Extrusion Coating &

Laminating
2008 Extrusion Coating Short
Course May 1,
Course, 1 2008
Beth Foederer
O t Process
Optex P Solutions,
S l ti LLC

Di
Discussion
i Topics
T i

z Equipment and Purpose

z Chill Water System Design and
Control
z Basics of Process
z Calculations
z T bl h ti
Troubleshooting
Extrusion Coating & Laminating

The goal in extrusion coating and/or

l i ti iis tto fform a continuous,
laminating ti
inclusion free polymer layer of uniform
thickness that adheres to the desired
thickness,
substrate(s).

E t
Extrusion
i Coating
C ti Uses
U
z Milk Cartons z Sugar Pouch
z Ream Wrap z Cheese Wrap
z Juice Cartons z Snacks
z Snack
S ac Food
ood z Dry
y Mixes
es
Packaging z Lidding Stock
z Photo Paper z Multiwall Bags
z Bakery Trays z Medical Packaging
Ni Roll
Nip R ll
z What: Water cooled (generally double shell)
roll with a rubber covering
z F
Function:
ti
z To combine the substrate(s) and molten polymer
together at the chill roll with even pressure
z It removes air from the product
z It facilitates cooling

Ni Roll
Nip R ll
z Operation
z Opens and closes with
pneumatic air
either p
cylinders or air bags.
z Pressure is changed by
adjusting air pressure
to cylinders or bags.
z Typical
yp p
pressure is 150
pli but can be higher.
z Both rolls open for
threading and safety
 Ni Roll
Nip R ll Coverings
C i
z Hypalon (Chlorosulfonated Polyethylene)
z Shore hardness range: 40-90
z Good release, temp resistance, ozone resistance and
easily reground
z Neoprene (Polychloroprene)
z Shore hardness range: 15-80
15 80
z Regrindable, not as durable, good release, inexpensive
z Silicone (Polymethylsiloxane)
( y y )
z Shore hardness range: 40-70
z Soft, v good release, temp resistance, good for porous
substances

Ni R
Nip Roll
ll Release
R l Options
O ti
z Why do the edges need
more release than center?
z Teflon® Tape
z Change for different widths

z Teflon® Belts
z Adjustable but difficult to use

z Teflon® Sleeves
z Costly
Ni Roll
Nip R ll Deflection
D fl ti
z Bending of the roll due to gravity
gravity, tension
and pressure
z Backing roll helps the deflection
z Function of roll diameter and construction
z Can be measured by nip impression tape
OR…
z Corrected by crowning the roll
z Caution: improper crowning will generate
p
wrinkles in the nip

B ki
Backing R
Roll
ll

z What: Water Cooled

z Chrome plated
Ch l t dd double
bl shell
h ll
z Increases the life of the nip roll covering
z F
Function:
ti
z Cools surface of nip roll to reduce sticking
z R d
Reduces b
bowing/deflection
i /d fl ti off th the nip
i rollll
 St i i
Stripping Roll
R ll
z What:
z Steel, aluminum or rubber covered idler roll
z Opened
p and closed with p
pneumatic cylinders
y
z Function:
z Initiate even removal of product from chill roll
z Location:
z Metal roll is 1” or less from chill roll
z R bb rollll contacts
Rubber t t chill
hill rollll
z Opens for threading and safety
z Is adjustable if a wide variety of products is to be made

Chill R
Roll
ll Function
F ti
z Quench
Q h molten
lt polymer
l tto
strippable temperature
z S t extrusion
Set t i lineli speed d – Lead
L d
section
z I
Impartt surface
f texture
t t to
t final
fi l
product (extrusion coating only)
 Chill Roll
R ll Construction
C t ti
z Diameter range: 18-50
18 50
inches
z Mono flow
z In one end
end, out other
z Single shell desgn
z Small Rolls only – not
R
Recommended!!
d d!!
z Double shell design
z Small amount of water, next to
outer
t shell
h ll
z Double shell spiral fluted
z Most common design
z Lowest delta T

Chill Roll
R ll Finish
Fi i h
z Surface roughness is a measure of the
smoothness or texture of the roll surface
z Ra – “Average
Average Roughness”
Roughness
z RMS – “Root Mean Square”
z 10 Ra = 11 RMS
z Surface roughness determines how easily the
polymer can be removed from the roll and the
surface finish of an extrusion coated product.
 Chill Roll
R ll Finishes
Fi i h
z Matte – 30-125
30 125 Ra typical
z Grit blasted, plated with dull finish and good
release
z Gloss – 4-10 Ra typical
z Precision ground and polished with good surface
finish and release
z Mirror – 2-4 Ra typical
z Belt
B l or stone polish
li h with
i h hi
high
h gloss
l and
d poor
release
z Optical Mirror – 1 Ra or less

M t i l Considerations
Material C id ti
z Heat Conductivity (k) – Steady state heat
transfer rate within solid or liquid materials
z Thermal Expansion – Fractional change in
length or volume of material for unit
temperature change
z Durability – resistance to dents, scratches or
deformation
z Weight
z Cost of raw materials and fabrication
 M t i l Selection
Material S l ti
Coefficient of Thermal
Material Heat Conductivity**
Expansion*

Aluminum 12.8 1460

Brass 11.4 833
Chromi m
Chromium 34
3.4 480
Copper 9.8 2670
Gold 7.9 2090
I (
Iron(pure)
) 66
6.6 529
Nickel 7.2 421
Silver 10.5 2910
Steel(SAE 1020) 6.6 360
Steel(SAE 1095) 5.7 360
Steel 285 Grade B 6.5 -
Stainless Steel(I8-8) 9.5 -

*10e-6 in/in *°F

**BTU-in /(°F –ft2 –hr)

Chill Roll
R ll Temperature
T t
z Whatt do
Wh d I need? d?
z The ideal chill roll temperature is cool
enoughh tto allow
ll th
the coating
ti tto release
l
cleanly, but warm enough so the
polymer does not cool before having a
chance to wet the substrate
adequately.
adequately
 W t Recirculation
Water R i l ti System
S t
z Usually a closed loop system
z Same water is chilled and re-circulated
z C li can b
Cooling be varied
i d
z Based on extruder output
z B changing
By h i ttemperature
t off rolls
ll
z Water temperature is controlled
z Usually runs at 50-85oF

Closed loop
p chill roll system
y
Makeup Water Temperature
50°F Controller
68°F 68°F
Chiller

Reservoir
etc
3-Way
Valve

50°F
Pump T
T
68°F
T

65°F T

65°F
65 F Shut off Valve
Pump T Thermometer
Pump
 Chill System
S t Fouling
F li
z What: Any layer or deposit of extraneous material on
a heat-transfer surface. This reduces thermal
conductivity of surface.
z Causes
z Scale or mineral deposits
z Algae
z Rust
z Prevention
z Initial system treatment
z Maintenance program
z Removal of build-up is either chemical or
mechanical

Chill Roll Temperature

600°F Melt Temp.
Contact time 0.24 sec

Shell= 12mm (0.5”)

1.0 mil coating
120°F
120 F
Substrate
70°F in
Line Speed
1000 ft/min 73oF out

450°F 230°F

340°F
E t
Extrusion
i Process
P Variables
V i bl
z Polymer Melt Temperature
z Linespeed
z Air Gap/Drawdown
z Die Position Lead
z Die Gap (not discussed)
z Chill Roll Temperature
p
z Nip Roll Pressure
z Nip Roll Hardness
O id ti
Oxidation (melt
( lt temperature)
t t )
z All substances are either organic or
inorganic
z O
Organic i materials
t i l will
ill b
burn
z High temperatures promote faster
oxidation
id ti rates
t
z At some temperature the ignition point
will be reached
reached.

B d / Adhesion
Bond Adh i
z All organic materials have a surface skin
z This is an oxidized layer of itself (rust)
z Some materials
S t i l resist
i t oxidation
id ti such
h as
stainless steel
z TO OBTAIN ADHESION BETWEEN TWO
MATERIALS, ONE MUST BE LIQUID!!!
z Too much oxidation destroys adhesion as
does too little.
 Ai Gap
Air G
z The amount of time the molten polymer is in
contact with air effects its adhesion to the
substrate.
z The longer the polymer is exposed to air, the cooler
it becomes and tends to decrease adhesion
z If the
h meltl temperature is
i hi
high
h enough,h iincreased
d
time will increase oxidation and will improve
adhesion
z Therefore, an optimum air gap permitting maximum
adhesion exists for each set of circumstances

B d versus Ai
Bond Air gap

bond

air gap
 M lt Curtain
Melt C t i Air
Ai Gap
G
z Determined by linespeed
z Raising Die
z Time in air gap increases
z 100ms for LDPE
z TIAG=60 x g gap(mm)
p( )/
linespeed (m/min)
z Neck-In increases
z Melt temperature drops Air Gap Line Speed
z 1” increase in gap = 10oF (in) (fpm)
increase in melt 7.0 up
p to 700
8.5 700 – 1,200
temperature 10.0 1,200 – 1,800
12.0 1,800 and up

N kI
Neck-In
z Determined by:
z Resin properties such as molecular weight and
molecular weight distribution
z Extrusion conditions such as melt temperature,
line speed,
p , output
p rate and die p
pressure
z Equipment geometry such as screw design, air
gap and die lip gap
 Di P
Die Position
iti Lead
L d
z Lead onto either
substrate for improved
adhesion
z Issues
z Substrate burn throughg
z Web contraction on heavy
coatweights
z Linespeed will effect
z Work needs to be done
to optimize location
Chill R
Roll
ll T
Temperature
t S
Setting
tti
z Too Cold produces rapid quench rate
z Reduced adhesion
z Roll mayy sweat in high
g humidity
y
z Too Warm produces slower quench rate
z Polymer may stick to roll
z Bond issues or tearing with substrate
z Can wrap chill roll
z Uneven Temperature
z Poor or uneven strippability
z Flow marks in product
p
z Indication that chill roll may be fouling

Chill R
Roll
ll St
Strip
i Position
P iti

If Roll to High….
…Chill Roll Surface Cannot
Recover
CL

CL
CL
If Roll to Low….
Chill Roll
CL ...Poor Stripability Resulting in
Quality Defects

A misaligned or Worn Roll Can Result

in Wrinkles in the Product
 Chill Roll Recovery
y
600°F Melt Temp. 90°F 100°F
120°F

B A

75°F
The Chill Roll needs
time and distance to
recover cooling of its
surface ( A to B ) Davis Standard

Ni Impression
Nip I i
z Amount of impression
determined by:
z Roll Hardness
z Roll Diameter Impression
z Nip Pressure
Width
z Wider nip
z Improved adhesion
z For heavier substrates
z C create
Can t pinholes
i h l
z Even nip across the
roll is important!!!
 Quick Calculation for Chill
W t GPM
Water
mwxCpwx¨Tw = mp(Cppx¨Tp+hfp) x Eff

mw = Mass Flow Water, lb/hr mp= Extruder Output, lb/hr

Cpw = Specific Heat Water, BTU/lb-°F
¨Tw= Temperature Rise Water, °F
GPM = [(mp x 0.75 x ¨Tp)/(¨Tw x 500)] x 1.2
Cpp=Specific Heat Polymer, BTU/lb-°F
¨Tp= Temperature Change Polymer, °F
y , BTU/lb
hfp = heat of Fusion Polymer, U/
Eff = Effeciency of System

How much water do we need to pump through our chill roll if we have a rate or 1000 lb/hr LDPE,
Melt Temperature 600°F, a Strip Temperature of 100°F, and 3°F Water Temperature Rise?

GPM = 1000lb/hr (0.55BTU/lb-°F x (600-100°F)+0.48Btu/lb) / (1BTU/lb x 3°F x 480) * 0.7 = 275gpm

GPM = [(1000 x 0.75 x (600-100)/(3 x 500)] x 1.3 = 325gpm

*Assuming Chill roll is of adequate size

**Increase GPM to allow for Nip and Backing Roll Flow

Quick Calculation for Cooling

Tonnage

Ton = [mpx0.75x¨Tp/12,000] x 1.2

Mp = Extruder Output,p , lb/hr

¨Tp = Temperature Change Polymer, °F
Ton = Tonnage of Refrigeration required or available at 50°F
1.2 = Efficiency of 80%

How much cooling is required if we are extruding 1000lb/hr of 600°F LDPE with a stripping
Temperature of 100°F.

Ton = [1000 lb/hr x 0.75 x (600-100)°F /12,000] x 1.2 = 37.5 Ton

 Chill Roll
R ll Contact
C t t Time
Ti
Calculate Contact and Recover Time and Lengthg for a Extrusion Line
Having a 24 inch Chill Roll with a 220° Wrap at a Line Speed if 500fpm.

Diameter
Contact Time, sec = CR Di t xW Wrap%%
Line Speed x 22.93
= 24 x 220
500 x 22.93
22 93
= 0.46 sec

Recovery Time
Time,sec
sec = CR Diameter x (1
(1-Wrap%)
Wrap%)
Line Speed x 22.93

= 24 x (360-220)
500 x 22.93

= 0.29 sec

Chill Roll
R ll Contact
C t t Length
L th
Calculate Contact and Recover Time and Lengthg for a Extrusion Line
Having a 24 inch Chill Roll with a 220° Wrap at a Line Speed if 500fpm.

Contact Length
Length,ft
ft = CR Dia. x Wrap%
p
1376

= 24 x 220
1376
= 3.84 ft

Recovery
y Length,ft
g = CR Dia. x 3.14/12 – Contact Length
g

= 24x3.14/12-3.84

= 2.44 ft
Troubleshooting – Problems
R l t d to
Related t the
th Laminator
L i t
z A problem with it’s
it s causes will be listed
z Solutions are based on what we have gone
over in
i thi
this presentation.
t ti
z Audience will give answers by filling out work
b k as each
book h problem
bl iis given.
i
z Group discussion and review of solutions.

S l ti
Solutions Workbook
W kb k
Problem #1 #2 #3 #4 #5 #6
Solutions
Increase Air Gap
D
Decrease Ai
Air G
Gap
Chill Roll to Die (Left/Right)
Increase Chill Roll Temperature
Decrease Chill Roll Temperature
Increase Nip Pressure
Decrease Nip Pressure
Change Stripper Position
Chill Roll Fouled (Clean)
Call Beth
P bl
Problem #1
z Poor Adhesion of Extrudate to base or
laminated substrate.
z Due to: Inadequate oxidation only
z There are two solutions related to the
laminator for this problem

P bl
Problem #2
z Poor adhesion of the polymer to the
substrate.
z Due to: Premature Cooling
z There are three possible solutions to this problem
P bl
Problem #3
z Poor Adhesion of the Polymer to the
Substrate
z D tto: Sticking
Due Sti ki tot the
th Chill R
Rollll
z There are two possible solutions to this problem

P bl
Problem #4
z Excessive Odor
z Due to Over-Oxidation
z There is
Th i one solution
l i relating
l i to the
h llaminator
i ffor
this problem
P bl
Problem #5
z Poor Heat Sealability
z Due to: Over-Oxidation
z There is
Th i one solution
l i related
l d to the
h llaminator
i ffor
this problem

P bl
Problem #6
z Poor Adhesion Across the Web
z Adhesion is good in some areas and poor in
others
th
z Due to: Reduced Thermal Conductivity
z There are two possible solutions related to this
problem and one is tricky!!
 C
Conclusion
l i
z Equipment
E i t and
dPPurpose
z Chill Water System Design
and
dC Control
t l
z Basics of Process
z Calculations
z Troubleshooting g
z Thanks to Optex Process
Solutions,, LLC