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Film Inspection: The Gel Count StandardWhat resolution and defect detection

can be realised and make sense- with practical examples

Presented by:Oliver HissmannSales ManagerOCS Optical Control Systems GmbH

ISIS 2011 Düsseldorf/Germany

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Introduction

Definition Gel

Inspection Standard of the Polymer Industry

Defect Types and Resolution

Practical Examples(Optical, Pharma, Technical, Diaper, Food & Surface Protection Films)

Summary

Contents

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Web Inspection in Film Extrusion

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Web Inspection in Film Extrusion

100 % Optical Control of the WebPhoto of every defect

Position of every defect

Database Interface

Reports

Alarms

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Advantages of Web Inspection

Process Control(cleaning, waste, reduction of downtime)

Raw Material(control material + recipe)

Product(better quality, less claims, more competitive products)

Considerable Cost Savings!!

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Definition Gel

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Gels & Defects

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Inspection Standard ofthe Polymer Industry

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Sampling

Feedback

Raw material

Additives

Process Production

On-line QualityAssurance

Process computerDetermination of the process parameters

Data (opt. measuring technique)

Online „Closed Loop Control“-Concept

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Online Laboratory at Kayan

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Online Quality Control at Sabic

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Online Lab at Basell

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Online Lab at Sasol

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Online Anticipation of Plant Shut Down

Sta

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own

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Online Transition Control

Sta

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trude

r cle

anin

g

Stop injection cleaning agent

Stop extruder rinsing

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Online Control of Extruder Start UpExtruder startup after plant restart, start extruder cleaning

Sto

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clea

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Sto

p ex

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r rin

sing

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Benefits of Online Control

Process Control(Optimisation, capacity, cleaning, waste)

Product(better quality, customer satisfaction/relation, less claims,more competitive products)

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Defect Types & Origin

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Defect TypesGels

Black Specs

Contaminations

Die Lines

Insects

Calander Defects

Oil Stains

Air Bubbles

etc.

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Origin of Defects

Extrusion Line 20 %(screw geometry / dead zones)

Resin 25 %(contamination, recipe)

Production Process 15 %(extruder temperatures, screen change)

Pellet Transport 40 %(external/internal)

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Practical Examples- Optical Films & Sheets- Pharma Films & Coatings- Technical Films- Diaper Films- PET Food Films- Surface Protection Films- Extrusion Coating on Alu Boards

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Optical Films & Sheets

Product: Optical Film & Sheet & Coatings

W = 1400 - 2500 mmV = 3 - 80 m/min.

Defects: gels, black specs, fish eyesoptical distortions, lenses, flow/die lines, scratches

Resolution Range: 25 – 100 µm

Defects Specs: various

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Darkfield Inspection

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Optical Distortion Inspection

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Optical Distortion Inspection: Lens

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Closed Frame Optical Films 50 µm res.

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Closed Frame

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Pharma Films & PVDC Coatings

Product: PVC Pharma Films & PVDC Coatings

W = 1400 - 2500 mmV = 100 - 200 m/min.

Defects: gels, black specs, fish eyes, holes, insectsinclusions, coating voids, coating structure defects

Resolution: 200 µm

Defect Specs: 1 defect < 1 mm² per 10 m²0 defect > 1 mm² per 10 m²

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Pharma Films & Coatings

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Inclusion

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Inclusion

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Coating Structure

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Technical Films

Product: Technical Films

W = 1400 - 2600 mmV = 100 - 200 m/min.

Defects: gels, black specs, fish eyes, holes, insects

Resolution: 100 - 200 µm

Defect Specs: various

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Closed Frame Blown Film

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Time History (Gel Level)

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Rolling Map / Die Defect

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Diaper Films

Product: Diaper Films

W = 1400 - 2600 mmV = 200 - 600 m/min.

Defects: gels, black specs, fish eyes, holes, insects

Resolution: 500 µm

Defect Specs: 1 mm

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Slit Alarm

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PET Food Films

Product: PET Food Films

W = 1400 - 2600 mmV = 200 - 250 m/min.

Defects: gels, black specs, fish eyes, holes, insects

Resolution: 200 - 500 µm

Defect Specs: visible

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PET Films

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Alarms / Repeating Defect

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Roll Stack Defect

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Surface Protection Films

Product: Surface Protection Films

W = 1400 - 2600 mmV = 100 - 250 m/min.

Defects: gels, black specs, fish eyes, holes, insects

Resolution: 60 - 160 µm

Defect Specs: 1 mm

Defect Height: factor 1.1 – 1.5 times film thickness

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Surface Protection Films

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Defect Results

Fish-eyein a 3-layer Coex Film

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Defect Results

Fish-eye marked in aluminium sheet

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Defect Results

Aluminium/Film Laminate withContamination

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Extrusion Coating on Alu Boards

Product: PE Coated Aluminium Board

W = 1400 - 2800 mmV = 500 - 600 m/min.

Defects: PE spots, black spots, coating spots,aluminium splices, missing coating,aluminium peel-off, paper board creases

Resolution: 350 µm

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High Power COB LED 3.000 mmExtrusion Coating Alu

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Metal Splice

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Oil Drop

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Burst Bubble

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Wrinkle

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General Specifications (Resolution)

PET Food Films: ∅ 200 - 500 µm

Technical Films: ∅ 100 - 200 µm

Surface Protection Films: ∅ 60 -160 µm

Optical sheets + films: ∅ 25 -100 µm

Extrusion Coating: ∅ 350 µm

Diaper Films: ∅ 500 µm

Pharma Films: ∅ 200 µm

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Thank you

PRESENTED BY

Oliver HissmannSales ManagerOCS Optical Control Systems GmbHhissmann@ocsgmbh.com