1

TAPPI 11th European PLACE Conference, Athens 2007

Online Quality Control ofPolymers and Extruded Films

Oliver Hissmann

2

Contents

Introduction

Online Quality Control in Polymer PlantsTechnology, Benefits, Online Lab, Close Loop Concept

Web Inspection in Film ExtrusionTechnology, Benefits, Integration

Interrelationships and Correlation

Practical Examples

Summary

3

Online „Closed Loop Control“-Concept

Sampling

Feedback

Raw material

Additives

Process Production

On-line Quality Assurance

Process computerDetermination of the process parameters

Data (opt. measuring technique)

4

Principal of Online Quality Control

Gloss Measurement Gel Counter

Thickness Measurement Haze Measurement

Polymer Analysis by FTIR Spectroscopy

Measurements on Extruded Films

Film ExtrusionBlown Film / Cast Film

Pellets Color Measurement

Pellets and Powder Inspection

Pellets Throughput Measurement

Pellets Size and Shape Distribution

Melt Index

Measurements on Pellets

Pellet PreprocessingDedusting / Drying

Pellet Transport SystemPellet Sampling and Transport

Production of Polymer Pellets

5

Benefits of Online Control

Process Control(Optimisation, capacity, cleaning, waste)

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

6

Pellets Color MeasurementPCM

Measurement of LAB Color Valuesand Yellowness Index

Pellets and Powder InspectionPS 25C, PS 25, PS 2 PT 2Detection and Evaluation of

Impurities in Pellets and Powder

Pellets Throughput MeasurementPTM

Weight Measurement of the inspected Pelletsover the time

Pellets Size and Shape DistributionPSSD

Measurement of Size and Shape of the PelletsDetection of Twin, Triple and Multiple Pellets

Measurements on Pellets

Online Measurement of Pellets

7

Pellet Scan System

CCD-Camera

Lighting unit

Hopper

Pellet stream

8

Pellet Scan System

9

Pellet Size & Shape Distribution

Lighting unit

Hopper

Pellet stream

CCD-Camera

10

Pellet Size & Shape Distribution

11

Pellet Size & Shape Distribution

12

Pellet Colour Measurement

visible light

color measuring device

visible light

13

Online Measurement on Extruded Films

Gel CounterDetection and Evaluation of

Gels, Fish Eyes, Black Specs

Polymer Analysis by MID-IR SpectroscopyMeasurement of Additive Contents and Physical Properties

by IR-Light Transmission Through Extruded Films

Gloss Measurement

Measurement of Gloss of Extruded Films

Haze MeasurementOHM

Measurement of Haze and Transmissionof Extruded Films

Thickness MeasurementTMD

Measurement of Films Thickness

Measurements on Extruded Films

Film ExtrusionBlown FilmCast Film

14

Online Quality Control

15

Online Integrated Measurement Solution

16

Online Integrated Measurement Solution

17

Online Gel Count

18

Online Gel Count

19

Defect Types

Gels

Black Specs

Contaminations

20

Web Inspection in Film Extrusion

100 % Optical Control of the WebPhoto of every defect

Position of every defect

Database Interface

Reports

Alarms

21

Benefits of Web Inspection

Process Control(Optimisation, capacity, cleaning, waste)

Raw Material(Optimisation material + recipe, control material)

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

22

Origin of Defects in Extrusion

Extrusion Line (screw geometry / dead zones)

Resin(contamination, recipe)

Production Process(extruder temperatures, screen change)

23

Defect Types in Film ExtrusionGels

Black Specs

Contaminations

Die Lines

Insects

Lamination Defects

Oil Stains

Fish Eyes

etc.

24

Web Inspection SystemEmbedded Multiple Camera Solution

25

Embedded Solution Technology

High Speed CCD Line Scan Cameras80 – 160 MHz, 512 – 8192 Pixel

Embedded PC with High Speed Framegrabber

Windows XP Server (network)

Exact information on defects within the web(mosaics, position, alarms, protocols, storage)

26

Quality Reports / Alarming

Single Defect

Trend Defects (20 gels per m²)

Slit Defects

Repeating Defect

Gel Shower / Cluster

Roll Defects

27

Rolling Map / Die Defect

28

Time History (Gel Level)

29

Mosaic View

30

3-D Defect Analysis

31

Lane Distribution

32

Die Defect

33

Calander Defect

34

Alarms / Repeaters

35

Teach-In Function - Fly

36

Teach-In Function – Oil Stain

37

Teach-In Function - Gel

38

Teach-In Function – Black Spec

39

Inspection Systems

40

Inspection Systems

41

Closed Frame

42

Interrelationship and CorrelationExample

Online Compound Control (Gel Analysis)

Oracle Database Integration

Decision for Film Extrusion Quality (Grading)

100 % Web Inspection in Cast Line(Diaper Breathable Film)

43

Online Container for Plant Control (Example)

44

45

46

Gel Shower

47

Online Anticipation of Plant Shut Down

Sta

rt in

ject

ion

clea

ning

age

nt

Pla

nt s

hut d

own

48

Online Transition Control

Sta

rt ex

trude

r cle

anin

g

Stop injection cleaning agent

Stop extruder rinsing

49

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

Sto

p in

ject

ion

clea

ning

age

nt

Sto

p ex

trude

r rin

sing

50

Summary

Close Loop Online Control (Process + Grading)is today‘s Standard in Polymer Plants

100 % Web Inspection in Film Extrusion

Different Defect Types, but close Interrelation

Working Together avoids Problems andimproves Film Quality

51

Thank You

very much

for Your Attention !