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Blown Film Measurement and Control System
Process Configurations
... over 600 systems worldwide...
... NDC leads in blown film measurement.. Two Decades of Leadership
Blown film production has become more sophisticated as the industry enters new marketplaces. Customers are demanding higher product quality and
greater roll uniformity. Thickness uniformity is especially important in films which are converted to bags, packaging, laminates and tapes. For over two
decades, NDC Blown Film Systems have helped manufacturers achieve their thickness uniformity objectives with field proven. reliable measurement and control systems.
With over 600 systems installed worldwide, NDC leads the industry in ...the gamma gauge offersmany advantages compared to competitive techniques... Starting with Measurement Accuracy The heart of the NDC Blown Film System is the Gamma Gauge. Field proven in thousands of installations, this sensor measures thickness by detecting gamma radiation backscattered from the film. The Gamma Gauge offers many advantages compared to competitive measurement techniques. The Gamma Backscatter Approach Measurement Advantages
Real-Time Displays for Process Visibility and Troubleshooting
The NDC Infrared Engineering system provides a real-time snapshot of the blown film process with easy to understand displays.
Polar Plots give a graphic indication of true profile. The die bolt display shows the average thickness at each die bolt position. This is an invaluable aid in detecting and troubleshooting proliferated problems such as eccentric die, clogged air rings, or dirty die lines. These displays provide immediate feedback on the effect of diebolt adjustments. Machine direction uniformity may be monitored using the In-Line Display. Nip roll drive problems, extruder feed section malfunctions and upsets due to blending or recycle are uncovered in this way. Trend Plot provides historical representation of quality trends. Histogram provides a statistical summary of the entire production. Die Bolt Mapping: Underlying the displays is a sophisticated diebolt mapping algorithm. By continually monitoring line speed and die rotation, the system is able to assign gauge thickness measured on the bubble or layflat to a specific location on the die, NDC is the first company to offer this unique feature. Management Information Reports
A printer/plotter is offered for hard copy output, including all screen displays and roll, job, time and shift summaries.
15Dec92 REPORT: ROLL 16:33:45
Typical Results: Reduction in Film Thickness Variations Profile Variations (2) Total Variations (4) (1) Variations which are much longer than the single cycle time for rotating or oscillation die, typically several hours in duration.
TOT = [(LTMD)2 + (P)2 + (STMD)2]1/2 The Results: More Uniform Product The NDC Infrared Engineering Blown Film System produces results from the moment it is installed on your line. Automatic thickness control goes to work at once reducing long-term machine direction variations. Improved visibility of profile and short-term machine direction variations allows you to address the causes, with immediate feedback on your solutions. The result: greatly improved roll uniformity, with total thickness variations reduced by 40% to 60%. ... total thickness variation reduced by 40% to 60% reported within weeks...
The Thickness Control Module controls the average or minimum film thickness to a preset target using automatic adjustments to nip roll speed, extruder screw speed, or melt pump speed. Combined with feedback from the gamma gauge , this supervisory control is highly effective in maintaining thickness to ±0.002 mils. Key features such as adjustable deadbands, process logs and limit alarms render the control extremely robust and insensitive to process upsets. ... savings in three key areas: yield improvement, faster startup, and scrap reduction... A Wide Range of Blown Film Applications The NDC Infrared Engineering model 5103T is designed to deliver optimum results over a wide range of blown film applications. A small, single sided sensor offers location flexibility, insensitivity to composition and a large measurement range starting at a thin 0.25 mils. Displays, software and reports are user configurable to reflect your current process and operations, Thickness controls accommodate a variety of strategies for nip speed, extruder screw speed or melt pump adjustments. Regardless of your product, process or line configuration, NDC has the measurement and control system to meet your needs. Flexible Measurement Configuration The basic NDC Blown Film System consists of two key components: a sensor probe employing the gamma backscatter measurement technique; and a
console with high resolution display and touchscreen. Features include automatic control, a printer/ plotter for screen prints, comprehensive management information reports and large screen remote monitors.
The single sided gamma backscatter probe is small and lightweight (2.2 Ib/1 kg), It is easily mounted either on the collapsing frame or on the edge of the
layflat. The collapsing frame location provides high profile resolution with direct measurement on the bubble. In the layflat configuration the sensor is
positioned over the edge of the double layer or after the web is slit on a dual winder configuration. This eliminates profile errors caused by thickness
averaging of film from widely separated die positions. In either location this rugged probe is easy to install and fits in the tightest spots. ... industrially hardened.. ... no disk drives to fail... Human Engineered Operator Interface The success of any new process instrumentation ultimately depends on operator acceptance. The NDC 5103T has been thoughtfully designed for ease of use by plant personnel. An interactive, high resolution CRT display and touchscreen guides the operator in the use of the system, Conceived and tested by an industrial psychologist, this interface excels in clarity, simplicity and ease of use. Designed for High Reliability in the Industrial Environment Compared to PC based systems, the 5103T has been industrially hardened to enhance reliability and uptime.
Forecast Your Savings with the NDC Infrared Engineering Blown Film System The
NDC Infrared Engineering Blown Film System produces documented economic savings in four key areas: yield improvement, faster start ups,
scrap reduction and improved converting efficiency, Payback is rapid less than a year and often as short as a few months! Yield Improvement.,
With online gauging and automatic control, you can significantly reduce the variation in roll film thickness by 40 to 60%, If you
sell film by length or area, this reduction allows you to shift the thickness target towards a minimum acceptable specification without risking off spec
production. The result is a significant increase in footage per pound of resin consumed. Yield improvements of 5% are typical. Scrap Reduction:
With tighter control of the line, less off spec material is produced. Scrap rates after installation of an NDC system are usually cut in half. Faster Start Ups:
Using the NDC tools for enhanced process visibility, the operator can get on grade faster after a break or product grade change.
This increases your throughput and overall efficiency. Typically, start up times may be reduced in half. Improved Converting Efficiency:
Bag machines, printing presses, coaters, laminators and slitters all run better with uniform film. Benefits of Real-Time Monitoring and Control
With an NDC Blown Film System on line, you'll know the status of your line in real-time in time enough to manage your process. Whether you use
manual or automatic line adjustments, faster feedback on film thickness means tighter control. It all adds up to greater profits and fast return on your investment. In many cases, payback is just a few months.
... payback is rapid less than a year .. often as short as a few months...
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Korins Co.,Ltd.
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Long Term Machine Direction Variations (1)
Short Term Machine Direction Variations (3)
Automatic Thickness Control