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.

 

PSA Tape Image 110515 B

Aimcal Conference

SHAPING THE FUTURE!

Aimcal logo
AIMCAL Web Coating & Handling Conference will be held October 25-28 at the Naples Grande Beach Resort in Florida.  Process Sensors is an active participant in Aimcal and we look forward to meeting our many friends and customers at the conference.  The congenial spirit and technical interactions help us learn from our customers and continue our strong support after sale tradition.

Please visit us at Booth #7 in the Royal Palm Ballroom!

PSA Calculator Courtesy of Dow PSTC Baltimore

The recent Pressure Sensitive Tape Council meeting in Baltimore allowed us an opportunity to present a paper on Near Infrared and Infrared measurement solutions in the PSA market.  Dow supplied a new PSA Calculator that may be of value.  Click Here for Dow PSA Calculator.

 

PSA Calculator

 

VERSION 2.0 AVAILABLE NOW

 

PSA Calculator Dow PSTC 060815

 

 

 

 

OPC, Kepware, DDE, Ethernet, Modbus/TCP! What Does All of This Mean?

Software communication options can sometimes be confusing and complex when first encountered.  Listed below is a glossary of common acronyms, what they represent and a brief outline of our PSC Viewer Suite Software and Guardian Communications.  Please visit our Process Sensors Website for more information.

 

Guardian Communication JPG 041615

 

Ethernet:  Physical method of cabling that connects devices on the Ethernet network.  Basically, there are two types of Ethernet, Local Area Network (LAN) and Wide Area Network (WAN).  LAN example might be computers in an office connecting to a central server.  WAN example might be doing your banking over the internet.  Our transmitters and Guardian Systems communicate on a Local Area Network.

IP (Industrial Protocol):  The Internet Protocol is the most basic protocol. It simply moves a packet directly from one Ethernet device to another Ethernet device. Almost everything moves across the internet using IP.

TCP (Transport Control Protocol):  TCP is a protocol that creates a connection between two nodes over Ethernet. TCP maintains a connection and uses acknowledged messaging to transfer messages between two devices. That means that all TCP messages generate a reply. If there’s no reply, there’s an error.

OPC:  For old timers, OPC is OLE for Process Control.  OLE is Object Linking and Embedding.   These are Industry Standards for communication platforms so that end users and suppliers agree to exchange data in a specific format.  Now OPC is Open Platform Communications.  It is a Client / Server technology. One application acts as the server providing data and another application acts as the client using the data. OPC is a widely accepted industrial communication standard that enables the exchange of data between multi-vendor devices and control applications without any proprietary restrictions.  OPC has also grown beyond its original OLE implementation to include other data transportation technologies including XML, Microsoft’s  .NetFramework,  and even the OPC Foundation’s binary-encoded TCP format.

Kepware is the communication platform we have selected for OPC communications.  End user needs to purchase a copy of Kepware Runtime and download for some nominal fee like $100 for the system that is communicating with the Guardian (or transmitter).  This is only required when customer requests OPC communication.

DDE (Dynamic Data Exchange):  DDE is a method for exchanging information between applications running on Windows.  A simple example is exchanging data between Word and Excel.  All you really need to know is that it is a Windows based method to exchange data between applications.  It’s been working since Windows 2.0!

CIP (Common Industrial Protocol):  CIP is the basic component that forms the basis of EtherNet/IP. There are two parts to CIP, an Object/Attribute Library and a Messaging structure.  CIP devices use a very specific data model based on Objects (related collections of data) and Attributes (Data Identifiers).  CIP devices have a very specific set of messages that they support. There are Explicit Messages and Implicit Messages. Explicit messages are sporadic, one-time messages requesting data values or setting parameters. Implicit messages are ongoing I/O messages that are exchanged between two CIP devices.

EtherNet/IP is a very complex protocol but you can break it down into this; the Scanner (usually a PLC) exchanges data buffers with each Adapter. The Scanner sends Outputs to each Adapter device. Each Adapter device sends some Inputs back to the Scanner.  This is not our physical across the web scanner, it is the PC scanning the network.  The Adapter is our transmitter or Guardian.

Modbus is a serial communications protocol that allows multiple devices to be attached to the same network.  An example might be connecting a moisture transmitter and separate temperature transmitter to the same network.

SCADA (Supervisory Control and Data Acquisition) is a system operating with coded signals over communication channels so as to provide control of remote equipment (using typically one communication channel per remote station). The control system may be combined with a data acquisition system by adding the use of coded signals over communication channels to acquire information about the status of the remote equipment for display or for recording functions

RS-485 is a Recommended Standard for local networks and multi-drop communications link that transmits data at 35Mbit/s at 10 meters and 100 kbits/s at 1200 meters.

HMI is a Human Machine Interface such as a PLC or a PC equipped with Wonderware or such.

Both EtherNet/IP and Modbus/TCP are Ethernet Application Layer protocols that use the TCP and IP protocols of the TCP/IP stack. They are both highly structured ways of moving data between automation devices in an industrial application.  The difference is in how data is represented to the network. EtherNet/IP represents data using the CIP object structure. Modbus TCP represents data as a series of registers (16-bit unsigned values).

 

Guardian System Communication as an Example

Our NIR (Near Infrared) Transmitter communicates to the Scanner Controller Board via RS-485 Modbus Protocol.  This is also how our transmitter communicates with the Operator Interface (OI). The Scanner Control Board communicates with the Guardian PC via Ethernet link using a Windows based Stand-Alone-System.

PSC Viewer Suite Software for the Guardian meets the needs of our customers.  Customers can get data on scan and zone averages for archiving.  Viewer Suite is not limited to just Ethernet.  It can use USB and serial links (RS232 and RS485 multi-drop) as well.

Viewer Suite Software is not limited to scanning frames. It can be connected to multiple sensors and scanning frames at the same time.   PSC Viewer Suite Software is smart.  If it’s connected to a transmitter only, it presents transmitter software.  If it’s connected to one or more scanners it automatically detects that and pulls up Guardian Viewer Suite Software.  It can also recognize when it is connected to a mix of scanners and static transmitters.

The Viewer Suite Software saves Zone /Average data to Excel, CSV, XML and to its built-in supplied industry standard SQLite database which is used for simple roll reports.   When an HMI is controlling the Guardian or advanced options are required OPC/Kepware and Modbus/TCP are available.

Guardian Web Profiling System Options

Guardian Basic Starter System consists of one MCT466 Transmitter, one industrial scanning frame and a 5.7” Operator Interface with digital display.  Display can also show position of transmitter across web.  System has automatic web edge detection but no standard data logging or roll report capability and no web profile.  It can scan automatically or manually jog to position for Machine Direction measurements.  Data logging can be accommodated with OPC option selection.  System includes analog outputs.  Ethernet or Ethernet IP options are available at additional cost.  Web temperature is available at an additional cost.

 

OI Touch Screen Good 070213 Crop

 

Manual scan screen on 5.7 OI Chris 073114

 

Guardian Mid-Level System consists of one MCT466 Transmitter, one industrial scanning frame and a 12” Operator Interface with Cross Direction Web Profile Display.  System has automatic web edge detection but no standard data logging or roll report capability.  It can scan automatically or manually jog to position for Machine Direction measurements.  Data logging can be accommodated with OPC option selection.  System includes analog outputs.  Ethernet or Ethernet IP options are available at additional cost.  Web temperature is available at an additional cost.  This is an OPC computer based system, not a PC based system.

Guardian 12 in scan brochure 092614

 

 

Guardian PC Based System consists of one or more MCT466 Transmitters, one or more scanning frames and a 19” or larger display for Cross Direction Web Profile.  It can scan automatically or jog to position for Machine Direction measurements. System includes analog outputs.  Ethernet or Ethernet IP options are available at additional cost. System includes automatic web edge detection and can display multiple measurements from multiple transmitter/scanners on a single display.  System can also have a Central Display and local displays at each frame end with two way Ethernet communications.  Web temperature is available as an option.  This is a PC based system and includes data logging capabilities and outputs for data archiving and roll reports.

4 Display Screen Good 032714

 

Guardian System Options 031415 Chart 2

 

 

 

 

 

 

 

 

 

 

ICE Europe a Great Success

ICE Europe Offered an Opportunity to Introduce Our Guardian System to Our International Customers!

ICE Europe featured visitors from over a wide International Spectrum, especially Germany, UK, France, Spain, Italy, Poland, India and Asia.  The three day Exhibit from March 10-12 in Munich was well attended and allowed us to feature our multi-tiered Guardian Cross Direction Web Profiling System for moisture, residual moisture, coat weight, hot melt and film thickness with options for web temperature and other parameters.

0309152140


Sino Label Show a Big Success!

China International Exhibition on Label Printing Technology 2015

SINO LABEL 2015

China International Exhibition on Label Printing Technology 2015 (SINO LABEL 2015), an ideal platform that showcases Label printing & converting machines, equipment, presses, softwares and technologies for self-adhesive labels, Converting and printing machines, Die-cutters, laminating machines and many more, is organized by Adsale Exhibition Services Ltd and was held at China Import and Export Fair Pazhou Complex, Guangzhoufrom March 9 to March 11, 2015.

Our team had great success meeting customers and developing new prospects in the important Asian market!

China Show 3_10_2015

 

Wet End Coat Weight Measurement on Bi-Oriented Film Lines

BOPP Film Lines2

 

Bi-Orientated Film is essentially stretched in two directions (machine and traverse direction) to manufacture shrink wrap and barrier type films with typical shrinkage in the 20 to 60% range dependent on formulation, label wraps, tapes, capacitance films and many other applications.  Typical films are Bi-Orientated Polypropylene (BOPP), Bi-Orientated Polyethylene Terephthalate (BOPET/polyester) and Bi-Orientated Polyamide (BOPA).  Stretching allows for the alignment of the polymer molecules to improve physical properties.

BOPP film is used in snack, pasta and other packaging applications including the overwrap for multi-packs.  BOPP is typically 15 to 30 microns and can be as thick as 50 microns.  Water based acrylic and PVDC coatings are often applied to increase moisture and odor barrier levels, and sealing properties.

Improved formulations and application technology allows for these acrylic and PVDC coatings to be measured with Near Infrared (NIR) technology on the wet end to optimize coat weight across the web profile.  Cost, regulation, standardization and maintenance are moving the measurement preference from nuclear to NIR.

Process Sensors Corp. MCT Nova Series of Near IR transmitters and Guardian Web Profile Systems make immediate and accurate coat weight measurement.  Please contact us today to discuss your application.

 

ICE-USA-2015-personalized-logo 012115

ICE USA Orlando 2015 – Booth 943

February 10-12, 2015
OCCC, Orlando, Florida

 

Join several thousand converting professionals from nearly 50 countries who will come together in Orlando, Florida, February 10-12, 2015, to see all the latest converting machinery and technologies on display from over 350 leading suppliers. The key decision makers from a wide range of companies that convert and process flexible, web-based materials will come together seeking innovative solutions to their specific challenges.

Process Sensors Corp. will be showing our Guardian System Series of Web Profile Systems featuring our multiple scanner and transmitter PC based system, our stand alone scanning system with Operator Interface (OI) and our economically priced starter system.  We will also have our stand alone MCT460 Near IR Transmitter.

Our MCT Series of Process Near IR transmitters can measure moisture, wet end water based coatings, dry end organic coatings, hot melt thickness, film thickness, residual moisture and web temperature.  Our lab and at-line QuikCheck can measure moisture and coat weight off line.

Please visit us to discuss your application needs during the ICE Show Orlando at Booth 943!

 

4 Display Screen Good 032714

 

 

ICE-USA-2015-personalized-logo 012115

Can I Afford a Cross Direction Coat Weight and/or Moisture Measurement?

Another question might be “Can you afford not to have a cross direction coat weight or moisture measurement?”

 

Process Sensors Guardian Nova Series of Cross Direction Web Profile Systems are designed to encourage early entry into the measurement and control of the web profile.

Our PC based Guardian Cross Direction Web Profile System is the work horse of the industry.  Fast, accurate, reliable, Ethernet communications, analog outputs, remote on-line diagnostics and Easy-to-Operate, the Guardian is an established brand in the industry.

What if you’re a new or expanding company that doesn’t have a lot of capital?  You get a new or bigger contract re-newel. Normal procedure requires start up, samples sent to lab, 20 minute response at best, make adjustments, new lab sample for confirmation and operation at best.  Contract is great but the time to get to set point is more critical and impacts production volume.  Also, if there’s a wedge or edge splurge that messes up profile, it messes up roll delivered to customer.  A complete cross direction web profile system pays for itself quickly.

Guardian opportunities now include a simple scanner, transmitter and digital display.  The basic system does not include a cross direction web profile.  It provides a digital measurement of coat weight or moisture across the web.  It can be programmed for automatic scanning or to machine direction lane with trend plot.  If you spot a problem, you can locate it, adjust the nip pressure, dye bolt, skew, or whatever is needed and immediately see the result to obtain a uniform profile.  This is especially important on start up.  It allows emerging or budget restricted companies a quick way to provide their production operators a tool for process control.

Measuring moisture or coat weight, film thickness or PSA Cross Direction Web Profile speeds start up, reduces out-of-spec product and increases profits.

 

 

OI Touch Screen Good 080213 Cropped  USE B

 

Scan Parameter Graphic 073114

 

 

The Guardian 12” Operator Interface System offers the same features as the basic system with a complete Cross Direction Web Profile.  No data logging, but it offers a quick, accurate and easy-to-operate system to optimize start up and detect problems.  Ideal for lowering start up time and increasing production for emerging companies.

 

Guardian 12 in scan brochure 092614

 

PC Based System can communicate with an HMI (Human Machine Interface) meaning that the operator can simply change a roll or customer order via the HMI and that activates appropriate product and historical codes automatically.  Multiple scanners, transmitters and measurements such as coat weight and residual moisture!

 

0401141048a

 

4 Display Screen Good 032714