PFAS Coating Measurement Is Important In Food Packaging

PFASs are polyfluoroalkyl chemicals commonly used in food packaging due to their resistance to oil, grease, moisture and stain resistance.  They are applied to everything from fast food burger/sandwich wrappers to pizza boxes in food packaging.  PFASs are also used on fabrics such as carpets, furniture and backpacks for stain resistance.

Essentially hydrogen atoms are replaced with fluorine atoms terminating with a Carbon chain.  The PFASs are similar to Teflon (PTFE) used in non-stick frying pans.  The danger with PFASs in food packaging is that if too much of this grease resistant coating is applied in food packaging, it can migrate into the food that we ingest and potentially increase cancer risks.

 

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Therefore, it’s critical that food packaging suppliers measure and control the amount of PFASs applied to their paper and board lines.  Near Infrared Cross Direction Profile Systems provide this measurement that can be sent to a Programmable Logic Controller (PLC) to precisely control the amount of PFAS being applied and they can also archive data.

Please contact us to discuss your application:  508.473-9901

Moisture Barrier Coating Consumption in Food Packaging Manufacturing

Moisture barrier coatings are used to prevent moisture migration and preserve quality and shelf life of food products.

Many moisture barrier coatings are relatively thin in the order of 0.5 lbs/ream (per 3000 Ft²) or less.  These coatings can easily be measured with Near Infrared Transmitters on printed substrates to optimize the coating thickness and insure a uniform Cross Direction Web Profile.  Measurement data can be archived in roll reports that are time and date stamped for future reference in the event of customer complaints or other issues.  These reports can also be used to compare the performance of different shifts on production runs.

Coatings and adhesive need to be applied in sufficient amount to meet specifications.  Without a method to measure the deposition, many manufacturers apply more coating than needed resulting in a higher production cost.  Too little applied coating will not provide the needed barrier to prevent the migration of moisture that can result in spoilage and an adverse impact on taste, texture and shelf life.

Stopping the line to collect lab samples slows production and does not supply archiving capabilities for roll or production runs.  On-line continuous measurement of coating speeds start up, increases production and in-specification product.

The wet water based coated substrate typically passes through a dryer and then a re-moisturizer where a separate moisture measurement system supplies the output to control the moisture profile and minimize or eliminate lay flat and edge curl issues.

Plant managers are often concerned about coating consumption which impacts the profit margin on specific orders.  Coating calculations determine the amount needed for a specific product run and the cost of coating associated with that product run.  For instance, if a 40 inch wide web with a target of 1 wet lb per 1000 ft squared and an anilox volume of 14 BCM is being manufactured, both the weight in pounds and volume in gallons can be calculated.  If the web width for another version of the same product is increased to 80 inches, the consumption significantly increases but it is not a simple doubling of necessary coating as that is a function of increased area not simply web width.

Near Infrared technology employed on-line can calculate the continuous consumption to aid in monitoring the production run or roll consumption when incorporating other parameters.

Please contact us to discuss your application today at 508.473-9901.

 

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ICE Europe and ICE USA Feature Guardian

Process Sensors Corp. will be exhibiting our Guardian Cross Direction Web Profile System at the International Converting Expositions in Munich & Orlando.  The Guardian features MCT Nova Series of Near IR Transmitters, Central Console for Multiple Cross Direction and Machine Direction Web Profiles, Web Temperature, Industrial Scanning Frames and Automatic Web Detection.  Software includes scanning speed, number of zones, zone and web average measurements, lane measurement and machine direction options, and data logging for customer archiving.  Ethernet, Ethernet IP, OPC Kepware, Modbus TCP and additional communication options for PLC, Networks and remote viewing.   Please visit with us to discuss your paper, film, foil or other application for moisture, coating, PSA or film thickness, residual moisture or solvent.  Or call us at 508.473-9901

Web

 

ICE USA is the only dedicated event for the conversion of paper, film, foil, nonwovens and other flexible web-based materials in the Americas and our 2017 event marks the 4th edition of ICE USA. This premier event is where converting professionals gather to see first-hand the latest machinery, technology, and manufacturing solutions. Attendees from around the globe are looking to develop new business partnerships and come ready to network and learn from leaders in the converting industry.

 

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ICE Europe celebrates the 10th anniversary event from 21-23 March 2017: 86% of exhibition space already booked
The 10th anniversary event of the ICE Europe show will take place from 21-23 March 2017 at the Munich Trade Fair Centre in Germany. The world’s leading exhibition for the conversion of flexible, web-based materials, such as paper, film, foil and nonwovens, targets industry professionals looking for innovative equipment and solutions within the converting sector.

 

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Guardian Multi Frame Multi Display System for CD Profile

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The Guardian Cross Direction Web Profile System can display multiple web profiles from multiple frames.  The Guardian can also display machine direction trends of profiles by zone and temperature profiles.  The Guardian can measure moisture, residual moisture, coat weight, film thickness and other parameters of interest.  Please contact us today at 508.473-9901 to discuss your application.

Reverse Roll Coating Measurement

Reverse Roll Coaters have a metering and applicator roll. Often there are 3 or 4 roll configurations.  Coating is applied through the gap between the metering and applicator roll where the nip pressure and gap control the specific coat weight.  The applicator roll runs in reverse direction of the web transferring the coating onto the web.  Reverse Roll Coaters are capable of producing highly polished surfaces and are more expensive than some other coaters such as slot-die that can’t always achieve that level of polishing.  If a Converter operates a Reverse Roll Coater a Cross Direction Web Profile System is a good investment to maintain uniform coat weight on high end products.  The Guardian Cross Direction Web Profile System meets the application needs for film, foil and paper coat weight and moisture measurements on Reverse Roll and other coaters.

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Let’s Laminate

 

Lamination is essentially marrying two or more layers of materials together to obtain superior performance characteristics for specific product applications.   Near IR Transmitters are well established to measure moisture and coating thickness in the lamination process.  Cross Direction Web Profilers greatly assist in producing an even in-specification profile of adhesive thickness.  The resulting composite may be designed as a superior moisture or odor barrier, to highlight/protect appearance or gloss, reduce sound transmission, to increase strength or structural stability and many other applications.

Auto windscreens (windshields)  laminate two pieces of glass with a layer of PVB (polyvinylbutyral)  or other suitable polymer to prevent or minimize sharp glass shards from showering on driver and passengers on impact by wrapping the glass surfaces with the polymer.  Near IR can measure the film moisture and thickness.

Converting industries such as Tag, Tape & Labels, Packaging & Release Liners, Textiles and others operate Near IR to measure the adhesive coat weight applied and the moisture after unit operations such as dryers, re-moisturizers and final windup for QC and Process Control.  For converting applications a two roll laminator is often employed with one roll made of neoprene or other suitable rubber and the other roll made of steel or chrome plated.  The rubber roll applies pressure to the adhesive but also allows for compensation of caliper variations.  Nip roll pressure and skew assist in optimizing the process.

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PSTC – PSC Poster Calibration Techniques Featured

Pressure Sensitive Tape Council Meeting Orlando Florida 

A Sticky Affair!

 

Pressure Sensitive Tape Council is a highly technical conference featuring world class presentations on current and emerging technologies that benefit the tape manufacturing process.  PSTC also has a very collegial feel with technical people who know situations change and friendships remain.  Our Near Infrared Calibration Procedures Poster was featured in the afternoon session.

We appreciate and thank you for our time together at PSTC May 2016!

 

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Corrugating Industry Moisture Control

Especially in Food Industry Packaging Applications with Custom Coatings!

The Corrugation Process requires the single face and double facer to match moistures to minimize warpage.  Historically when corrugated board warped, small companies would just have employees flip it over until humidity leveled it out.  Not scientific but functional and at the time economically effective to create good board if time and order delivery allowed.  The increasing demand for corrugated packaging is driving efficiencies.

Times have changed with industry consolidation, importance of short delivery times and need for high quality flat board for folding operations.

Process SensorsMCT460 is a stand-alone Near Infrared Moisture and/or Coating Analyzer.  The Guardian Cross Direction Web Profile System supplies alarms, archiving and much more.  The screen display easily shows the web profile in bright green, yellow and red for in-spec, alert and alarm conditions.

Process Sensors can supply solutions for warpage and coating measurements.  Water based wax coatings can be measured on the wet end at the moisture peak of 1.94µ or on the dry end at the 2.34µ hydrocarbon peak.  Ethernet outputs, Kepware OPC, Modbus TCP allow easy communication for moisture control systems.  Steam Re-Moisturizers, Liquid Application Systems and Sprayers can benefit from moisture and coating measurements to optimize process control.

Additionally, our Process Sensors IR Division can supply all of your Product Temperature and Thermal Imaging needs.  PSC IR excels at understanding and meeting your immediate need through an international network of specialists.

SenWare can supply all your On-Line, Lab and Portable Color Measurement Needs.  Their specialty is in determining if you need full tri-color stimuli that they offer in all formats such as L*a*b*; L,a,b;  RGB etc.  or a simpler version for your needs.  Contact SenWare to discuss your color measurement needs.

We work with leading Re-Moisturizer, Coating and Dryer Suppliers.  Please contact us at:  508.473-9901 to discuss your needs!

 

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Lane Adhesive Measurement Made Easy

Adhesive lane thickness and moisture measurement across a paper or film web continues to increase with food and other packaging demands.  Instead of coating an entire web for label stock, these applications only coat narrow lanes of adhesive spaced across the web.

Process Sensors has developed a system that is quickly becoming the industry standard for spaced lane adhesive thickness and substrate moisture measurement.  The Guardian Lane Measurement System allows operators to monitor each adhesive lane across the web.

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The Scanning Frame System automatically detects web edges and stores lane locations from the edge to make measurements.  The Near Infrared (NIR) transmitter can measure the coating on the wet end at the 1.94µ water peak or on the dry end at the 2.34µ hydrocarbon peak.  The unique elongated and rectangular angled viewing area for measurement insures accurate measurement on even very narrow stripe/lane widths.

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This Lane Measurement Profile System reduces start up time and scrap.  After start up, systems normally run through and process measurement is less needed unless in closed loop control.  Many small to medium sized companies benefit from these reasonable priced measurement systems but find that after start up and achieving set point, operators don’t always pay attention to profile.  To meet this need, many incorporate Stack Alarms that trigger when any zone goes out of specification to alarm and cause the operator to view the profile and take corrective action (clean or replace a valve, increase actuator pressure, change water disk speed, adjust skew on LAS, etc.).

Data and Roll Reports can be saved and archived for QC and QA needs.

 

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Stack Alarms

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Pressure Sensitive Adhesives

Pressure Sensitive Adhesives (PSA) continue to expand their applications in packaging, converting, assembly, bookbinding, nonwovens, foot wear, automotive and many other markets. Infrared (IR) and Near Infrared (NIR) transmitters offer economical tools to improve Quality Control and Assurance while increasing Production Opportunity with improved Process Control.

Near Infrared Transmitters can measure wet end water based coatings, dry end organic depositions, pre-treatments and hot melt adhesive thickness.  Roll, Doctor Blades, Air Knifes, Die Bolts and other coaters benefit from these measurements.  These NIR transmitters can also measure moisture at the dryer exit and after re-moisturizing unit operations to reduce lay flat and edge curl.  Mounting these transmitters on a scanning frame equipped with a position encoder, the web profile can be mapped on a PC to assist in maintaining a uniform profile across the web.

Infrared Pyrometers and Thermal Imaging Systems allow for temperature measurements to be incorporated into the control scheme and detection of hot spots in the manufacturing process.  Pyrometers can be mounted at the exit of the dryer or internally for specific zone measurement.  Thermal Imagers can identify cold and hot spots across the product to identify problems in unit operations that can then be corrected.  Together NIR and IR tools greatly assist the development of consistent and uniform manufacturing while reducing the cost of manufacturing in-specification product.

 

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