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008.1 A. BOPP and SPT Manufacturers how to turn around part one

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BOPP & Surface Protection Tape
Now Produce cost Effectively Adhesive Tape , Part One
How to Turn Around ?
Think on it now
Task 1
There is very High Rejection
In terms of loose wound , Tight wound Rolls, Telescoping of rolls, Poor Tack, peel , Pin holes, Folding , Wrinkle's
Task 2
It is difficult to earn even 10% profits
On the contrary there is accumulated loss since the Plant was Installed
Task 3
From March 2019 The business totally Down
There is Mad competition on Pricing
Task 4
Lockdown
Business at stall still
Business is at lowest level
Manpower Migration

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008.1 A. BOPP and SPT Manufacturers how to turn around part one

  1. 1. 2017 There is very High Rejection In terms of loose wound , Tight wound Rolls, Telescoping of rolls Poor Tack, peel , Pin holes, Folding , Wrinkle's 2018 It is difficult to earn even 10% profits On the contrary there is accumulated loss since the Plant was Installed 2019 From March 2019 The business totally Down There is Mad competition on Pricing 2020 Lockdown Business at stall still Business is at lowest level Manpower Migration
  2. 2. Cost of Manufacture Depends on ? 01 RAW MATERIAL COST 0302
  3. 3. Cost of Manufacture Depends on ? 01 RAW MATERIAL COST The is a purpose to choose Red Background ? Can you guess why ? Yes. In real sense it is the RED Light Area
  4. 4. Cost of Manufacture 02
  5. 5. 03
  6. 6. So how do we Increase the Gross margin from 15% to Any Guess ?
  7. 7. Yes You are Right . RAW MATERIAL COST And That is why we are here tonight , let us see How we achieve it
  8. 8. Increase the Process speed Reducing the Energy cost Reducing the Manpower cost Reducing the Raw Material Wastage Reducing the Down time during the Process
  9. 9. : by increasing the drying efficiency . This is possible by Modifying the existing drying tunnel , or Installing a New Drying Tunnel. How is this possible ? It is very much possible by switching over to Innovative drying tunnel ( from Floating Hot Air , with Idler support , typical and traditional design to a Direct contact Tunnel ) . How will this change the drying efficiency ? The Drying efficiency will increase form 45 to 50 % to 85 to 90%. More the drying efficiency more will be the drying speed hence more will be the Production speed.
  10. 10. : By adopting the Latest Solar Technology. Invest once in Solar Technology , and produce your own Electricity. India is blessed by the Almighty with min of 10 months in a year with bright sunshine. This will allow you to reduce the Electrical cost upto 25 to 30% . Now use this Electricity to Produce Heat Energy , by using Hot Air , steam or Hot Oil Generators , operating on Electrical Heating system.
  11. 11. : can be reducing by adopting very simple techniques , such as , Organizing smart Material Handling equipment , ( handling Film, Paper rollers strictly on wooden / Plastic pallets, using material handling trollies, handling coated or prior to coating rolls using trolleys , Charging the Adhesive or coating automatically from the drum to the coating tray, monitoring the adhesive flow based on the consumption etc. ) Does it mean that you reduce your Manpower ? Seriously not. You utilise you Manpower smartly , and distribute the available Manpower for multiple location
  12. 12. , while Handling in your plant : Many a times the Raw materials like Film , Paper are mis handled while unloading form the vehicles, they are rolled on the shop floor . In this way most offal few layers on the top are damaged and have to be discarded , and they add to the Wastage of Raw Material as well as Production Time.
  13. 13. Reducing the Raw Material Wastage
  14. 14. Reducing the Raw Material Wastage
  15. 15. variables or challenges in Adhesive Let’s see what are the variables in the Adhesive 1. The Base polymers used to manufacture Acrylic co polymer 2. The % solids content 3. The particle size 4. The pH 5. The Viscosity 6. The expiry date 7. The type of packing 8. The storage condition 9. The handling 10. And last but not the least the cleaning after the coating run is over.
  16. 16. 5. How cautious we are about Quality ? variables or challenges in Adhesive The Base polymers used to manufacture Acrylic co polymer 1 A good Formulation is based on Pure Butyl Acrylate and Vinyl acetate However due to Volatile Market and Prices of Butyl Acrylate , the formulations are altered with more quantity of other polymer or tackifiers and the adhesive is sold . The Adhesive looks alike but with a drop in the Peel and shear Properties. A general tape Manufacturer do not notice any change in the appearance of the adhesive .
  17. 17. 5. How cautious we are about Quality ? variables or challenges in Adhesive The % solids content 2 I am sorry but must mention that many of us do not even know what is solids content ? A new adhesive supplier offers his Adhesive at say 5-10% lower Price than the established Adhesive supplier . Anyone gets tempted to buy the adhesive from the new supplier , without giving a thought on the solids content .
  18. 18. The % solids content Here is an example for you . Suppose the Established supplier is supplying an Adhesive with say 55 % solids ( Mean out of 1000 grams of liquid adhesive , 550 grams remain and 450 grams of water is evaporated , after drying .) at say 65 Rupees a Kg. The new supplier offer the same adhesive( with say 48% solids, what it means is , out of 1000 grams of liquid adhesive , 480 grams remain and 520 grams of water is evaporated , after drying ) at 60 Rupees a kg . Any one , that too a BOPP Tape Manufacturer will be happy for saving 5 rupees , per kg , but now lets check whether he is saving or loosing.
  19. 19. The % solids content Here is an example for you . So what is the outcome From the Established Adhesive supplier you are buying 550 grams of solid adhesive at 65 rupees , that is equal to 118 rupees / kg And From the new supplier you are buying 480 grams of solid adhesive at 60 rupees , that is equal to 125 rupees / kg . Hence you are loosing 7 rupees per kg , for buying a cheaper adhesive . I hope you get my Point ?
  20. 20. 5. How cautious we are about Quality ? variables or challenges in Adhesive The particle size 3 Particle size also plays a very Important role in the quality of the Tape produced. Larger the Particle size , more are the chances of coating defects. You may notice a problem in a particular batch of adhesive . It’s a right time for you to cross check the particle size .
  21. 21. 5. How cautious we are about Quality ? variables or challenges in Adhesive The pH Variation in pH , does not have a severe effect on the quality , as long as the pH is maintained above 6.5 , and this can be very easily adjusted by , adding few drops of Liquid Ammonia . 4
  22. 22. 5. How cautious we are about Quality ? variables or challenges in Adhesive The Viscosity The change in Viscosity matters a lot. Higher the Viscosity , higher will be the coating weight , using the same Gravure Roller or Myer Bar And vice versa . Hence Testing of Viscosity is very essential. 5
  23. 23. 5. How cautious we are about Quality ? variables or challenges in Adhesive The expiry date Expiry Date plays a crucial Role as far as the quality of the Tape is concerned. Hence check the expiry date before opening a new Barrel 6
  24. 24. 5. How cautious we are about Quality ? variables or challenges in Adhesive The type of packing Generally water based adhesives are packed in Plastic barrels and that is fine. But in case if it is packed in a metal barrel than check the adhesive against any contamination. Ferric Oxide contamination can ruin the adhesive due to Oxidation. 7
  25. 25. 5. How cautious we are about Quality ? variables or challenges in Adhesive The storage condition Storage of Adhesive plays a very important role. The Adhesive barrels must be stored under a shade , and without direct exposure to Sunlight. I have seen Adhesive barrels stored outside the Factory shade in open ground , even without a Tarpaulin covering. And what's the result ? 8
  26. 26. 5. How cautious we are about Quality ? variables or challenges in Adhesive They were coated around 26 to 27 grams of dry adhesive per sq. mtr of BOPP Tape , in place of 20-21 gsm. Imagine they were loosing/ wasting almost 23 % of Adhesive , purely due to negligence . Due to open storage the adhesive degradation process starts , thanks to UV Rays and hence the adhesive properties start dropping , within no time. 8
  27. 27. 5. How cautious we are about Quality ? variables or challenges in Adhesive The handling I have visited many Factories in India and have seen a very shabby way of handling the adhesive. At many places the adhesive is charged / or added into the coating tray by hand. One Helper / person is dedicated only to add adhesive . This can be easily done without a permanent or dedicated helper simply by using gravity flow method , or by using a simple attachments , that works on air pressure. 9
  28. 28. 5. How cautious we are about Quality ? variables or challenges in Adhesive The handling You can save on cost of a helper’s salary And also the quality of the BOPP Tape produced How ? 9
  29. 29. Reducing the Raw Material Wastage
  30. 30. 5. How cautious we are about Quality ? variables or challenges in Adhesive How ? 9 a Handling of Adhesive Here is an very cost effective alternative to Adhesive Pumps. You just need a Air Compressor ( 3 HP ) line and the rest you can do it yourselves
  31. 31. 5. How cautious we are about Quality ? variables or challenges in Adhesive How ? 9 b Maintain min possible level of adhesive in tray Right way of 1. Charging Adhesive 2. Adhesive level in tray 3. Tray size This helps Minimising Foam , and wastage
  32. 32. 5. How cautious we are about Quality ? 9 b 1 General Mistakes or Practices followed in the Industry are Wrong way of 1. Charging Adhesive Wrong way Too high Adhesive level in tray Too big Tray size Results Creates maximum Foam , and wastage
  33. 33. 5. How cautious we are about Quality ? 9 b 2 General Mistakes or Practices followed in the Industry are Wrong way of 1. Charging Adhesive Wrong way Too high Adhesive level in tray Too big Tray size Results Creates maximum Foam , and wastage
  34. 34. Reducing the Raw Material Wastage
  35. 35. Reducing the Raw Material Wastage
  36. 36. 5. How cautious we are about Quality ? variables or challenges in Adhesive How ? 9 c Avoid foaming 1. By charging adhesive from the bottom of the tray 2. Maintaining minimum level of adhesive in the tray 3. Avoid dilution of the adhesive by adding extra water , for adjusting the coating weight. 4. For adhesive coat weight adjustment use , alternate Myer bar or gravure cylinder. 5. Dilution of adhesive with water is not a right method for controlling the adhesive coat weight.
  37. 37. How is the Foam Destructive ? This will wipe off your profits 1. Due to huge wastage of Adhesive 2. Create pinholes , craters, uncoated patches
  38. 38. Reducing the Raw Material Wastage
  39. 39. Let’s consider , Case Study no. 1 Generally the features of stock lot are 3. Nonstandard thickness , The Nonstandard thickness will also have the same impact like Gsm Variation. But Incase if there is a variation in Thickness across the width than , it will be a serious issue. The same is explained below via , some sketches/figures
  40. 40. Some Possible variations are as follows Base paper thickness variation across the width ( no / little variation) 60 mic Example 1 Base paper thickness variation across the width 50 mic60 mic Example 2 Base paper thickness variation across the width 60 mic 50 mic 60 mic Example 3 Base paper thickness variation across the width 50 mic 60 mic 50 mic Example 4 O
  41. 41. Base paper ( no / little variation) 60 mic Example 1 Some Possible variations are as follows Now as per Example no. 1 What will be the impact after , assuming , the Adhesive coating is done by Comma ( where the paper + adhesive ,passed through a pre metered gap ) Base paper ( no / little variation) + Adhesive coating 60 mic ( only paper ) Example 1 PAPER + ADH 85 mic ( paper + adhesive ) 25 mic ( only adhesive )
  42. 42. Base paper thickness variation across the width 50 mic60 mic Example 2 Some Possible variations are as follows Now as per Example no. 1 What will be the impact after , assuming , the Adhesive coating is done by Comma ( where the paper + adhesive ,passed through a pre metered gap ) Base paper thickness variation across the width 25 mic Only adh Example 2 PAPER + ADH 35 mic Only adh
  43. 43. Base paper thickness variation across the width 60 mic 50 mic 60 mic Example 3 Some Possible variations are as follows Now as per Example no. 1 What will be the impact after , assuming , the Adhesive coating is done by Comma ( where the paper + adhesive ,passed through a pre metered gap ) Base paper + Adhesive 35 mic ( only Adhesive) Example 3 PAPER + ADH 85 mic ( paper + adhesive ) 15 mic ( only adhesive )
  44. 44. Base paper thickness variation across the width 50 mic 60 mic 50 mic Example 4 Some Possible variations are as follows Now as per Example no. 1 What will be the impact after , assuming , the Adhesive coating is done by Comma ( where the paper + adhesive ,passed through a pre metered gap ) Base paper thickness variation across the width Example 4 PAPER + ADH35 mic ( only Adhesive) 15 mic ( only adhesive )
  45. 45. After studying the thickness variation across the width You will see the variation is adhesive coating thickness, as follows. Example no. Paper Thickness Adhesive Thickness Tensile str. of tape Adhesive Peel Str 1 Uniform Uniform Uniform Uniform 2 One side thick/other side thin One side thin/other side thick more on one side /less at the other side less on one side /more at the other 3 Two sides thick/ thin at center Two sides thin/ thick at center More on Two side /less at the center less on Two side / more at the center 4 Two sides thin/ thick at center Two sides thick/ thin at center less on Two side / more at the center More on Two side /less at the center
  46. 46. Reducing the Raw Material Wastage
  47. 47. Quality ability to handle varies substrates So, what is the corrective step? Improve upon loading and unloading Install simple mechanical devices and cut short the Downtimes How? Material Handling on Shop Floor The Major Areas of mis handling are Incoming Raw Material o Adhesive Barrels Manual Handling : Unloading on used Rubber tires Unloading on floor o BOPP / PE Film Manual handling : Unloading on used Rubber tires Unloading on floor o Changeover on Coating Machine / Converting Machine ( slitting / Slicing ) Manual handling : Unloading on floor
  48. 48. Improper Handling BOPP Film rolls are unloaded directly to shop floor using old Tyres Improper Handling Results into two major losses and the same are overlooked many a times 1. Loss of Material (BOPP Film) A small piece of stone or any other sharp material, can pierce into several layers of film. A 4000-meter Film roll has a circumference of approx. 3 linear mtrs, that is equal to 3.6 sq. mtrs, and if 20 layers are damaged, the total wastage per roll can be almost 72 sq. mtrs or 1.5 kgs of film. This means almost INR 182 per roll. If there are 20 rolls per consignment, the total cost of damage is, 20X INR 182 = INR 3628 / consignment
  49. 49. Improper Handling 2. Loss of precious Production time Main at times, 4 operators are utilized just for unloading the incoming Film rolls. On an average an operator is paid INR 15000 / pm, or INR 600/per day, or INR 75 / per hour Hence considering 4 hrs. spent on unloading The cost of unloading one consignment is approx. INR 75 / per hour X4 hours X 4 person = INR 1200 / consignment Hence the cost of mishandling is INR 4828 / consignment
  50. 50. Proper Handling Use of Wooden / Plastic pallets is highly recommended and unloading should be done on pallet trucks Incoming Raw Material o Adhesive Barrels Manual Handling : Unloading on used Rubber tires Unloading on floor
  51. 51. Material Handling on Shop Floor Changeover on Coating Machine / Converting Machine ( slitting / Slicing )Manual handling : Unloading on floor While Coating Film rolls are loaded on the machine manually Many a times 4 operators are employed for the same Here there are some losses like damaging the film edges while loading Damaging one of the operators physically Loss of production time to the tune of 30 minutes per change over In general , in many factories 4 people are utilised for Roll loading or Un loading on M/c & how workman purposely delay the process is a very Interesting thing to watch
  52. 52. After Coating Adhesive coated Film rolls are unloaded on the machine manually Many a times 4 operators are employed for the same Here there are some losses like damaging the film edges while loading Damaging one of the operators physically Loss of production time to the tune of 30 minutes per change over Many a times there are minimum 2 such change over With This kind of attachments on the Coating Machine & Slitting Machine, just one operator can carry out the changeover with lot of ease, Quite fast, And with no chances of any accident The Film rolls are totally free from any kind of damage Losses due to Changeover on Coating Machine / Converting Machine ( slitting / Slicing ) Manual handling : Unloading on floor Can be very easily avoided by installing , I beam mounted chain pully blocks Or I beam mounted Air Hoists
  53. 53. This can avoid a Precious Time loss of almost 1 to 1.5 hour per shift of 8 hours This amounts to nearly 18.75% , Time wastage. Assuming a per shift cost of INR 10000 for a modest small unit of BOPP Tape manufacturing The indirect loss is INR 1850 per shift , that is equal to INR 46875 / per shift In general BOPP tape manufacturers operate in 2 shifts of 8 hour Or 2 shifts of 12 hour Hence the Loss per day / 2 shifts of 8 hour could be INR 93750 Hence the Loss per day / 2 shifts of 12 hour could be INR 140625
  54. 54. Down Time Losses on Machine , while cleaning the Idler Rollers inside the Tunnel , and near the Printing Station All of us are aware of the Time lost / Down Time on the Main Coating Machine , due to the need of cleaning the dirty Idler Rollers inside the Tunnel or near the Printing stations. This Down time proves to be very expensive , sometimes even 4-5 hours are lost due to cleaning. There is no doubt that the Idler cleaning is essential , however at the same time this Down time can be easily avoided if a proper precaution is taken. The Idler rollers should be wrapped or covered with Silicone paper / silicone polyester film once in the beginning of the week. This may take few hours in the beginning , however the Down time that is occuring every day could be easily avoided .
  55. 55. The last but the most important one is the Profit Here we all will agree that the quality and quantity will play a major role in controlling the cost. How ? Let us analyze the same one by one. Another major issue with many tape Manufactures ? Give a guess ?????? Yes You are right There is no testing facility. Lack of Quality Control And Quality Assurance Testing I am sure some of you might be shocked to know this , but trust me I have seen some manufacturers , where there is no other testing equipment except a mere Thickness gauge and a GSM balance Quality Control
  56. 56. Quality can be monitored and controlled while manufacturing. The Product will have good quality and the wastage will be below 2-3 % or Rejection will be avoided. The basic tests as mentioned below can help you to produce a right product . Web Thickness and GSM Adhesive thickness and GSM The residual solvent / water under 0.2 % Web shrinkage under control Proper rewind tension ( the rewound roll is never rock hard , etc. Quality Assurance Quality cannot be rectified or altered after the coating or slitting process is over. Quality Testing is only possible , but the properties cannot be altered. The reworking , in many a case is impossible , And Or the same is very expensive if possible .
  57. 57. Conclusion Tape manufactures Can you survive the cutthroat Competition . The answer is : YES You can How ? Aim at Minimum Wastage , Zero Defect or Rejection and Increase the Productivity. Choose , Right quality Raw Materials , A correct machine Trained manpower Bare minimum Testing equipment Draw product specifications, process parameters and follow them strictly And most importantly try and Increase the Productivity by 25 % , 35% or even 50% By increasing the productivity or by Increasing the Production , the manufacturing Over Heads will go down and this will help you in improving upon the Profit and Loss account.
  58. 58. Reducing the Raw Material Wastage Install , CCTV Camera’s at Coating end, Rewind end, and In between Connect these to a PC or even to your Cell and make some one responsible for even coating This will not cost you more
  59. 59. Quality ➢ mismatching rollers , in terms of width , in terms of diameter RUBBER ROLLER Width is lesser than Gravure Roller GRAVURE ROLLER Width is more than the Rubber roller THE WEB , is lower than rubber roller Above is a typical Example of mismatching roller width as well as the web to be coated. This will result into lot of wastage and Rejection HOW or WHY , is explained in the next few slides
  60. 60. Mismatching rollers , ( width ) Web Width say 1020 mm Rubber roller Width say 1080 mm Gravure roller Width say 1140 mm The Impact of this mismatch The rubber roller picks up adhesive ( fuller width of 1080 mm ) from gravure roller ( of 1140 mm ) However the web width is only 1020 mm. This results in the web being coated , to entire width of 1020 mm , and sometimes this causes adhesive being coated on the backside of the web also. All this causes major challenges in handling the web after coating , inside the drying tunnel , as well as during Rewinding at rewind end HOW / WHY , IS EXPLAINED IN THE NEXT SLIDE
  61. 61. Mismatching rollers , ( width ) Web Width say 1020 mm Gravure roller Width say 1080 mm Rubber roller Width say 1140 mm The Impact of this mismatch The rubber roller picks up adhesive ( fuller width of 1080 mm ) from gravure roller ( of 1080 mm ) However the web width is only 1020 mm. This results in the web being coated , to entire width of 1020 mm , and sometimes this causes adhesive being coated on the backside of the web also. All this causes major challenges in handling the web after coating , inside the drying tunnel , as well as during Rewinding at rewind end HOW / WHY , IS EXPLAINED IN THE NEXT SLIDE
  62. 62. Mismatching rollers , ( Diameter ) Web Width say 1020 mm Rubber roller Di say 200 mm Gravure roller Dia say 300 mm The Mismatching diameters causes a sort of pull by the roller of higher diameter , and hence coating problems, web stretching etc. All this causes major challenges in handling the web after coating , inside the drying tunnel , as well as during Rewinding at rewind end HOW / WHY , IS EXPLAINED IN THE NEXT SLIDE
  63. 63. Mismatching rollers , ( Diameter ) The Mismatching diameters causes a sort of pull by the roller of higher diameter , and hence coating problems, web stretching etc. All this causes major challenges in handling the web after coating , inside the drying tunnel , as well as during Rewinding at rewind end HOW / WHY , IS EXPLAINED IN THE NEXT SLIDE Web Width say 1020 mm Rubber roller Di say 300 mm Gravure roller Dia say 200 mm
  64. 64. Mismatching rollers , ( width ) The rubber roller picks up adhesive ( fuller width of 1080 mm ) The Gravure roller picks up adhesive up to 1140 The web get coated to entire width of 1020 mm , and sometimes this causes adhesive being coated on the backside of the web also. Web Adhesive Adhesive on edges , at the back side NOW LET US SEE HOW THE UNWANTED BACKSIDE ADHESIVE CAUSES WEB HANDLING PROBLEMS, IN THE NEXT SLIDE
  65. 65. DRYING TUNNEL ADHESIVE COATED SIDE UNWANTED ADHESIVE COATED ON EDGES OF BACK SIDE GRAVURE ROLLER ADHESIVE TRAY The above sketch will explain you how the adhesive is getting coated on the backside edges. UNWANTED ADHESIVE COATED ON EDGES OF BACK SIDE, later on comes in contact with all the idler rollers in the tunnel as well as the other rollers.
  66. 66. DRYING TUNNEL UNWANTED adhesive UNWANTED ADHESIVE / back side NOW LET US SEE HOW THE UNWANTED BACKSIDE ADHESIVE CAUSES WEB HANDLING PROBLEMS, IN THE NEXT SLIDE The Back side adhesive on the edges , than starts sticking to each and every roller/ Idler roller and is responsible for creating wrinkles, creases and the web handling is more and more difficult. This results in poor quality rewinding, and the coated rolls with full of wrinkles, folds , and result into huge wastage and rejection. The entire machines / rollers need to be stopped and clean thoroughly.
  67. 67. RUBBER ROLLER Much higher diameter of rubber roller than the gravure roller GRAVURE ROLLER, diameter much lower than the rubber roller THE WEB, width lower than rubber roller Above is another Example of mismatching roller diameters as well as the web to be coated. This will result into lot of wastage and Rejection
  68. 68. Quality ➢ mismatching coating trays All these factors add to the Quality of the finished product . How ? You will see some illustrations in the next slide
  69. 69. Too big or too deep tray Also leads to more wastage or rejection RUBBER ROLLER GRAVURE ROLLER THE WEB
  70. 70. Too thin tray Also leads to more wastage, like adhesive coming out of tray during high speed operation or rejection RUBBER ROLLER GRAVURE ROLLER THE WEB
  71. 71. Reducing the Raw Material Wastage
  72. 72. Un uniform thickness or salvage group creates higher wastage
  73. 73. Mismatching width of webs result into higher wastage Web Adhesive Liner Widths not matching
  74. 74. Packaging Material Quality Especially the quality of paper cores can reduce the wastage to a great extent. Poor quality paper cores , might result into , core collapse and unwanted but very expensive rejection. For example , just for the sake of saving some money the paper core wall thickness or the quality of paper , or the quality of paper glue is compromised . No doubt there is some saving , but this is a short term saving. The value of the Adhesive tape wound on this paper core is almost 10 times of the value of paper core . Hence the outcome is there is loss incurred to the tune of more than 10% , due to wrong select of paper core. Same is the case with packaging cartons. A 3 ply carton , in place of 5 ply might save some money , but the same will result in huge wastage of quality product packed inside , at the end Quantity , will also be contributing to the wastage
  75. 75. This is a Typical Example of total rejection of a good quality Adhesive tape , just due to inferior quality of paper core . Hence a saving of mere 5% in the coat of paper core can result into very ejection of finished product
  76. 76. This is a Typical Example of total rejection of a good quality Adhesive tape , just due to inferior quality of corrugated box . Hence a saving of mere 5% in the coat of paper core can result into very ejection of finished product
  77. 77. Processing Equipment Quality Plays a very vital role and depends on the ➢ Accuracy of the machine , especially the Coating Heads, the Lamination , the unwind and rewind tension ➢ ability to handle varies substrates ➢ types of coatings that can be handled ➢ the ease of handling ➢ the ease of change over's ➢ the machine control panel user-friendly or complicated ? ➢ coat ability, the coating methods available , faulty or unsuitable coating methods ➢ mismatching rollers , in terms of width , in terms of diameter ➢ mismatching coating trays ➢ machine drying tunnel efficiency All these factors add to the Quality of the finished product . How ? You will see some illustrations in the next slide
  78. 78. Quality ➢ Accuracy of the machine , The accuracy of the machine plays a very crucial role in the quality of the finished product and there by the amount of rejection or wastage.
  79. 79. Quality ➢ Accuracy of the Coating Heads, Uniformity of the Nip , or the Gap between the coating rolls , The dynamic balancing of the coating rolls Surface evenness of the coating rolls contribute to the good quality of final product
  80. 80. Quality ➢ Accuracy of the unwind and rewind tension
  81. 81. Many a times a compromise is done on the Rewind and Unwind tension control systems. A relatively old clutch and brake system is preferred in place of auto tension controlling devices. No doubt you save some Money in terms of low capital Investment But the result ? You keep losing money every day in terms of wastage and rejection, and sometimes may be the reputation or loss of the customer Why this happens ?
  82. 82. Why ? Because the rewind tension set at the beginning of the coating is say “ X ” As the coating progresses and the diameter at the rewind end increases , there is a increase in the tension. This affects the line speed. As a matter of fact the line speed increases , and This results in improper drying, increase in residual solvent , unwanted wrinkles and creases , which ultimately results in higher wastage or sometimes rejections.
  83. 83. Quality ➢ ability to handle varies substrates
  84. 84. Reducing the Raw Material Wastage
  85. 85. Reducing the Raw Material Wastage
  86. 86. Shrikant Athavale Pune Maharashtra Cell : 0091 9850242282 / 7498956621 Website : https://spatechnicaladviser.com/ +91 9850242282 / +91 7498956621 https://www.linkedin.com/in/shrikantathavale/ https://www.facebook.com/shrikant.athavale live:spathavale_1 https://www.youtube.com/channel/UCgovR9rsYHWKLzdg4N5eLSQ?view_as=subscriber
  87. 87. 92 SPA TECHNICAL ADVISOR Website : https://spatechnicaladviser.com/

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