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,

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.

WEB COATING AND DRYING PROCESS TECHNOLOGY

The AIMCAl  Converting School is sponsoring  a course on Web Coating and Drying Proces Technology. The detaieled course outline is below. For more information and to register, see www.AIMCAL.org

                    WEB COATING AND DRYING PROCESS TECHNOLOGY
                    Edward Cohen, Ph. D Edward Cohen Consulting, Inc.
                E. J. (Ted) Light foot, Ph. D Dupont Fluoroproducts

CEMA Coating & Laminating Fundamentals

AIMCAl & CEMA will be sponsoring a Seminar on Coating & Laminating. The schedule is below. For more information and to register go to
        www.AIMCAL.ORG

Response to Query on Drying Stresses

                                                    Drying Stresses

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

Concepts for Controlling Process Drying Rates

Title: Concepts for Controlling Process Drying Rates
Authors: Dan Bemi, Regional Sales Manager, Mike Bria, Project Engineer, MEGTEC Systems
Contact Information: e-mail – dbemi@megtec.com (Tel : 262-255-3275)

Controlling the drying or evaporation rate inside a forced air, convection-style dryer can be accomplished using several different approaches. Before examining specific methodologies, let’s briefly review how convection drying works and what variables define this heat and mass transfer based process.

Comparison of Roll Support and Flotation Dryers

                                         Comparison of Roll Support and Flotation Dryers
                                            Todd Rueckl, Regional Sales Manager, MEGTEC Systems
                                             e-mail – trueckl@megtec.com, tel: (920) 337-1533

For more than a century, forced air, convection-style drying technology has been widely applied to many different web-coating processes.  Like any mature technology, this method of drying and curing has undergone relatively few dramatic changes over the past couple of decades.  Nevertheless, high-efficiency, convection air dryers continue to be an effective and popular choice.  Let’s take a closer look at the differences between the two predominant styles:  roll support and flotation.

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