30. Hofer Vliesstofftage 2015
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1 30. Hofer Vliesstofftage 2015 Advanced polymer film inspection systems for process analysis and yield optimization full integration into the production Presented by: Dr. Michael Kohlert Mondi Gronau GmbH Oliver Hissmann OCS Service GmbH
2 Contents Introduction Web Inspection Technology Integration within Mondi Gronau OCS Historical Data Manager Summary
3 Solutions for Polymer Industry Films & Converting Industry More than Inspection Systems installed worldwide
4 OCS Quality Control Equipment High speed pellet scan system PS400C Scans and sorts up to 800 kg/hour Examples of our wide range of products
5 Pellet Analysis
6 Online Cast Line with Gel Counter Transmission
7 Web Inspection System FSP600 Embedded Multiple Camera Solution
8 Web Inspection in Film Extrusion 100 % Optical Control of the Web Photo of every defect Position of every defect Database Interface Reports Alarms
9 Definition Defect Types
10 Defect Types Gels Black Specs Contaminations Die Lines Insects Calander Defects Oil Stains Air Bubbles etc.
11 Origin of Defects Extrusion Line 20 % (screw geometry / dead zones) Resin 25 % (contamination, recipe) Production Process 15 % (extruder temperatures, screen change) Pellet Transport (external/internal) 40 %
12 Benefits of Online Control Process Control (Optimisation, capacity, cleaning, waste) Raw Material (Optimisation material + recipe, control material) Product (better quality, customer satisfaction/relation, less claims, more competitive products)
13 TDO Films
14 Web Inspection on Slitter and Cast Film Line
15 Closed Frame Blown Film
16
17 Film Grading
18 Quality Control OCS Viewer
19 Find the right way
20 Plant Mondi Gronau GmbH Jöbkesweg Gronau, Deutschland Staff: ~900 employees Mildenberger & Willing -> Nordenia -> Mondi Dr. Michael Kohlert Oktober 2015 Page 1
21 Facts & Figures Product Segments Technical Films Hygiene Components Surface Protection / Decorative Films Label Films Elastic Laminates Protective Films Lamination Films Elastic Films Functional Films Packaging Films Frontal Tape Decorative Films Hygiene Films Dr. Michael Kohlert Oktober 2015 Page 2
22 Facts & Figures We serve the following industries: Food and Beverages Hygiene and Toiletries Medical and Pharma Automotive Wood and Plastic Steel and Metal Dr. Michael Kohlert Oktober 2015 Page 3
23 Facts & Figures References Dr. Michael Kohlert Oktober 2015 Page 4
24 Facts & Figures Mondi Gronau GmbH Compounding Blown Film Extrusion Cast Film Extrusion Rotogravure Printing Coating /Siliconizing Lamination Roll-Slitting -> 60 processing machines Dr. Michael Kohlert Oktober 2015 Page 5
25 Facts & Figures Extrusion Lines Monoextrusion Coextrusion n - Layer Film thickness: µm Film width: mm Dr. Michael Kohlert Oktober 2015 Page 6
26 Facts & Figures Further Lines Coating / Siliconizing Rotogravure Printing Slitting Lamination Dr. Michael Kohlert Oktober 2015 Page 7
27 Facts & Figures Quality Assurance Thickness measurement Tensile measurement Hysteresis measurement Bending stiffness Elmendorf tear test Seal bond strength Friction measurement Colour measurement Opacity measurement Dr. Michael Kohlert Oktober 2015 Page 8
28 Monitoring
29 Monitoring Optical Control Systems 34 In-Line OCS Systems Urlaub Dr. Michael Kohlert Oktober 2015 Page 10
30 Monitoring Integrated into Production Good Product Dr. Michael Kohlert Oktober 2015 Page 11
31 Monitoring Elastic Film Process Good Product Dr. Michael Kohlert Oktober 2015 Page 12
32 Monitoring Elastic Film Process Good Product Dr. Michael Kohlert Oktober 2015 Page 13
33 Monitoring Compounder Stage Good Product Source: OCS GmbH Raw Material Surface Detection Colour Analysis Dr. Michael Kohlert Oktober 2015 Page 14
34 Monitoring Elastic Film Good Product Quality Index Traffic Light System Dr. Michael Kohlert Oktober 2015 Page 15
35 Monitoring Lamination Rework Good Product Rework Inspection Laminated Film Surface Detection Nonwoven + Elastic Film Dr. Michael Kohlert Oktober 2015 Page 16
36 Monitoring Data-Browser Good Product Analysis of all rolls Comprehensive 3 Stage Process Monitor Database Dr. Michael Kohlert Oktober 2015 Page 17
37 Monitoring Benefits Gronau GmbH Good Mondi Product Waste Product Good Product Reduction of Waste Material Advanced Quality Monitoring Customer Satisfaction Yield Optimization Dr. Michael Kohlert Oktober 2015 Page 18
38 Thank you!
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