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Send to KindleTri-extrusion heightens Haremar's capability
The material from the extruders is directed through a common block and then to the circular die from where with a pressurized air ring it rises skyward.
At the top of a 35’ tower the bubble is converted into layflat orientation through an
A-frame assembly and then by primary and secondary nip rollers. Lichtblau points out that the first nip is an 84’’-capacity-wide Transversanip oscillating system from Battenfeld. It rotates 360° in one direction then 360° back to smooth out bubble gauge variations. It’s a great contributor to consistency. He says this eliminates the need for an oscillating die at the extruder thus reducing a chance for seal leakage during extrusion. Rotation timing is programmable; Haremar uses a 10-minute cycle set time.
In between the two nips film destined for printing is full-layflat corona treated. The electrical charge roughens the film surface to permit a better ink bond.
The film then goes through a web guide that using proximity sensors centers it ahead of edge trimming. The trimmed material is reclaimed and reused. The material can also be slit at this point. Haremar’s slitting options enable it to supply folded U-shape film or film slit into as many as six rolls. The film is wound into rolls on a two-turret winder that can handle roll diameters of up to 30’’ and widths to 70’’. The winder is a ’98 vintage Battenfeld unit used on the previous line. Lichtblau says $100 worth of new gears upgraded its speed by 100’/min to match the new line’s capacity.
The new line increases speeds up to 450’/min a 38% increase over the previous line’s 325’/min.
Faster is better but even more important is consistency which Lichtblau emphasizes is really the bottom line. “Improved consistency is one thing a customer will never complain about” Lichtblau says adding that the new line’s film variance is now half of what it was before as measured by standard deviation. And he attributes that to the many “small” things along the entire line.
When asked about the return-on-investment for the overall C$2- million cost of the line Lichtblau responds “It’s immediate due to the positive impact it has on the employees our company’s reputation and also in raising the standard for the industry.”
See sidebar to this article: Film wraps McDonald’s Canadian buns
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