sampling, since a defect caught in the lab may be hours old! Add proof of compliance and process troubleshooting and an on-line gauging system becomes a tool in this effort. The purpose of this session is to discuss the applicable on-line gauging sensor technologies and coating measurement techniques.

11:30 - 12:00pm High Speed, High Resolution Coating Inspection
Tim Potts, Dark Field Technologies

The ability to inspect coatings, at high speed and high resolution has been a long-standing industry need. Coating operations can exceed 100m./min. and defects of 10µm – 100µm must be detected. This is not possible for human inspectors. The only inspection option is to post production and this means rewinding and handling – adding to the cost and the risk of creating more defects. Also, process upsets go undetected until after the fact, reducing yield.

The inability of conventional inspection systems to reliably operate in a production environment in reflection has frustrated the industry; missed defects and false hits plague these systems.

Solid State Laser Reflection (SSLR) technology solves these problems. Line scan cameras and solid state lasers are married together inside a single scan unit for the first time. This scanner is easily installed even in the tightest locations. All active modules are in a single unit, located on one side of the film. In addition, SSLR is self-aligning, operates in ambient light and requires no maintenance.

System theory will be explained and a number of application examples and results will be presented.

Web Handling
10:00 - 10:30am Drive System Engineering for Web Fed Machinery
William Gilbert, Siemens Industry, Inc.

Drive system and automation technologies continue to evolve at an ever increasing rate. This creates the opportunity to take a fresh look at several topics important to converting machinery drive system design. The topics reviewed in this paper include; Motor and drive sizing for center driven unwinds, winders and zone tension control sections. Engineering units used in motor sizing and optimizing winder drive sizes through motor base speed options. Motor technologies and best application practices of synchronous and asynchronous motor types. A review of the tension control modes, and application best practices. Drive system architecture options and the benefits of utilizing a Common DC Bus configuration.

10:30 - 11:00am Improving Efficiency and Product Quality with Precision Alignment of Equipment
Roger Cross, OASIS Alignment Services, Inc.

Precision alignment of coating and laminating equipment can significantly improve operating efficiency, product quality and customer satisfaction, while reducing machine downtime and excess waste. With so many alignment methods and technologies to choose from however, it can be difficult to select the option that will provide the highest return on investment. In this presentation, Roger Cross, Project Manager, OASIS Alignment Services, will provide an overview of alignment procedures and technologies, as well as a review of the various alignment tools available. Additionally, case studies will be discussed showing the impact precision alignment has on production levels, product quality, downtime and ROI.

11:00 - 11:30am Color Line Sensing for Web Guiding
Bill Scala, Erhardt + Leimer Inc.

The new FE 52 uses a color matrix chip instead of a line chip for web guiding based on lines or color contrasts. This means that a real 2-dimensional live image of the web surface can be displayed on the color touchscreen of the connected command station, making it easier for the operator to select the line or contrast edge to be used as the guidance criterion for web guiding.

11:30 - 12:00pm Static Control Best Practices for Converting and Printing
Kelly Robinson, Electrostatic Answers

Static charges cause shocks to operators, sticking and jamming of cut sheets, and sparks that can ignite flammable solvents. Static in a typical converting or printing operation may be effectively controlled using commercially available devices by installing these static dissipators to form a fault tolerant control system. Implementing a fault tolerant static control may be implemented using best practice locations for static dissipators. The best practice locations for a slitting operation are presented.

Extrusion Coating
10:00 - 10:30am Advances in Extrusion Coating
Andy Christie, SAM-NA

Extrusion coating and laminating is a mature industry and advances are often incremental. When process and equipment changes occur the critical information asked by the converter: What will it do for me? This paper will review the basics of the extrusion process and discuss several technology improvements which are available for testing in the recently installed Extrusion Technology Center at SAM-NA. The discussion will cite trial work at SAM-NA supporting the impact and interaction between equipment and processing. Topics will include: screw design & mixing, direct torque drives, infrared barrel heating, motorized back pressure valves, layer multiplication, and edge profile control.

10:30 - 11:00am Specialty Polymers used for Packaging Applications
Jim Cooper, The DOW Chemical Company

A variety of polymers are used as tie layers and sealants in the extrusion coating and extrusion lamination process, especially metallized films and foils. A wide range of polymers and copolymers utilized in the flexible packaging industry will be reviewed during this presentation.

11:00 - 11:30am Adhesion Parameters in Extrusion Coating
Bruce Foster, PolyKnows


11:30 - 12:00pm "Charr Proof" Hot Melt Systems
Michael Budai, ITW Dynatec

In the coating and laminating world much of the lamination is done with hot melt adhesives. The number one challenge in working with hot melt adhesives is preventing Charring or burning of adhesives. Once Charr is in the equipment it immediate affects downtime, quality, and can damage equipment. It is very time consuming to clean and costly. This presentation will demonstrate how to design and built a guaranteed charr proof system.Result is consistent quality.

Wednesday, February 11, 2015
Coating Productivity
10:00 - 10:30am Improving Productivity with OEE
Adrian Pask, Vorne Industries

Overall Equipment Effectiveness is a manufacturing best practice metric for measuring machine productivity. In context: 100% OEE = making only good material, at full speed, with no stops. In this presentation we will look at: 1. How to measure OEE in converting, finishing, and printing 2. How to use OEE with Operators, Supervisors, Engineers, and Managers to improve productivity The presentation will be given by Adrian Pask, co-author of and

10:30 - 11:00am The Answer to Cost Savings, Safety and Environmental Compliance
David Roey, Progressive Recovery

Performance, speed, quality and automation all have merged together to deliver the best possible result for today’s converters. The solvent using converter is also struggling with the dangers of hazardous waste, suffocating in environmental compliance and is frustrated by the rising costs of solvents. In house solvent recovery is a solution to addressing all of these issues by linking the new system directly to the press. This eliminates potential hazards to personnel and environment.

11:00 - 11:30am Laser-Based Process Optimization
Felix Rominski, Polytec, Inc.

Web handling in general and printing or finishing in particular is characterized by a variety of materials. Thickness and surface quality change thus the mechanical properties change. Laser-Doppler bases devices measure from colorless transparent foils to black rubber or delicate webs. They can be used as footage counter or speed sensor to improve processes by better material flow or product properties and improved printing quality. Cutting scrap and shorter change over times save costs.

11:30 - 12:00pm A Cost Effective Method for Increasing Converting Machine Productivity
Joe Martin, Qualitek Solutions, Inc.

Converters invest $ millions in state-of-the-art finishing machines, yet few know if these machines and their operators are performing at optimal efficiency. A new approach to measuring machine performance continuously and making this information available to management and crews in real-time will be presented. Using this method, converters can maximize machine uptime, optimize order processing speeds and minimize material waste. Companies can expect to achieve a return on investment in less than 6 months.

10:00 - 10:30am Selecting an Unwinds and Unwind Splicers System
Bob Pasquale, New Era Converting Machinery

There are many factors that need to be considered when selecting an unwind and unwind splicing system. These include the number of unwind positions, the loading of new material rolls into the unwind, how the rolls will be held in the unwind, how the unwind tension will be controlled and how the material rolls will be splice together. This presentation will address the considerations of these topics when selecting an unwind and unwind splice system.

10:30 - 11:00am Diagnosing Wound Roll Telescoping
David Roisum, Finishing Technologies

Telescoping is a catch-all term for at least 5 distinctly different mechanisms that would cause the roll edge to move during winding. Diagnosing the correct type is essential because the list of remedies for each type are as distinctly different as the mechanisms themselves. For example, some types are taper or roll structure defects, while the adhesive shear version is a tight defect. Some types respond to winding curves, while others respond much more to product/process design and a few may require a different type of winder. There are even products that might not safely be wound on any winder with any settings. This paper sorts out which specific telescope you have and what you can do effectively to remedy it. [Same paper as given in AIMCAL Web USA 2014 ]

11:00 - 11:30am Developing Roll Hardness on Center and Center-Surface Winders
Duane Smith, Davis Standard

Winding web materials into wound rolls with the proper residual stresses, better know as better known as roll hardesss, is extremely important to be sure that high quality rolls are produced, handled and stored, shipped and then processed by your customer with at maximum production speeds without defects. This article addresses the winding principles that are used to develop roll hardness in wound rolls. Then how these principles are used on different types of winders to produce the stresses or inwound tension profile to help assure that rolls of web material are wound with the proper hardness profile. Althought the best combination of these winding roll hardness principles for different winders and differient types of web material has to be imperically determined for specific applications, this article suggests “rules of thumb” for starting values for differient materials to assist in optimizing the roll struction that works best for consistantly producing high quality rolls of materials to meet your customer’s requirments.

11:30 - 12:00pm Automatic Control of the Unwind Process in a Converting Plant
Timothy Rye, RYECO, Inc.

Complete control of the unwind process involves automatic stopping for defects, automatic end of roll stopping and accurate length and position control regardless of slabbing or splicing. Other benefits include set-stopping for accurate daughter roll length, automatic preselection of severe defects or upsets for auto-stopping and full defect database management including history and trends. For flexible webs a complete automatic control solution can provide information on instantaneous stretch or shrinkage of the web during processing. Adding an automatic unwind control system to a converting line will provide more through-put, higher quality, better yield and create a safer work environment for operators.

Web Slitting
10:00 - 10:30am Razor Slitting - Benefits and Limitations
David Rumson, DR Consulting

Discussion begins with razor slitting web fracturing stresses compared to crush and shear slitting stresses. Also presented are the web material characteristics that most benefit from razor slitting, the importance of perfect blade perpendicularity and the two blade-to-web engagement methods; wrapped or suspended in-air. Common blade materials will be briefly presented, including my encounter with the diamond coated razor blade. Finally a comparison of all the razor slitting benefits and limitations will be reviewed.

10:30 - 11:00am Crush Cutting Force Analysis and Trouble Shooting
George Benson, Dienes


11:00 - 11:30am Managing Overspeed in Tangent Slitting Applications to Reduce Edge Defects
Sean Craig, Maxcess - Tidland

Overspeed of the lower anvils is a fundamental requirement for shear slitting but how to manipulate it to reduce slitting defects is often misunderstood. This paper will look at specific variables that affect overspeed and review examples of how overspeed can be manipulated to reduce angel hairs in plastics applications, improve slit quality in dense non-wovens, in addition to other real-world examples.

11:30 - 12:00pm Static Electricity: Causes & Cures in Web Converting
Matt Fyffe, Meech Int.

The purpose of this presentation is to look at what static is, how it occurs, what factors affect static electricity, the methods available to counteract it and how to use these methods in a variety of web handling applications. It is not intended to be an exacting, scientific reference guide; instead its aim is to answer the most commonly asked questions about static electricity control. We will focus on the different technologies available to control static electricity and the advantages and disadvantages of each. We will also explore the use of generating static electricity for the benefit of web converting. Generating a controlled static charge on a non-conductive material will allow temporary adhesion between two or more surfaces of opposite polarity.

Thursday, February 12, 2015
Surface Treatment
10:00 - 10:30am Clean it Before you Treat it
George Zuments, Web Systems Inc.

A cleaner substrate may enhance surface treatment methods. This presentation examines the types of various cleaning methods available and discusses their pros and cons. We will attempt to help determine your cleaning goals and how effective these methods may be in accomplishing them. We will only discuss “high end” cleaning requirements and systems, those that are capable of removing 20µ and larger particles, those that are able to remove particles as small as 1µ. A variety of methods are available. From hand powered rags (not appropriate to our discussion here) to sophisticated systems capable of cleaning to the low micron level. All of these cleaning systems will clean to one degree or another. Any method will have advantages and disadvantages which we will discuss, including budgetary considerations. There are various detriments to effective cleaning, including static attraction, a boundary layer on moving substrates that can entrap particles and the difficulty presented by Impressed & embedded particles. In many applications a dual system approach may be necessary.

10:30 - 11:00am What is the Future of Water Based Inks and Adhesives on Raw BOPP?
Ronni Nielsen, Vetaphone

Today, the use of water based inks and adhesives on raw BOPP is limited, without the added use of an expensive primer. The reason behind this is the limitation of the materials’ ability to react with oxygen, resulting in a maximum obtainable surface tension of 46 dyn/cm, after using Corona treatment. The only solution today is to buy BOPP that is already primed or has an inline primer for the purpose.

11:00 - 11:30am Polyolefin Film Surface Preparation Leveraging Atmospheric Plasma
Rory Wolf, Pillar Technologies

Preparation of polyolefin surfaces for commercial applications is a developing field of study, as frequently these surfaces must be specifically modified to optimize performances many times related to adhesion. The simultaneous cleaning and functionalization of common polyolefins by atmospheric pressure plasma treatment (APPT) is a promising way to modify the surface and meet these demands. This work investigates the removal of low molecular weight species as well as the simultaneous functionalization of polyolefin films.

11:30 - 12:30pm Why All Films Do Not Treat the Same- The Signature Relationship Between Your Film and Corona Treaters
Tom Gilbertson, Enercon industries

How well do you understand the relationship between your films and your corona treater? A treatment level of 2.0 watt density yields different results on PET and Polypropylene. This paper examines the relationship between various films and watt densities. It also provides valuable takeaways on the economic impact of specifying higher watt densities. Recognizing that each film has its own signature relationship with a corona treater helps converters control surface energy, improve adhesion & manage costs.

Coating Process
10:00 - 10:30am Fundamental Causes of Coating Defects
Edward D Cohen, Edward D Cohen Consulting, Inc.

An understanding of fundamental causes that control the formation of defects is essential to reproducibly manufacture a high quality low cost coated product. This is important, because defects that appear to be different in appearances can be different can result from result from the fundamental cause. Therefore; eliminating a basic cause can result n reducing many different defects. These fundamental cause swill be discussed.

10:30 - 11:00am Pull Rollers: Plain, Vacuum and Unported
Kevin Cole, Optimation Technology

The role of a pull roller in a web machine is identified. The ability of pull rollers, plain or vacuum type, to permit tension differences is explained. Three types of pull rollers are described. Among them is the unported roller that utilizes holes and grooves to increase effectiveness.

11:00 - 11:30am Electron Beam Curing for Printing, Packaging, and Converting Applications
Stephen C. Lapin, PCT Engineered Systems

Interest is increasing in the use of electon beam (EB) curing for printing, packaging, and converting applications. EB provides instant curing of solvent and water free inks, coatings, and adhesives. The applied energy is very consistant and no photoinitiator is required. This helps ensure low migration propeties of the cured materials. Established applications include web offset printing, flexo printing, functional coatings over conventional inks, and bonding of laminate layers. The use of EB for ink jet printing is also being developed. EB equipment is now avaiable from 250 to 2700 mm wide.

11:30 - 12:00pm In-Line Cleaning, Drying, and Coating Process Using Aerostatic Porous Media Bearing Technology
Drew Devitt, New Way Air Bearings

A true “in-line” cleaning, drying and coating (C-D-C) process is shown for solid and flexible substrates. This process takes place as the substrate is transitioned through small gaps between aerostatic Porous Media® bearings. Due to the non-contact nature of the device, high pressures can be induced with various fluids without damage to the substrate, allowing the system to utilize the viscous nature of fluids to accomplish the desired cleaning, drying, coating, etching or baking.

Web Slitting
10:00 - 10:30am Slitting Process Do's and Don'ts
David Rumson, DR Consulting

This presentation covers recommended policies and procedures to help gain better control of the slitting process. Discussed are slitting dust, quantifying shear knife set-up, setting knife side load force, the all important overlap and knife run-out tolerances. Additional subjects include checking knife sharpness, holder integrity, knife care and slit trim removal. Techniques and tools to mitigate certain slitting web and roll defects impacting the production process will also be presented.

10:30 - 11:00am Efficiency Comparison of Manual vs. Automatic Positioning System
Bill Cowan, Atlas Converting Equipment

The use of an automatic knife positioning system on slitter rewinders will reduce downtime and waste but also increases productivity and slit width accuracy when slit widths are changed frequently. This presentation will demonstrate a computer program that calculates and compares the slitter rewinder production output based on the number of slit widths or job changes per shift, using an automatic knife positioning system compared to setting the knives manually.

11:00 - 11:30am Introducing Ultrasonic Welding Technology into Continuous Web Lamination and Slitting Applications
Guy Gill, Chase Machine

The presentation will begin with an explanation of ultrasonic technology. What it is and how it creates the thermal properties required for the lamination and slitting of synthetic materials. Available frequency and power ranges will be discussed along with the benefits of each. Comparisons to other technologies will be provided so the audience may be provided alternatives should Ultrasonics not be a suitable solution.

Upon completion of “Ultrasonics 101”, an examination of ultrasonic friendly materials will be reviewed. Nonwovens, wovens, knits, laminates and films will all be touched upon. Additional information will be provided regarding various blends and synthetic content ratios. End use products and their respective market segments will conclude this segment.

At this point, an in depth description of ultrasonic lamination will take place. The importance of pattern / anvil roll selection including weld area and expected line speeds. The significance of machine construction that is necessary in order to hold the very tight tolerances required to ensure control and uniformity across the entire web width. In addition, examples will be provided as to how Ultrasonics is a superior joining method when the product being laminated may be cross contaminated with foreign materials.

Finally, existing slitting technologies will be reviewed with Ultrasonics being highlighted. The pros and cons will be evaluated. Comparison photographs will be shared that clearly define the benefits of Ultrasonic slitting.

11:30 - 12:00pm New Combined Rotary Die Cutting and Laser Cutting Machine to Help You Increase Your Profits
Jean Louis Dorey, DCS France

The Sysco's new solutions provides die-cutting, laminating and laser cutting for high and low volume production, while increasing materials economy with precise die-cut part placement and nesting. Sysco offers the electronic industry and engineers the conception freedom to solve problems materials & specifications that are considered unmachinable with conventional equipment. With capabilities such as servomotor controlled stations, highest accuracy on the market, unique CCD camera vision systems and close loop tension control we produce equipment that will make you reach new breaking grounds.