Film show

Better connections

K 2004 has expanded its services to exhibitors and visitors with the construction of a new tube train station inside the re-designed North entrance. In addition, the Düsseldorf Trade Fair Centre has now become the site of one of Europe's largest wireless LAN networks, allowing rapid connection and access to the internet.

The new station, which connects directly to Düsseldorf Hauptbahnof, allows travellers to reach all of the halls under cover. Admission tickets and exhibitor passes for K 2004 include free use of all public transport to and from the fair within the fare zone of the Rhine-Ruhr and Rhine-Sieg Regional Transport Networks.

This represents a substantial enlargement of the atchment area to include several of Düsseldorf's neighbouring cities in the ride-for-free zone.

The WLAN network will enable exhibitors and visitors to access the latest information off the internet, answer emails or exchange data with their company networks. T-Com, a subsidiary of Deutsche Telekom, has installed more than 100 access points for wireless internet connection and will operate the WLAN network, which extends over an area of almost 285,000m2.

It has the capacity for 2,000 computers to be on-line simultaneously and data transfer rate is said to be up to 170 times faster than that of a conventional ISDN connection.

Slitting specialities

Bimec will show the latest models in its range of slitter rewinders for film, paper and laminates. The duplex turret model TCA/64.E features automatic change-over and a shaftless unwind stand, plus a version with overhead web path. The machine unwinds mother rolls up to 1,000mm diameter and rewinds finished rolls up to 600mm. It will be displayed in a full optional version, with accessories including differential rewind shafts, computerized control through a touchscreen operator panel with easy setting systems for the operator, laser core positioning and a system for unloading finished rolls.

The STM/43 is a duplex, single face type model suitable for mother rolls up to 800mm diameter and finished rolls of 450mm. Hall 3, stand B06.

Boosting bag making

ISO 9001 certified Indian manufacturer of plastics bag and pouch making machines and wicketers Mamata will display a new high speed pouch maker for the flexible packaging industry. It will be demonstrated processing regular laminated films and PA/EVOH based co-extruded films.

Mamata says its Vega series, launched at K 98, combines flexibility in processing a variety of materials with quick, easy and consistent change-over. The flat bed universal model handles various polymers on side weld, bottom seal and skirt seal (twin seal), with change-over said to take within 15-20min. The wicketer, a derivative of the universal bag maker, is claimed to be "a value for money proposition". The company says it is the first to allow wicketed bags to be produced at a much lower cost than normal. "This allowed wicketed bags to be produced by a larger number of processors because of the lower investment risks."

Mamata has more than 1,600 installations worldwide. In January, 2004, the company established a US operation to cater to the growing demand in the Americas. Hall 3, stand A34.

Known for its knives

Dienes will show examples of its knives for longitudinal slitting, knifeholders and knife positioning systems, all featuring the latest technical advances designed to improve productivity and profitability. On show for the first time will be the Easy Change knife replacement system for high speed and safer knife change. This system can be retrofitted to existing knives. The company will also display straight knife products for guillotines, sheeters and trimmers from its subsidiary Johann Krumm.

Dienes claims to "set the industry standard" for shear cut and crush cut knifeholders, rotary top and bottom knives, glass hard shafts, and semi automatic and automatic knife positioning systems. Its patented DF knife support technology is said to ensure constant slitting precision and performance. Hall 3, stand 3A76.

Drying, blending and conveying

Conair will show its ResinWorks material handling and conditioning system, a new constant dewpoint desiccant dryer, and the ILS Intelligent Loading System.

The ResinWorks combines drying, blending and conveying technology in one package, custom built to meet the needs of processors large and small. Up to five drying hoppers, each sized specifically for either multi machine/long run or single machine/short run operations, are factory assembled onto a sled-like base and fitted with heaters, controls, dry air manifolds and purge valves for easy place-and-play installation. Multiple sleds can be integrated for larger installations. The system can also include an Octobin or bag station, allowing an almost unlimited number of different materials (dried or un-dried) to be managed through the central resin distribution manifold and control system. A Conair gravimetric blender can mix different materials and additives, which can then be conveyed to a drying hopper or directly to processing machines.

Among the control systems available for use with ResinWorks or any central material handling system, is the ILS. This fully featured control platform now supports up to 144 loaders, 26 pumps, and multiple operator panels, all operating simultaneously. Offered in three connectivity/installation configurations, it can be matched to a processor's requirements.

The new Carousel Plus dryer is claimed to offer more control over dewpoint and temperature than ever before, "in a package that is simpler, smaller, lighter and easier to use and maintain than any other dryer". It is said to deliver "rock-steady" temperatures and dewpoint levels, which are critical to processing many of the moisture and temperature sensitive polymers in common use today. It is also claimed to be more compact, with a footprint 40 to 60 per cent smaller than other dryers, while the weight of the desiccant assembly has been reduced by 85 per cent. Hall 10, stand B74.

Blades to suit

Lutz manufactures a wide range of razor slitting blades, and will be exhibiting special blades for a variety of technical applications, such as film, foil, high volume LLDPE and PET, magnetic tape, OPP and BOPP films. Depending on the application, the blades can be made from steel, tungsten carbide and ceramics, with different coatings such as titanium, Teflon, chromium nitride and others according to the requirement. Hall 11, stand C58.

Masterbatch manufacturing to be multiplied

Now operating under the umbrella of parent company Tosaf, with access to manufacturing facilities in Germany and Belgium, as well as its own production operation in the UK, Colloids will be promoting the suitability of its masterbatch products for film production.

To provide operators within the film markets with a fast turnaround of price competitive products, in small lots manufactured to exacting lead times, the company is investing in three new additional masterbatch production lines that are due to be commissioned ahead of the K show. Serving to increase capacity by 2,000t/year, the new lines will manufacture products primarily aimed at cosmetic, toiletries and laundry product end use applications. In addition, seven new 50t polymer silos at the manufacturing site in Knowsley, UK, will provide an automated feed of polymers direct to each masterbatch production line.

Comments managing director John Dilley: "We aim to position Colloids as a one-stop-shop with the capacity to produce small lot orders to extremely short lead times." Colloids is exhibiting on the Ravago/Tosaf stand - C12, in Hall 7.

More from improved materials

Borealis has developed a range of PP materials for production on conventional blown film machinery traditionally used for PE. The new Borclear and Borsoft grades are said to take advantage of molecular engineering to overcome previous material shortcomings. They feature increased melt strength, molecular structures that prevent splitting, and enhanced cooling and optical properties.

They also provide a range of properties and possibilities for film appearance, mechanical behaviour, and potential for use in new packaging applications, it is claimed. These include stiff packaging film with excellent gloss and heat sealingfor textiles or foodstuffs; films for hygiene uses with good mechanical properties; and stand-up food pouches with balanced toughness and stiffness. Labelling film with outstanding planarity and stiffness, and packaging films combining water and gas barrier with good optical properties are also offered.

Two new families of single site catalysts PE from Borealis have been designed to create new packaging options for all major segments of the fast growing SSC PE market. Borecene marks the company's entry into the unimodal SSC LLDPE blown and cast film market. The bi-modal BorPlus products are available for blown film applications. They are said to exhibit excellent film clarity, and "second-to-none" sealability. The BorPlus materials are also billed as the first SSC LLDPE grades with excellent bubble stability, drawdown and throughput for blown film applications. Applications include shrink or overwrap films for food products, freezer film, stretch and shrink films, and shipping bags, industrial liners and grocery bags.

Borealis has also developed a range of PP grades for extruded film applications such as medical pouches and monoblister packaging. They are said to offer low migration into medical products and liquids, and provide high security and integrity during transportation and handling. Hall 6, stand C58.

Controlling process temperatures on the line

A new range of on-line process imaging systems for temperature measurement and control will be exhibited by Land Instruments International. The company has developed two high speed infra red line scanner systems to measure process temperatures and thermal profiles during the coating and extrusion coating of film and sheet, stretching, laminating, embossing and calendering.

The scanners can generate high speed accurate temperature profiles at scan rates up to 100Hz, the company states. Scan angle is 80 degree, with a 100:1 field of view (95 per cent energy) and a focus range up to 3,000mm.

The output is transmitted to the new Landscan Control signal processors, which provide serial and Ethernet data outputs that can be interfaced either to local process control systems, or to the Windows based Landscan WCA Control and Analyse software system. Hall 12, stand C51-8

Masters in slitting

WT Wickeltechnik will highlight its Master range or slitter rewinders for flexible packaging. It includes the Slitmaster twin-spindle machine, the Automaster with automatic turret rewinding, and the Multimaster with individual winding stations. Automatic knife and core positioning, and integrated roll handling systems are included.

The Multimaster offers the advantage of a combination of individual winding stations and winding shaft rewind. The Ecomaster is the "little brother" of the Slitmaster, and the Remaster is a compact machine for the repair and optimization of telescoped and faulty finished rolls. Hall 3, stand 3A47.

IES on view

A selection of the range of air expanding shafts, chucks, safety chucks, reel lift turners and shaft extractors IES offers will be on view. The company claims to be "the first choice for leading OEMs" for knife/slitter shafts, especially for applications with high precision automatic knife setting systems, and for special requirements. Differential rewind shafts are designed especially for flexible packaging slitter rewinders. Hall 3, stand 3E84.

Desktop control of materials handling

Plastics materials handling specialist Wittmann is to highlight innovations to its M7 Teachbox system. This allows a single point of control of all the materials distribution through a typical plastics processing operation.

The M7 now includes control logic for administration of up to 30 hopper loaders and 30 purge valves linked by a CANBUS system. New features include acoustic and optical alarm modules, throughput measuring, silo content measurement, error recording, and hopper loader level visualization. The new graphics display features for pumps, filters, hopper loader and purging valves. Simple clicking on the graphic for any of these will show the detail of their configuration. Up to eight pumps are free to be defined for any given hopper loader and up to 240 purging valves in similar fashion.

The new material administration is said to allow free selection of material at the hopper loader. Parameters for this include material listing (up to 20 characters), residence time (minutes) and bulk density (kg). The error recording allows for 1,000 error messages of the last 100 days to be stored in the control system and these can be downloaded through a serial interface.

The M7 network will also be able to interface with the WittLink system for monitoring automation and auxillary equipment thorugh an array of embedded web servers. This enables robots, dryers, hopper loaders and many other pieces of equipment to be remotely programmed and monitored from any location in the world.

In addition, the WebOpen module allows WittLink to connect to all types of plastics ancillary equipment from other suppliers. And web cameras in the production place can integrate into WittLink, also allowing the user to view the production processes from any location in the world. Hall 10, stand A04.

Put to the test

Lloyd Instruments plans to display five of its LFPlus test machines to show how to analyze the physical and mechanical properties of polymers at different stages of manufacture using the same machine. A simple change-over of grip or fixture enables a wide range of raw materials and finished products to be tested on the same machine. This is said to increase cost efficiency without compromising on quality for any industry, whether in a QC, research or training environment.

The LFPlus is the company's latest 'affordable', 1kN single column machine with a modular design for an extended choice of features. It is said to be extremely easy to operate, with a simple plug and play operation. Test speeds range from 0.05-1,270mm/min (accuracy claimed greater than one per cent at full load) and, unlike other machines on the market, according to Lloyd, it features a deep 170mm throat and generous working area to accommodate larger samples.

Also on show will be the powerful 10kN LR10KPlus twin column testing machine, the Davenport MFI-10 melt flow indexer for automated melt flow and melt volume rate polymer testing, and Nexygen MT advanced materials testing software. Typical applications include tensile strength tests of plastics film, packaging, sealing tape, and adhesives. Machines from the Davenport range are designed to evaluate the physical properties of polymers. Hall 11, stand D03.

Plasma provides special treatment

A narrow web atmospheric plasma treatment system said to be ideal for applications requiring stringent surface specifications, improved hydrophilicity and precise surface coating performance will be exhibited by Enercon's UK operation.

The Plasma 3 is a proprietary atmospheric glow discharge surface treatment system for narrow and wide non woven webs. It can modify the entire fibre network of webs with two-side treatment, the company declares. Uniformity of treatment is achieved and functionalization is precisely controlled to promote many hydrophilic surface properties. Process chemistry consumption costs are said to be extremely low, reacting in the discharge area and yielding high and long lasting surface energy to improve adhesion of dyes, inks, coatings and adhesives.

The Plasma 3 technology can produce exceptional non woven performance, it is claimed. Custom designed solutions can include improved pigmentation and coating adhesion for wipes, padding, and electrical and thermal insulators using both natural and synthetic fibre blends. Hall 12, stand C51-6.

Treatment at high speed

Vetaphone will display a new corona-plasma treater for polymer objects, to provide better wettability. According to the company, the system will ensure a high treatment level with a long lasting effect. It includes an automatic control system linked to the production line, and can be equipped with an automatic in-feed/out-feed system for high speed in-line operations. Hall10, stand A59.

Die development gains quality time

A new system for coating flat-die lip surfaces is said to enable extruders of film and sheet, or processors of hotmelt adhesives to improve product quality while gaining several days of added machine uptime each year. To be introduced by Extrusion Dies Industries, the new technology is based on a tungsten carbide coating claimed to last eight times longer than the standard chrome plating used for flat die lips.

Called EverSharp, it is based on two developments. One is a proprietary method employed by Praxair Surface Technologies to apply tungsten carbide coating to wear-prone tooling surfaces. The second is EDI's investment in special systems for grinding tungsten carbide to the exceedingly precise lip surfaces and sharp edges required for products like BOPET film. EDI is now the sole worldwide distributor of the Praxair coating technology as applied to flat die lip surfaces, with the exception of Japan, Korea, Southeast Asia, and Taiwan, which it will serve on a non exclusive basis. Praxair will coat the lip edges, and EDI will grind them for new or existing dies.

Christopher W Curtin, EDI executive vp of sales and marketing, says that, compared with chrome plating, tungsten carbide is substantially more resistant to micro fractures during initial sharpening, abrasion during normal use and cleaning, and corrosion. "Because worn edges lead to lip buildup that causes die lines and other defects, a BOPET film producer typically takes a die off-line every three months to clean and sharpen the lips," he explains. "This takes at least a day and costs thousands of dollars in lost output. By reducing buildup and eliminating need to take the die off-line, our EverSharp edges quickly pay back the cost premium over chrome plating."

EDI has also made its UltraLock boltless die "even more operator friendly" by developing a device for lifting the upper die body that is simple enough to be activated with a standard power drill. This die splitting system is said to eliminate the time and risk associated with using a hoist to raise the upper die body once it has been released from the lower body, through the flipping of a switch that activates the UltraLock system.

EDI introduced the boltless die at the previous K show. Instead of body bolts, it has a clamping system that replaces the laborious tasks required for flat die clean-outs and colour changes with a mechanized process that is said to clamp and releases the die halves in less than a minute. Also contributing to downtime reduction is a special cart for the die that can be deployed in the extrusion line to facilitate splitting and cleaning without having to take the die off line. UltraLock technology is available only on new dies. Hall 16, stand E67.

Offering the latest in film stretching solutions

Leading supplier of film stretching lines for oriented films, in particular for packaging material and technical applications, Brückner will present its latest technology for high quality PET and PP film structures from 150-1,500 micron. Additionally, in co-operation with Processing Technologies, the company will exhibit sheet lines with a thickness range of up to 10mm.

Brückner ServTec offers various upgrading solutions for existing lines, in order to increase the efficiency, quality and availability of the customer's production lines. The company however does not limit itself to only servicing and upgrading Brückner lines, but will work with equipment from other manufacturers. Hall 3, stand D52.

Small scale vacuum web coating

General Vacuum Equipment developed the Holosec vacuum web coater to meet the requirements of small batch size and high value production in the security hologram and small converter market. It combines General's vacuum web coating technology in one compact production unit (occupying a floor area of about 2x2m) for specialist producers.

Versatility is very important in this market, so the machine has been designed with technology for zinc sulphide, chromium, aluminium and copper coatings. This also meets the need for low volume, high added value materials, without a large capital investment. It is also suitable for developing coating solutions for RFID label and other flexible electronic circuit applications, using low cost PVD technology.

General's precision pattern printing technology is available as an option. The company has been working closely with Bobst Group sister company Schiavi to integrate the latest printing and holographic register sensing technology into the machine, increasing the potential for precision 'in-line' de-metallization processes to be realised in the future. A medium frequency plasma treater is also included.

The Holosec allows quick change-over of both anilox and print sleeves, from job to job. Individual loading of both anilox and print cylinders is said to give extremely accurate print definition and metering of the oil onto the substrate. A Bobst Registron sensor ensures accurate in-line de-metallization to a holographic mark. Maximum web width is 400mm and roll diameter 450mm on a 76mm core. Hall 3, stand C73.

Recycling efficiency doubled

In addition to its own exhibit, Plasmac will be demonstrating the new Alpha recycling extruder on the Primplast stand A26, in Hall 17, working with a blown film production line, reprocessing in-line trims and off-spec reels. The Alpha series incorporates Plasmac's 'ultra high efficiency' SST screw technology and the latest touchscreen PLC control system, combined with other features from the company's Compact series. The new control system, fitted on all machine sizes across the range, facilitates network integration with optional connection to one or more PLCs. Providing enhanced feature functionality such as password authentication, it also has the ability to switch between five on-line languages.

The SST screw technology is said to enable a massive increase in production efficiency, with some models demonstrating a 100 per cent jump in kg/hour rate of output per kW of input power. Also, the screw length, said to be one of the shortest available, has been reduced by up to 12 per cent on some models - further reducing the heat history of the material and consolidating the existing quality of the recycled granule.

With the Alpha, uncut material is fed directly into the reprocessing screw, using one or more of a variety of automatic input devices – such as reel feed unit or trim conveying system. The material is then gently heated and plasticized in the very short, dual diameter screw, which is said to ensure absolutely minimal heat degradation prior to being filtered and extruded through a multi hole die face. Polymer is then cut into granules by a variable speed rotary die face cutter and subsequently cooled in either air or water, depending upon the output and type of material.

The resulting granule is said to be of extremely high quality, with minimal heat history, free flowing with an excellent bulk density and essentially dust-free compared with an agglomerate. It is suitable for mixing by volumetric or gravimetric weigh systems with virgin feedstock at up to 100 per cent, says the company.

Plasmac claims to be one of the few companies to provide a complete turnkey solution incorporating trim handling equipment and even installation, if required. Its recycling extruders are manufactured in screw diameters ranging from 45-120mm and with maximum outputs from 35-700kg/hour. Hall 11, stand H74.

Static stopping and using

Unveiled to the global plastics industry by Meech will be the new 986 pulsed DC feedback intelligent static elimination system, and the 990v2 generator for static charging applications.

The new 986 DC feedback is said to be an easy to use, fully automatic static control system that senses and reacts to changing levels of static charge on a target material. It works in conjunction with Meech's powerful 976-977v3 pulsed DC product range and is easy to install, the company states - after set-up, it is said to require no further manual adjustment.

The 990v2 static generator creates a controlled level of static to provide temporary bonding between materials, one of which must be insulative. Different voltage and current output options are available and multiple connections have been included to link up a network of Meech generator bars or heads for large scale applications. Hall 11, stand B60.

Extrusion excursion

Manufacturer of extrusion lines and components Reifenhäuser will be presenting its latest machines, not only in the Düsseldorf fairgrounds, but also at its Troisdorf R&D centre. During the show, a shuttle service will run from Düsseldorf to Troisdorf, where different lines can be checked out in detail.

The highlight at K 2004 will be a new three-layer blown film line with gearless REItorque extruders and a REIcofly Micropore non contact turner bar system. In addition, the line that will be demonstrated in production will feature a novel non contact sizing cage. A laminator for extrusion coating is a further interesting development to be showcased. Essential components are a roll adjusting system with counter pressure roll, embossing roll and electromechanical gap adjustment, as well as an adjustable contact pressure of 350-1,000N.

In addition to the above lines, Reifenhäuser is presenting a wide array of die components, including the new ISR II slot die with 1,400mm nominal width and in-line gap adjustment, and a five-layer coextrusion feed block with in-line layer distribution of all individual layers.

The RQS Reifenhäuser Quality Service - providing a hotline 356 days around the clock - will also be available on the stand. Hall 17, stand A21.

Slitter builds on success

The new Titan SR8 cantilever slitter rewinder effectively replaces the "very successful" SR7 model. Ten of these high performance secondary slitters have already been sold since the world premiere at drupa, in May. It has a modular design to facilitate future machine enhancements and up-grades to meet changing production requirements.

According to Titan, this concept has also enabled the machine to be competitively priced while providing a higher level of technology, with improved web guidance and web handling capabilities for an even broader range of sensitive, flexible materials. Lightweight, cork covered carbon fibre rollers and 'S' wrap centre drives help to provide the highest quality finished slit reels at speeds of up to 700m/min for web widths of 1,050-1,350mm, the company states.

A compact and user friendly movable 'overhead' operator console replaces the former operator desk, saving considerable space for installation. It has a robust, 'compact flash' embedded PC system to provide the operator with easy to read, visual machine diagnostics and access to stored data, for improved productivity and simple job repeatability. To conform to new EU directives, a strong and operator friendly safety system uses a combination of photoelectric, laser beam and mechanical guarding.

The Titan SR8 offers three web path configurations to suit converters' specific requirements. Optional features include a fully programmable automatic knife positioning system that is said to enable accurate positioning of 10 razor or rotary type knives in only 90s. Hall 3, stand C73.

Economically friendly

It makes good business sense for the plastics industry to lead on environmental responsibility says IMSM managing director Michael Bright. "Operators throughout the plastics industry are under growing pressure to show they are taking the environment seriously but many are still struggling to reach the ISO 14000 environmental standard."

He continues: "We are at K2004 to convince visitors that the development of a sensible environmental management system need not cost the earth, can lead to a more positive profile and can contribute to lower production costs. It makes good business sense for the plastics industry to lead on environmental responsibility."

IMSM says it is focused on assisting smaller plastics companies to add value to their business through raising the standards of both quality and environmental management systems. Hall 5, stand A21-5.

Adding to performance

New Ciba products include Irgatec CR 76, a polymer modifier that allows the use of standard PP spunbond grades or recycled granules from fibre scrap to design melt blown non woven fabrics that have significantly improved liquid barrier and mechanical properties. Better spinability and enhanced flexibility are also promised.

Shelfplus UV 4100 is a new filter for transparent packaging that blocks the broad spectrum UV radiation found in both sunlight and in fluorescent lighting used in stores. This protects the stability and appearance of the package content to increase the shelf life of products in transparent packaging. Irgamod RA 20 chain extender provides PET material with better mechanical properties. It can be combined with effect additives such as Shelfplus UV for superior functionality and performance of PET packaging.

According to Ciba, its new ED (Easily Dosable) product forms are tailored to meet customers' requirements for a number of granular product form features, for problem-free handling of plastics additives. Improvements are said to include a reduced attrition rate, low dust content and a narrow particle size distribution, all of which will result in more precise dosing control, ultimately reducing costs and enhancing productivity, the company promises. Hall 6, stand A27.

The view from F&K

Fischer & Krecke will demonstrate the "extraordinary capabilities" of its Flexpress View web based service and maintenance system, through a live transmission to the stand from a press operating in the company's Bielefeld facility. Flexpress View is an internet based service and maintenance tool which works with extremely high data transmission speed. Said to adhere to the highest security standards, its configuration is unique to each installation, allowing construction of an intranet around the press in which information can be exchanged and operations executed from remote locations. The company will also demonstrate live, remote proofing during the show. Hall 4, stand B37.

Raising the coating curtain

New curtain coating technology that allows application of multiple layers with media based on organic solvents is to be introduced by Polytype Converting. The company says it can also be used to process solventless organic media, such as UV or EB curable coatings. Polytype has curtain coating experience for photographic films and papers, inkjet films and paper, adhesives, thermal, carbonless and decorative papers, foils, and flexible packaging materials. Hall 4, stand C56.