Web Coating Blog

AIMCAL Fall Technical Conference October 2008

AIMCAL Fall Technical Conference
October 2008
Edward Cohen
The AIMCAL Fall Technical Meeting was help in October in Myrtle Beach,
NC. It provided a forum for the exchange of Information between
technical personnel in the web coating Industry. Technical papers were
presented in four sessions as follows:
• Environmental Responsiveness
• Web Coating & Laminating
• Vacuum Web Coating
• EmergingT echnologies
• Advances in Web Coating Technology
In addition there were table to exhibits, which also provide an
opportunity for additional technical discussions.

I found all of the presentations were useful and relevant to the technology of importance
to the Converting Industry. While the Coating process is sold, there is
still a a lrge amont of new technology that is being developed.

Wide ranges of topics were discussed, energy concerns, coating methods, slitting,
barrier layers, Coating hardware etc.

The following are the titles and a summary of some of the key
presentation. Details of the papers and contact information can be
found in the Conference Proceedings available from AIMCAL.

A Paradigm Shift In Knife Holder Slitting Technology
David Rumson
Sigmala, USA

Conventional slitting systems, consisting of mechanically
mounted and pneumatically activated knife holders (Mech/Pneu) have been
in existence for approximately 60 years. Although shear knife holder
and positioning systems have advanced during this time, there are some
basic operating requirements that remain limited in efficiency and
usefulness relative to today’s computer controlling capabilities. This
paper will present a basic overview of the physical operating
differences of Mech/Pneu holders and Servo Motor-Computer Controlled
holders (Serv/Com).

Application Of Surface Analysis For Root Cause Failure Analysis
David Cole
Evans Analytical Group

X-ray Photoelectron Spectroscopy (XPS) and Time-of-Flight Secondary
Ion Mass Spectrometry (TOF-SIMS) are valuable analytical techniques in
determining the rooot cause of failure in multilayer films.

Breaking Thru A Paradigm:New Technology For Coating And Laminating
Mike Budai
TW Dynatec

The purpose of this presentation is to break thru a paradigm in
laminating nonwovens, textiles, and composites. This paper will present is to
introduce the latest technologies in coating and laminating utilizing
hot melt polymers.

Reducing Changeover Time on a Coating Line,
Larry Gogolin
Gogolin & Associates

This paper will cover the steps to consider in establishing a reduction in the changeover time. It will look at planning, data collection, analysis and what to do with this
information.

Optimizing Mix Performance”
Ken McCarthy

This paper presents a discussion of mixing time and its importance to
coating operations.

Stay Ahead of Static Problems in Film Conveyance
Kelly Robinson,
Electrostatic Answers LLC

Demands for static control in film conveyance are increasing because
products are more complex and sensitive to static discharges. Four keys
to staying ahead of static problems in web conveyance are presented T
he implementation of these four recommendations for a typical coating
operation is presented.

Primerless Heat Seal Coatings for Film Substrates
Virginia Cushing &Robin Cooper
Michelman

This paper presents a single pass, aqueous heat seal coating which
exhibits excellent hot tack and a wider operating window as compared to
conventional heat seal coatings and common extruded sealants.

Increasing Energy Efficiency in the Web Coating Process
Edward Cohen, Dan Bemi Megtec

This paper focuses on reducing energy consumption, by modifying the
overall coating process and to utilizie renewable resources in their
production in order to remain competitive in this climate of rising
energy costs.

Intelligent Process Cooling: Saving Money, Protecting the
Environment
& Curing Process Headaches
Steven Petrakis
Frigel

Process cooling with ambient air, closed loop cooling systems can save
up to 25% on energy and water consumption in addition to eliminating chemical
evaporation and the disposal of contaminated waste water.

Nanoparticulate Barrier Films and Gas Permeation Measurement Techniques
for Thin Film Solar and Display Applications
Senthil Ramadas*, Shwe Zin Ma, Mark Auch, Chua Soo Jin
Institute of Materials Research and Engineering.

This paper presents innovative approach to resolving the ‘pore effect’
by literally plugging the defects in the barrier oxide films using
nanoparticles. The nanoparticles used in the barrier stack have a dual
function – not only sealing the defects but also reacts with moisture
and oxygen. The result is an achievement of moisture barrier
performance of better than 10-6g/m2/day that surpasses the ideal
requirements needed for flexible applications,

Comment on Dyne SOlution Sources

                                    

A new comment from “David Tanner” was received on the post “Response to Query” of the weblog “Web Coating Blog”.

                         

Comment:
I would like to add to this post by saying that the Dyne Solutions that referred to are availible from selected companies, in the UK and Europe for instance CDE Products have manufactured Dyne solutions for over 20 years.

            

• Commenter name: David Tanner
• Commenter email: info@cdeproducts.co.uk

Response to Query on Curl

                                    Response to Query on Curl
                                        Edward D Cohen

In response to your question about curl when ink is applied to film, the curl is the usually towards the coated side of the film.  It is caused by   residual stresses in the coating applying a force to the substrate, which causes the substrate to bend. The stresses can arise form several causes. Stresses generated, as the coating shrinks during the drying process will cause curl if not relieved. The magnitude of these stresses will depend on the amount of shrinkage, the properties of the binder system, the substrate physical properties transition temperatures and stress relieving in the dryer.  Often a high relative humidity et eh end of the dryer and in ambient air.  A stronger substrate may also be needed.following diagram shows  curl and stresses.

Response to Query on Curl

In response to your question about curl when ink is applied to film, the curl is the usually towards the coated side of the film.  It is caused by   residual stresses in the coating applying a force to the substrate, which causes the substrate to bend. The stresses can arise form several causes. Stresses generated, as the coating shrinks during the drying process will cause curl if not relieved. The magnitude of these stresses will depend on the amount of shrinkage, the properties of the binder system, the substrate physical properties transition temperatures and stress relieving in the dryer.  Often a high relative humidity et eh end of the dryer and in ambient air.  A stronger substrate may also be needed.following diagram shows  curl and stresses.

The following diagram shows  curl and stresses

Effective Networking, A Path Through The Information Overload

                        Effective Networking, A Path Through The Information Overload
                                            Edward Cohen

Even though we live on large planet, with large physical dimension (a Volume of 1.0832073_1012 km_ and a  Mass of 5.9736_1024 kg); technologies such as the Internet, Information Sciences, World Wide Web, rapid digital communications ,easily accessible databases and search engines have made it a very small world. It now possible to instantly communicate with persons all over the world and to obtain technical information from most countries, businesses and Universities.

Response to Query on Drying Stresses

                                                    Drying Stresses

                                            Edgar B. Gutoff, Sc.D., P.E.
                                        Consulting Chemical Engineer
                                                ebgutof@coe.neu.edu

One Thing to Optimize Process

A question that is often asked about the Web Coating Process is “ What are the one or two most critical areas of the process that I should concentrate on to obtain a coated product with high quality and low cost?”. A possible basis for this question can be found in an interchange in the 1991 movie “City Slickers”, between Billy Crystal and Jack Palance

Defect Reduction Process: What’s in a name

One of the most important step steps in an effective defect reduction process in the web coater is the accurate naming of the defect. This name must be unique for a defect, unambiguous and interpreted in the same way by all who use the name. Naming is usually an easy straightforward process because most areas of science have standard naming conventions. For example, there are standard names for organic chemicals, which are used by all scientists. These are issued by the International Union of Pure and Applied Chemistry. Thus all chemical compounds can be unambiguously named.  Similarly the disciplines of Chemical Engineering, Electrical Engineering and Physics all have standard naming conventions.

NEW YEAR ANNOUNCEMENT

NEW BI-MONTHLY POSTINGS WILL FOCUS ON THE DRYING PROCESS

Daniel Bemi Megtec Systems, is joining the Web Coating Blog as a contributing author. His focus will be on new bimonthly postings on all aspects of the Drying Process.

Drying and curing of coatings, along with other drying and annealing applications, are often a critical component of the coating and laminating process. While there are several good texts available on drying theory, there is a shortage of written materials focusing on application “know-how” and real world drying challenges. As such, AIMCAL will be introducing a bi-monthly posting of dryer-related technical articles beginning in January 2007. These postings will be aimed at bridging the gap between drying theory and application-based, process knowledge.

If you have a topic of interest that you would like to see addressed by our experts, please send your suggestions to Ed Cohen email cohened146@aol.com

Summary of AIMCAL Fall Meeting

The October AIMCAL Fall Technical Meeting provided a forum for the exchange of Information between technical personnel in the web coating Industry. 60 papers were presented in three sessions as follows:

• Web Coating & Laminating
• Vacuum Web Coating
• Emerging technologies

In addition there were table to exhibits, which also provide an opportunity for additional technical discussions.

I found all of the presentations were outstanding and provided me with useful technology about the web coating process.