Online gauge improves efficiency for leading manufacturer of metallised film

Citation

(2001), "Online gauge improves efficiency for leading manufacturer of metallised film", Sensor Review, Vol. 21 No. 2. https://doi.org/10.1108/sr.2001.08721baf.001

Online gauge improves efficiency for leading manufacturer of metallised film

Online gauge improves efficiency for leading manufacturer of metallised film

Keywords: Infra-red, Film, Gauge

Packaging manufacturer Rexam High Performance Flexibles is using NDC Infra-red Engineering's infra-red online gauge to measure coat-weight consistency as part of the company's continuous improvement initiative to maintain high quality, while reducing scrap material and costs.

Located at Thetford, UK, Rexam High Performance Flexibles produces flexible packaging materials for a wide range of food and drink products including crisps, concentrated orange juice and wine. These are manufactured using metallisers and laminators to meet industry demands for high specification products with excellent moisture and oxygen barrier properties (see Plate 1).

Plate 1 NDC Infrared Engineering's near infra-red gauge measuring lacquer on film in an application similar to that at Rexam High Performance Flexibles

The Thetford site has two infra-red gauges installed on different lamination lines – one uses solvent based adhesive and the other non-solvent – an iso/poly mixture.

Before the infrared gauges were installed the coat-weight applied had to be checked using a manual sampling process several times a day. This sampling process involves an operator physically placing a piece of wax paper between two layers of film. The sample layer coated with adhesive is then cut out and weighed. After careful removal of the adhesive layer, the sample is weighed again – the difference in weight equals the coat-weight applied. The success of the infra-red gauge has meant that this exercise is now only carried out occasionally to confirm the accuracy of the gauge.

The gauges scan across the width of the web, taking continuous measurement of the coat-weight applied to the film substrate. The measurements are viewed on a computerised profile display unit, which also indicates user-set tolerances. This enables operators to see at a glance if the coatweight is in danger of going out of specification.

NDC Infrared Engineering's infra-red gauge has reduced scrap costs and allowed products to be produced to coat-weight specification limits with much greater ease and confidence. As a result of taking continuous measurement the operators can see at a glance if the coat-weight is being applied evenly across the web within upper and lower specifications for any product. As the coat-weight details are also recorded for each reel produced, the gauges also provide valuable information for quality control and assurance purposes.

As part of the continuous improvement programme, Rexam will be introducing statistical process control (SPC) in the future and is currently acquiring data from all areas of the plant to provide operational performance efficiency (OPE) data. When Rexam has extended its data acquisition system to provide machine process running conditions, the data gathered from both infra-red gauges will be used by the production management team for SPC purposes.

For further information contact: Dr Ian B. Benson, NDC Infrared Engineering, Galliford Road, Maldon, Essex CM9 4XD, UK. Tel: +44 (0)1621 852244; Fax: +44 (0)1621 856180; E-mail: ibenson@ ndcinfrared.com; Web site: www.ndcinfrared.com