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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Wet End Coat Weight Measurement on Bi-Oriented Film Lines

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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.

 

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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!

 

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Choose Your Guardian!

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Guardian CD Web Profile System Options

Process Sensors Guardian Cross Direction Web Profile System can be as simple and inexpensive as an automatic scanning frame with 12” frame mounted Operator Interface (OI) for profile display and controls.

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The Guardian Profile System can also connect to a 19” Display at the Central Console or a 55” or larger display for multiple scanners and measurements integrated into a single distributed system.  The Guardian System can be operated manually or via a Human Machine Interface (HMI).

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Modeling Different Products for NIR Transmitters – Global Vs. Separate Product Calibration

Global vs. Local Modeling for Different Products with NIR Transmitters

Near IR transmitters can be calibrated with separate channels for each product or they can utilize a global calibration.  A Global calibration is easier to generate while separate calibrations for each product usually provides tighter standard errors.

Illustrated below are three different product results based on Global versus individual (local) product codes (calibrations) within a product family.  The application data is for the measurement of PSA coat weight in the range of 8 to 40 GSM (grams per square meter) on polyethylene (PE) film at 25, 35, and 55 mils thickness.  The chart and graphs below compare results of a local calibration for each coat weight measurement on film with various thickness versus the PSA measurement of all with a single global calibration and the impact it has on accuracy and standard error.

Film Thickness

MCT PSA Accuracy

Local Model (+/-) GSM

MCT PSA Accuracy Global Model (+/-) GSM

MCT PSA Standard Error Local Model (+/-) GSM

MCT PSA Standard Error Global Model (+/-) GSM

Correlation

Coefficient

25 mils 0.1 0.3 0.05 0.05 0.99
35 mils 0.1 0.6 0.1 0.2 0.99
55 mils 0.1 0.4 0.1 0.4 0.98
All 1.0 0.43 0.99

 

Accuracy:  How close measurement is to target.  E.g. how close a dart is to the bull’s eye.  Accuracy is calculated from the Standard Deviation of Calibration Residual Values (difference between Lab and Calibrated MCT Values).

Precision:  How close the subsequent dart is to initial dart for same conditions (reproducibility/repeatability).

Standard Error:  Standard deviation of sample distribution for sample population mean or standard error of mean.  Think standard deviation and variable depending on sample population.

Standard Deviation:  How much variation from the average value.  Low SD indicates data points close to mean and high SD indicates values spread out over large range of values.

Correlation Coefficient:  Linear relationship between two variables, in this case Lab vs. MCT PSA mils thickness measurement.  All Correlation Coefficients (CC) are 0.99 which is close to perfect at 1.0.  Non-linear relationships can also be handled with NIR software technology, though not necessary in these applications.  Low CC indicates a low performance expectation.

 

PSA coating on PE

Universal Calibration Across Product Changes

 

 

NIR Transmitters Calibration Approach Comparison

NIR Calibrations for Single Products Vs. Global Calibration