2005 TAPPI PLACE Conference 9/25/2005-9/28/2005 Caesar's Palace Las Vegas, NV

Transcription

1 2005 TAPPI PLACE Conference 9/25/2005-9/28/2005 Caesar's Palace Las Vegas, NV Updated: 9/23/ :10:29 AM

2 9/26/2005 Session: :00 am 9/26/2005 Session: :30 am :00 am 8:00:a.m. - 9:15:a.m. Plenary Session Warren Durling, Clorox Services Company Optimization by Integrating Engineering and Business Models David R. Roisum, Finishing Technologies Inc., Speaker To optimize is to find the best solution given certain conditions and constraints. What is meant by best and how to find it has received scant attention. To the engineer, best may be quickest, strongest, most reliable and so on. The engineer will have models to determine whether one solution or setpoint is better than another based on objectives such as these. Best in business is quite different. It means to maximize profit or minimize loss. The economist or accountant also has models. Note the obvious disconnect between the objectives of engineering and business models. This disconnect has hindered us from finding a practical best to improve profit on the plant floor. Simple questions like what is the best tension to run have no useful answers from a strictly engineering or business viewpoint. This paper begins by defining best for several familiar examples. However, it quickly concludes that the only best that makes sense in an industrial environment is that which will minimize total costs. To find this best we must integrate engineering and business models. This technique developed here is very powerful, flexible and adaptable approach. The technique can be applied explicitly using calculus or similar numerical techniques when cost functions are well known. Even more flexible is an implicit approach which can be used when very little is known about costs. Five web handling examples are used to illustrate this problem solving technique. These examples include a variety of objectives such as optimum rejection levels, core waste, web tension, layon roller nip and water flow rate. These examples show how it is easy to combine apples and oranges, such as waste and delay, when one converts to a common denominator of cost. 9:30:a.m. - 11:00:a.m. Structure Optimization Bob Dietrick, International Paper Understanding Why Adhesion in Extrusion Coating Decreases with Diminishing Coating Thickness, Part I: Penetration of Porous Substrates Barry A. Morris, DuPont Pkg. & Ind. Polymers, Speaker It is well known that in extrusion coating the adhesion of PE to paperboard and other porous substrates decreases with decreasing thickness. Several hypotheses are proposed for the origin of this decrease, including a reduction in time for oxidation, faster cooling in the air gap, and more rapid quenching in the nip. A model of the penetration of the molten polymer into the substrate shows that the greatest effect is cooling in the nip; thinner coatings have less time to flow into the interstices of the substrate once contact with the chill roll is made. The model results agree well with experimental adhesion data from the literature. How Sealant Film Choice Can Affect a Laminated Structure s Properties David G. Timm, Charter Films, Speaker When designing films for use as sealant layers, there are some functionalities that are well translated into the laminations properties, especially the sealant functionality that the film provides. Some properties, such as toughness, stiffness and body are not well understood once the films have been laminated to oriented substrates, primarily polypropylene (OPP) or oriented polyester (PET). Oriented substrates, such as OPP and PET, demonstrate orders of magnitude increases in stiffness over typical blown PE-based films. Therefore, when combining, through lamination, a soft, amorphous substrate, along with a rigid, crystalline substrate it is difficult to understand what the composite lamination s properties will be. Packaging engineers, marketing departments, and brand managers would all desire to be able to understand, and even better, predict, these interactions.

3 2-3 10:30 am Using Primers in Combination With Adhesive Tie-Layer Resins or Their Blends to Make Structures With Unique Performance Richard B. Allen, Mica Corporation, Speaker We have blended adhesive tie-layer resins with commodity resins and made structures with excellent adhesion and water resistance. Primers were critical to success and good results were obtained even at very low extrusion temperatures. Potential benefits include improved adhesion, water resistance, processability and productivity. We also tested unblended adhesive tie-layer resins, such as those used in the co-extrusion process. Adhesion and water resistance were greatly improved by using primers. 9/26/2005 Session: 3 9:30:a.m. - 11:00:a.m. Process Optimization Ken E. Klaber, Equistar Chemicals 3-1 9:30 am Inertial Measurement of Roller Parallelism - a New Approach to Solving an Old Problem :00 am Sebastian Busch, PRUFTECHNIK Service, Inc., Speaker Web handling in converting - Roller parallelism as a frequent root cause Many web handling problems can be traced back to roller alignment issues. Symptoms range from fissures and creases in the product to vibrations in the machinery and, ultimately, to unscheduled stops in production, resulting in downtime and waste material. Benefits and limits of conventional alignment techniques While roller parallelism is reasonably easy to determine and to assure with conventional alignment methods, it has traditionally been hard to determine whether a given product quality or process quality issue can be traced back to roll misalignment. This is because traditional methods of aligning rolls depend on line of sight and a certain degree of proximity between rolls. Application of 3D Flow Simulation towards Blown Film Die Optimization :30 am John Perdikoulias, Compuplast Canada Inc., Speaker Jiri Vlcek, Compuplast International Jiri Svabik, Compuplast International Inc. This paper demonstrates how a 3D Finite Element Method (FEM) flow simulation can be applied towards the analysis and optimization of a spiral mandrel type die for the production of blown (tubular) film. The paper also shows how a 3D FEM flow analysis can identify a die design flaw that would otherwise be difficult to solve. How to Improve Cross-Machine Drying Profiles William R. Henry, ASI Advance Systems Inc, Speaker Be it a flotation, roll-support, through-air or infra-red dryer, the ability to produce an even drying profile across the entire width of the web is critical for producing a consistent product and achieving high production efficiency. Existing dryers may have inherent drying deficiencies or may develop uneven drying profiles over time. The cause, effect and resolution of several profile problems are discussed with special emphasis on improvements that can be implemented in existing dryers. 9/26/2005 Session: 4 9:30:a.m. - 11:00:a.m. Building Better Barrier The session includes three papers on non-traditional high barrier solutions, including high oxygen barrier primers and specialty polyethylene resins providing imrpoved water and flavor barrier Jose M. Torradas, E. I. du Pont de Nemours & Co.

4 4-1 9:30 am A New Family of shdpe Polymers for Enhanced Moisture Barrier Performance :00 am Norman D. Aubee, Nova Chemicals, Speaker Sarah K. Marshall, Nova Chemicals Patrick Lam, Nova Chemicals Conventional Ziegler-Natta catalyzed HDPE homopolymer is used as a moisture barrier in the production of multilayer films for packaging dry food-stuffs and other moisture sensitive products. Barrier properties for these HDPEs are improved by narrowing the MWD and decreasing the molecular weight, at the expense of melt strength and processability. NOVA Chemicals Corporation has developed a new class of shdpe resins for moisture barrier applications utilizing Advanced SCLAIRTECH Technology and NOVA Chemicals proprietary single site catalyst. These new shdpe resins offer superior moisture barrier properties, exceeding the barrier performance of multilayer, multiple HDPE component films, without compromising processability. TOPAS Cyclic Olefin Copolymers in Food Packaging - High Aroma Barrier Combined with Low Extractables :30 am Randy D. Jester, Ticona, Speaker Films of LLDPE, cyclic olefin copolymer (COC) and blends of the two were subjected to extraction testing under conditions of 10% ethanol in water at 60oC for 24 hours. Extractables were examined by GC/MS. Total extractables in ng/cubic cm. were 35 for the LLDPE and 6.6 for COC. Films were also evaluated for aroma/odor barrier using d-limonene, onion, and sardine. A 80% COC / 20% LLDPE blend film was found to have ~ 7 times the barrier of a 100% LLDPE film for d-limonene and 5X and 3X better barrier to onion and sardine odors respectively. Scalping propensity of COC for d-limonene, a major flavor component in orange juice was evaluated and found to be similar to that of LLDPE. Placing a layer of COC as the food/beverage contact surface in a package will reduce off-taste in container contents and reduce aroma loss / odor. Adding Oxygen Barrier to Adhesive Laminations Jessica C. Bodine, Mica Corporation, Speaker It has been previously reported that barrier primers contribute adhesion and oxygen barrier to extrusion coatings and extrusion laminations. The same technology allows barrier primers to contribute these properties to a different market: adhesive laminations. Coating of a barrier primer, oxygen transmission rates, adhesion and adhesive lamination will be discussed. 9/26/2005 Session: 5 11:30:a.m. - 1:00:p.m. New Technology Showcase Laurie Beth T. Pestle, Marketing Management Center :30 am :35 am :45 am Improved UV Stability of Urethane Adhesives David Horst, Ciba Specialty Chemicals, Speaker Maintaining low color upon UV aging is very challenging with urethanes. Ciba Specialty Chemicals has developed UV stabilization packages that allow urethane adhesives to pass stringent footwear UV tests. Thin Barrier Layers - More with Less Beth M. Wells, Black Clawson., Speaker Thinner multiple barrier layers create a lower cost, superior product. The Black Clawson Microlayer Feedblock is able to make layers as thin as 1% with the possibility of thinner yet. New Styrenic Block Copolymers in Blends and Coextrusions with Polyolefins for Film Applications Richard P. Schmidt, Kraton Polymers, Speaker Presentation will showcase an innovative use of styrenic block copolymer, SBC's, materials in flexible packaging applications. A combination of these SBC's in monolayer film structures in blends with polyolefins produce unique film properties. Further innovative films are produced by combining these SBC's with polyolefins and other materials in coextruded film structures.

5 5-5 11:50 am Michem Prime the Latest Innovation in the Series :55 am Martin A. Cohen, Michelman, Inc., Speaker Michem Prime specialty dispersions are uniquely suited to today s flexible packaging needs. Michem Prime provides a clear, flexible, FDA-compliant barrier to water, grease, and solvents in addition to low heat-seal temperatures and high hot-tack. Commercial applications include film, paper and foil laminating, metallized paper, extrusion coating, nonwovens, textiles, and more. Airflex EF9100: A Novel Barrier Coating for Grease Resistant Packaging Ronald B. Jones, Air Products Polymers L.P., Speaker Paper substrates used in food packaging typically are coated and / or treated to prevent penetration of oleophobic materials such as grease, oils and fats. In Europe this is typically accomplished by applying either polyethylene or polyester in an off-machine extrusion process. In North America, fluorochemicals are typically used in these applications. Fluorochemicals, however, are not viewed favorably in either Europe or North America due to bioaccumulation issues, and have recently come under close scrutiny when used in food packaging grades. The paper and packaging industries are searching for alternatives that not only provides comparable performance but can also be applied on the paper machine :00 pm :05 pm :10 pm :15 pm :20 pm This paper will discuss the recent development of an aqueous barrier coating that imparts oleophobic properties to paper. This non-fluorochemical coating is non-blocking yet flexible enough to protect fold areas making it ideal for packaging applications. This novel technology is safe for use with US and German food packaging clearances. The coatings are inherently solvent resistant and potentially heat sealable. Furthermore, paper coated with these developmental coatings is repulpable and readily recyclable. New Patented Winder Technology for Inline Slitting and Winding Large Diameter Rolls on Small Diameter Cores R. Duane Smith, Black Clawson Converting Machinery, Speaker Black Clawson Converting Machinery Inc., Fulton, New York, introduces their recently patented winding technology for high speed in-line slitting and winding of large diameter rolls on small diameter cores. The Advanced Technology SurfaStartTM (ATS) winder eliminates the shaft critical speed and deflection challenges that are posed by in-line slitting and winding large diameter rolls on 3"ID cores. The ATS winder winds materials that can be surface wound, such as films, non-wovens, papers, paperboards, and composites. These materials can be wound up to 62" diameter at speeds up to 2500 fpm on 3"ID cores. A Novel Approach for Coextruded High Modulus Clarity Shrink Film Lawrence Szmutko, Chevron Chemical Company, Speaker mpact Polyethylene D350 & D449 can be used to produce unique films with outstanding sparkle, clarity, gloss, modulus, and shrink for use in point-of-sale packaging. They are unique to the industry in that a film structure using mpact polyethylene can combine traditionally conflicting properties into one coextruded film. Zincometal Dominique G. Gallou, Dienes Corporation, Speaker Generation IV Oxygen Barrier-Primer Bruce W. Foster, Mica Corporation, Speaker Mica Corporations's efforts to develop a robust oxygen barrier-primer have recently resulted in a significant improvement in the utility of this exciting technology. MICA M-2802, our Generation IV product, combines the excellent processing, adhesion, and oxygen barrier performance of the Generation III material (M-2345) with significantly enhanced performance under exposure to high humidity. New Burner Design Eliminates Laning Joseph D. DiGiacomo, Flynn Burner Corporation, Speaker For coating, laminating or printing lines operating at high line speeds (in excess of 2500 fpm (760 m/min) using flame surface treatment, laning (or non uniform treatment) is a problem. Conventional ribbon burners as well as drilled port burners have not been able to solve this problem. This burner eliminates laning.

6 :25 pm SURPASS FPs016: Fractional Melt SSC LLDPE Todd E. Maples, NOVA Chemicals, Speaker Nova Chemicals' latest film product introduction from their proprietary Advanced SCLAIRTECH technology, is a fractional melt SSC LLDPE being marketed under the SURPASS brand. FPs016 boasts the highest melt strength in the industry. With incredible toughness, this resin provides strong value drivers for converters, brand owners and consumers in markets such as food packaging, consumer packaing, medical packaging and many others that consistently seek the latest and greatest technology. 9/27/2005 Session: 6 8:00:a.m. - 10:00:a.m. Additives; Understandings and Applications Amy B. Hitchcock, Voridian Div Eastman Chemical 6-1 8:00 am 6-2 8:30 am 6-3 9:00 am Polymer Processing Additives and Melt Fracture in Blown Film: Die Geometry Considerations Paul Neumann, Dyneon - a 3M Company, Speaker The die geometry was investigated to gain a better understanding of the polymer processing additive (PPA) coating mechanism in a blown film extrusion process. In particular, the land length of the die, the extrusion throughput rate, the width of the die gap, and the apparent shear rate at the die wall were systematically varied to identify optimal processing conditions and die geometry configurations for rapid PPA conditioning. The results show that PPA efficiency improves as the length-to-gap ratio of the die increases, particularly at low shear rates. This is consistent with a coating mechanism based on PPA migration from the melt to the die surface. The Influence of Process Aids on Zig-Zag Type of Interfacial Instabilities in Film Blowing Multi- Layer Flows Martin Zatloukal, Tomas Bata University, Speaker The effect of process aids on the zig-zag type of interfacial instabilities in film blowing multi-layer flows has been investigated experimentally as well as theoretically. For deeper understanding of the PPA role in these types of the flows, new slip model based on 'effective continuum methods' for the description of the slip was developed and used. The Use of Calcium Carbonate in Polyolefins Offers Significant Improvement in Productivity James E. Cara, OMYA Inc. Lane G. Shaw, OMYA Inc. Mike Roussel, OMYA Inc., Speaker Allen R. Guy, OMYA Inc. The thermal conductivity, specific heat, and thermal expansion characteristics of calcium carbonate offer the ability to improve fabrication productivity and performance of physical properties. This paper will present case studies of plastics processing applications including blown films, extrusion coating, sheet extrusion / thermoforming, and extrusion blow molding. It is the attempt of these studies to show that the proper selection of calcium carbonate in conjunction with an optimized masterbatch carrier resin is required to achieve the desired productivity improvement. It is the unique selection of calcium carbonate and carrier resin that maintains or improves the physical properties for these respective applications.

7 6-4 9:30 am 9/27/2005 Session: 7 Discoloration Resistant Polyolefins: Part IV; Gamma Irradiated LLDPE Film David Horst, Ciba Specialty Chemicals, Speaker Roswell E. King, III, Ciba Specialty Chemicals The preservation of physical properties and aesthetics are two important aspects of the film industry. As such, forethought and care need to be taken in terms of the type of polymer and stabilization systems that are used to derive robust and attractive film products. For most applications, a combination of a phenolic antioxidant and a phosphite melt processing stabilizer can provide the base stabilization that is necessary to provide the retention of physical properties, good processability, and long term thermal stability without compromising the overall aesthetic appearance of the film product. However, in selected end-use applications, it is particularly desirable to have film products that do not discolor during initial processing or while the product is kept in storage. Under a selected set of circumstances, certain types of phenolics have been shown to be susceptible to discoloration, due to inadequate stabilization, harsh processing, film storage with oxides of nitrogen (pollution), and various types of ionizing radiation. In particular, gamma irradiated polyolefins films are finding a variety of end use applications in areas such as medical packaging as well as hygiene related articles where sterilization plays a key role in the life cycle of the plastic product. There is also significant potential with food packaging. While this sterilization technique is valued by end users, the stress on the plastic article is quite significant in terms of not only maintaining the original physical properties of the product, but also it s aesthetic appearance. The study described below was carried out in a film grade linear low density polyethylene where phenol and phenol free stabilization systems were compared in regard to their ability to maintain physical and aesthetic (discoloration) properties of the polymer. The results of this study demonstrate that phenol free systems were better than the phenol based systems. 8:00:a.m. - 10:00:a.m. Productivity Developments-Machinery Designs to Improve Efficiency The ten papers that will be presented in this session (and the continuation in session 10) will include recent developments in Extrusion Dies and Control Systems, Servo Air Knife Systems, Benefits of Automatic Slitter Positioning Systems, Advancements in Melt Fracture and Static Elimination Systems, Advancements in Automatic Splicing Systems, New Developments in Gearless Press Technology, Implementation of On-line Web Inspection Systems, Advancements in Melt Fracture Elimination Technology and Non-nuclear Gauging Systems. This information packed Session promises to provide many useful new technologies that you can take back to help improve the Productivity and Profitability of your Web Production and Converting Operation. R. Duane Smith, Black Clawson Conv. Mach. Inc :00 am Automatic Servo Positioned Air Knife Systems for Optimal Cast Film Quenching Beth M. Wells, Black Clawson Conv. Mach. Inc. Fred Suppon, Black Clawcon Conv. Mach. Inc., Speaker It could very well be that the days of cast film manufacturers running the same product day after day without changeover are fast becoming a thing of the past. With demands increasing for more custom blends, bringing new products to market and shorter runs, the film industry has seen a need for quicker changeover between products, less down time, less set up time and the ability to obtain spec on a product in less time from start up. One response to this demand is an innovative new servo positioned air knife system with enhanced manual features as well, that has been developed to help address these issues by providing multiple axis position repeatability, stable air pressure and velocity, consistent air temperature control and more user friendly set up. These features have all been combined into one system that provides optimal cast film quenching as well as gentle pressure to lay the film smoothly on the chill roll and minimize the entrapped air layer between the film and the chill roll with superior repeatability over traditional air knives. This paper will examine these and other features and list expected benefits.

8 7-2 8:30 am 7-3 8:45 am 7-4 9:00 am 7-5 9:15 am 7-6 9:30 am Improving Productivity with Automated Slitter Positioning Quino Lorente, Tidland Corporation, Speaker Automated slitter positioning technology offers many opportunities to improve productivity. Fast and accurate slitter setups increase production capability and flexibility. Automation improves product consistency, minimizes tool wear, and reduces worker exposure to production hazards. Automation also enables synergistic integration of the automated slitting system with other management and production systems. Achieving the benefits of automated slitter positioning depends upon installing slitting system hardware and controls that are appropriate for the application. Many types of automated slitting systems are available and numerous factors must be considered when choosing an automated slitting system to achieve maximum productivity improvements. Benefits of Automatic Computer Positioning Systems David A. Rumson, Dienes Corporation, Speaker This paper and information is based upon direct feedback from end users who have enjoyed the benefits of modern Automatic Slitter Positioning Systems. A questionnaire was sent asking for general information comparing relative production improvement realized from installation of an automatic slitter positioning system that replaced a manual system. Although this is not a scientific survey it does identify key finishing and converting improvement potential for end users weighing the purchase of an automatic slitter positioning system. Benefits of New Technology Ionizers for Web Handling Scott Shelton, Simco Company Inc., Speaker Ionizers are critical to the web handling process, controlling electrostatic charges to enhance product quality and throughput. In solvent coating and printing processes, they are critical to safety, reducing the chance of fires and explosions. All ionizers require periodic cleaning and performance verification, but this is rarely done due to lack of understanding of the importance and little knowledge of the ionizers and how to evaluate and service them. New technology ionizers solve these problems, offering constant monitoring of system operating status and performance. Local display or remote computer display indicates when maintenance is required. Fully-Integrated Mulit-Station Static Control System With Web Charge Verification Mark Blitshteyn, ION Systems Industrial, Speaker Static neutralizers on web coating lines have traditionally been add-on devices, installed and often forgotten until static would cause quality or safety problems. The paper describes an advanced static control system with long-range neutralizing capabilities which measures the ion current flowing to the charged material and calculates charge on the web before and after neutralization. Functions of this system can be integrated with the line s controls to communicate diagnostics and performance information over industrial networks. Improving Production Efficiency of Flexible Film Printing Lines by the Print Control and Changeover Benefits of Gearless C.I. Presses Mick Karchinski, Paper Converting Machine Company, Speaker Thomas J. Jacques, Paper Converting Machine Company Major global forces are changing the structure and focus of the global packaging industry. As a result of the so-called Wal-Mart Effect the drive to drastically reduce costs through economies of scale and increased production efficiencies flexible packaging suppliers are responding in two major ways: Consolidate market share worldwide to increased size/scale Improve internal production efficiency of converting lines The goal of this paper is to give some insight into the industry as a whole, review the actions of some major players, and then, delve into the fine details of improving production efficiency of flexible film printing Lines by the print control and quick changeover benefits of gearless central impression (or C.I.) drum flexopresses.

9 9/26/2005 Session: :00 am 8-2 8:30 am 8-3 9:00 am 8:00:a.m. - 10:00:a.m. Advancements in Retort Packaging Flexible retort packaging is becoming an increasingly attractive alternative to cans in the marketplace. However, many industry professionals are unsure of what contitutes "typical" retort conditions, how to effectively test these during the product development cycle, and what the latest technologies are in flexible retort packaging. This session presents a comprehensive overview of the latest technology in flexible retort packaging from may different viewpoints. Presentations to be made by a Clemson University professor, a retorot packaging co-packer, an adhesive supplier, a clear barrier film supplier and a high performance additive supplier. Dante F. Ferrari, Celplast Metallized Prod. Ltd. Introduction to Retort Pouch Technology Scott Whiteside, Clemson University, Speaker Retort pouches have been in existence for several decades with the only major market being MRE s for the military. Since the late 1990 s, retail food products in retort pouches have experienced substantial growth. Much is known about processing shelf stable food products in rigid, metal cans, but the processing technology for retort pouches is different. This presentation will present an overview of current processing technology for retort pouches. Retort Flexible Pouches: Selecting a Co-Packer Winson Kutte, Palmetto Food Packaging LLC, Speaker The food industry continues to evolve and become ever creative in its approach to food production, food packaging, food marketing, and food delivery (both at the retail and food service levels). This combined effort at all levels of the food delivery chain is aimed at increasing sales and market share, of course, by giving the consumer a sense that they are not only purchasing a product, but more importantly, making a lifestyle decision that represents them. These lifestyle decisions can be based on the convenience and/or value a product offers, the tastes and variety a product offers, and even the perception that a chosen product or brand conveys a premium lifestyle over other brands (example, Starbucks versus other coffees). Every industry has its share of products and product marketing that aims to sell not just a product but to sell a brand, a definition of a lifestyle and an image as created by that product (witness bottled water in its many different packages and now, flavors, which consumers drink to suggest that they are health conscious and care about their well-being or drink to suggest their choice of a premium lifestyle by preferring bottled water over tap water or other bottled water brands). The rest of the food industry is no different, and increasingly in the last few years, has become more creative in marketing to consumers, as a result of competition both locally (on a national level) and globally, as more ethnic food products make their way onto the shelf and as more products continue to break the stereotype of typical packaging solutions. To this end, food products prepared, packaged, and marketed in flexible retort pouches are no different. They have been around in this country for many years (on the fringe) as military MREs and available in other countries as normal food solutions in areas where refrigeration, shelf-space, and disposal space are at a premium. The Effects of Retort Conditions on Clear High Barrier Laminated Structures Thomas R. Mueller, Rohm and Haas Company, Speaker Retort packaging is rapidly developing as a flexible alternative to cans. The ability to offer packaging with see through qualities has spurred the growth of high barrier laminate films. The clear retort package also offers the advantage of microwaveability right in the pouch, offering consumers extra convenience. This paper will examine the barrier and interlaminate bond qualities before and after retort of several different clear, high barrier film laminates, as compared to conventional foil structures.

10 8-4 9:30 am 9/27/2005 Session: 9 PVDC Barrier Concepts for Demanding Coextrusion and Lamination Applications Valerie Renard, Dow Deutschland GmbH & Co OHG Steve Jenkins, The Dow Chemical Co., Speaker Copolymers of polyvinylidene chloride (PVDC), are-well known for their use in demanding barrier packaging applications to minimize the permeation of oxygen, water vapor, and odors. New die designs incorporating patented early encapsulation technology (US Patent 6,685,872, International Publication Number WO 02/06047, US Patent 4,643,927), coupled with temperature isolation technology developed by equipment suppliers, have eliminated degradation problems existing in the typical spiral mandrel dies used in the blown film process. These new die designs, coupled with new resin offerings; enable PVDC resins to be processed on large multilayer blown film dies. Multilayer films incorporating PVDC resins with higher temperature polymers such as Nylon, PP, and LLDPE in the skins are now possible. 10:30:a.m. - 1:00:p.m. Additivies-Understandings and Applications Manufactures have developed resin additives to enhance specific resin properties, improve resin performance during processing and improve handling in the final product. This session will discuss how various additives interact with different resins to provide the improved performance. Various topics that will be discussed in the session include: elimination of sharkskin in LLDPE, application of controlled architecture materials, discoloration of PE film due to gas-fading, engineered resins used to extend PP performance, and improvements in barrier properties with high clarity technology. Amy B. Rode, Voridian Div Eastman Chemical :30 am Polymeric Nanocomposites Enabled by Controlled Architecture Materials :00 am James Nelson, 3M Dyneon, Speaker Controlled architecture materials (CAMs) (i.e. block copolymers) are being explored as specialty additives for the formation of polymer nanocomposites under melt-processing conditions. These blockcopolymer-based additives provide interesting exfoliation solutions for clays of differing hydrophobicity in a variety of polymers. In this paper we demonstrate the ability of CAMs to exfoliate both organically modified and unmodified natural clays in polystyrene (PS) and polypropylene (PP) resins. Complementary characterization techniques of Transmission Electron Microscopy (TEM), x-ray diffraction (XRD), and rheology are used to identify exfoliation. Additionally, we demonstrate the efficiency of CAMs to exfoliate clay at low additive levels. Improving the Gas-Fading Performance of Polyethylene Film Resins by Addressing the Over- Oxidation of Phenolic Antioxidants :30 am Tony Tikuisis, Nova Chemicals Ltd., Speaker Discoloration of polyethylene due to gas-fading is an ongoing nuisance in the film packaging industry and can result in significant product claims and potential loss of business. It is well known that gasfading can be attributed to the over-oxidation of phenolic antioxidants. There is a correlation between the changes in color that can occur during processing and the subsequent discoloration due to gasfading. NOVA Chemicals has recently introduced gas-fade resistant polyethylene film resins into the marketplace. Data comparing the melt flow and color stability, physical property performance, longterm thermal stability and improved gas-fading resistance of these resins to conventionally stabilized formulations are presented. The new resins have been designed to tolerate the addition of moderate levels of phenolic antioxidant (from blending with other film resins) without a significant effect on color performance. Proprietary Engineering Resins as Additives to Polypropylene Bob McKay, GE Advanced Materials, Speaker Ken Rudolph, GE Advanced Materials Todd Washburn, GE Advanced Materials To extend the performance of polypropylene, additives manufacturers have developed a variety of products (light stabilizers, antioxidants, nucleating agents, etc.) to enhance specific material properties. However, to bridge the gap between polypropylene and engineering resins, converters must improve its impact resistance and also its elevated temperature dimensional stability, and do so economically. PPO* resin, a proprietary polymer of poly(2,6-dimethyl-1,4-phenylene ether) available from GE Plastics, is a unique product which may be utilized as a low level additive in polypropylene to achieve such property enhancements.

11 9-4 12:00 pm High Clarity Masterbatch: A New Technology for Improving the Clarity and Gloss of PE Films :30 pm Prakash R. Patel, Ampacet Corporation, Speaker A lot of advances have been made to improve the barrier properties of the PE films. The clarity has also improved with the advent of mlldpe and cleaner polymers. But all films need to be modified to accomodate easy handling during packaging and dispensation. Commonly slip and antiblocks are added to the film to modify the surface. While these additives provide the necessary surface properties, they adversely affect the clarity and gloss of the film. A new masterbatch has been developed to address these issues. The following paper discusses the virtues of this patented technology. Advances in Polymer Processing Additives (PPA) Claude Lavallee, 3M Canada Inc., Speaker In previous work1,2, flow visualization was used to understand how polymer processing additives (PPA) eliminate sharkskin in linear low-density polyethylene (LLDPE). The PPA migrates to and coats the die wall, induces slippage, and eliminates sharkskin. In this work, the interface between the PPA and LLDPE was further characterized using reflection light microscopy, scanning electron microscopy, energy dispersive X-ray, and profilometry. The coating is characterized by long stripes in the flow direction. The coating density obtained from different technologies was characterized on gold and nickel. The coating thickness was also measured. 9/27/2005 Session: 10 10:30:a.m. - 1:00:p.m. Productivity Developments-Machinery Designs to Improve Efficiency Continued from session 6 R. Duane Smith, Black Clawson Conv. Mach. Inc :30 am :00 am More Than Defect Detection - The Real Value of Web Inspection Brian Heil, ISRA Surface Vision, Speaker This article explores opportunities to maximize the value of automated on-line film inspection. Examples are presented of implemented inspection systems that provide critical real time process and converting information to maximize yield, improve raw material quality, and strengthen customer relationships. A solution for automated re-wind control for defect removal that increases converting throughput is discussed. The implementation of this technology offers its users a variety of methods to achieve value. The user realizes the maximum value when all of the possible methods are implemented. Non-Nuclear Gauging Alternatives Offer Enhanced Performance with Simplified Use Hector E. Marchand, NDC Infrared Engineering, Speaker This paper considers the role non-nuclear Infrared backscatter and X-Ray transmission sensors can play in the measurement of coatings and laminate layers online. For a long time, Beta transmission sensors and gamma backscatter sensors have been the preferred choice, due to their design simplicity, and ability to be used on a wide range of materials and applications with fairly predictable results. However, radioactive source regulations and disposal requirements are getting increasingly tougher, and many countries and companies are adopting green initiatives to reduce or eliminate the use of hazardous materials in the workplace. In this new environment, the possibilities and advantages that Infrared and X-Ray sensor technologies can deliver are starting to be realized in a number of applications including the converting industry, particularly where high performance is demanded, such as extrusion coating and lamination. The acceptance of Infrared and X-Ray sensors for the use in measurement of converted materials has come about due to a change in attitudes and philosophies while the advancement of the hardware technology has also promoted its use. Some of these advances have been made at the sensor level, and some at the system level, where use of such tools as same spot measurement, more robust calibration techniques, and improved sensor management have resulted in significant performance gains.

12 :30 am New Die Designs and Advancements in Automatic Die Controls for Improved Efficiencies in Film Production :00 pm James F. Foederer, Extrusion Dies Industries LLC, Speaker Frequent product changes has driven die designers to develop new technologies. This paper will focus on new die designs targeted toward the thin film producer. Features and benefits of these dies include uniform deflection, streamlined polymer flow, reduced die start up time and reduced scrap resulting in increased productivity. Automatic die lip control will be discuss as well as additional die features and coatings, all relating the increased extruder uptime and complementary to the Lean Manufacturer. Challenges of High Speed Splicing :30 pm Donald L. Teich, Black Clawson Conv. Mach. Inc., Speaker Richard S. Tetro, Black Clawson Conv. Mach. Inc. Reliability is a key objective of any continuous web splicing operation, as web speeds increase and parent roll diameters are reduced; the challenge to increase reliability becomes much more difficult. Accuracy and repeatability of splicing systems become critical when splicing at high web speeds, and failure to consider and solve the obstacles will result in decreased splicing reliability and increased downtime. The goal of this paper The challenges of high speed splicing is to explain what the obstacles are and the solutions required in overcoming these obstacles. Advancements in Melt Fracture Elimination Technology Rafael J. Castillo, Dual Spiral Systems, Inc., Speaker In extrusion, melt fracture or sharkskin is a phenomenon attributed to the stick/slip behavior of molten plastic flowing through a melt channel. If unaddressed, melt fracture causes the extrudate surface to appear rough with diminished physical and optical properties. Typically, melt fracture occurs when polymer melt is forced to flow through narrow die chambers at elevated shear stress levels. Traditionally the onset of melt fracture has been delayed through the application of polymer processing aides that have acted as a lubricant between the melt and the wall of the channel in which they are flowing. Dual Spiral Systems has recently completed field trials of a new low coefficient of friction coating that is showing promise in reducing melt fracture in high output extrusion lines. The melt fracture reducing die coating compound, called K05, has been tested at several blown film extrusion plants processing various LLDPE and HDPE resin grades. Previously the concentration of polymer processing aide (PPA) to eliminate melt fracture these companies were using was between ppm. So far the coating has been applied on blown film and tubing dies. Some preliminary data has been collected on film extrusion processes. This paper will detail the results of our preliminary data and analysis to date on the K05 trials and introduce the notion of using low friction coatings as an alternative to addressing melt fracture elimination. 9/27/2005 Session: 11 10:30:a.m. - 1:00:p.m. Select Topics Brice T. Hunnicutt, Westlake Polymers LP :30 am Viscoelastic Coextrusion Flow Modeling by Advanced Constitutive Equations: The Influence of the Die Design on Interfacial Instabilities Jiri Vlcek, Compuplast International Martin Zatloukal, Tomas Bata University, Speaker Petra Saha, Tomas Bata University in Zlin Michael T. Martyn, University of Bradford Fully viscoelastic FEM together with flow visualization technique are employed to quantify the effect of the die design on the wave type of interfacial instabilities in coextrusion. It has been shown experimentally that the minor channel geometry has a strong impact on the wave type of interfacial instabilities and the results can be correlated through novel criteria called as Total Stress Difference (TSN), which takes in to account the bulk change of the total stress in normal as well as tangential direction with respect to the interface. It has also been shown that specific type of high stress area occurs around the interface at the end of the converging section. This total stress has been found to be non-monotonic and discontinues along the interface and related for the onset of zig-zag type of interfacial instabilities.

13 :00 am Flame Plasma Surface Treating System Applied to a High Speed Coating Line :30 am Dom Medina, Flynn Burner Corporation Joseph D. DiGiacomo, Flynn Burner Corporation, Speaker This paper describes a flame plasma surface treating system successfully applied to a coating line operating from 100m/min (328 fpm) to 1000m/min (3280 fpm). The line coats a variety of polymer and paper substrates. This is one of the fastest coating lines operating in a manufacturing environment. The issues in applying a flame treating system to this range of line speeds and how they were addressed will be presented. The results obtained with flame plasma treatment at line speeds of 800m/min (2624 fpm) 1000m/min (3280 fpm) will be compared with the results using corona treatment at significantly lower line speeds. Printing on Metalized Polymer-Paperboard Compounds: Improvement of Adhesion by Optimized Flame Plasma Pre-treatment :00 pm Werner Eckert, Arcotec GmbH, Speaker Polymer films have low surface tension and wettability due to non-polar molecules on the surface. Therefore, to print on laminated paperboard, there is a need to pretreat the surface to get proper adhesion of the ink. The most common physical treatment methods are Corona and flame treatment. This presentation deals with results obtained from the latest flame treatment technology. Electronically controlled unit, web speed controlled burner power and automatic burner deckling for varying web width as well as with the optimized adjustment of the flaming parameters can achieve high treatment level ensuring good adhesion of the ink. Significant reduction in gas consumption makes this technique even more interesting. Future European Regulation on Adhesives for Food Contact Articles :30 pm Hermann K. Onusseit, Henkel KGaA, Speaker Food contact materials are used for the production of articles intended to come into contact with foodstuffs and shall not transfer their components into the foodstuff in unacceptable quantities. These articles are requested to not influence the food they contact, neither toxicologically i. e. no health threat for the end user, nor may they change the composition of the food or its properties like smell, taste and appearance. On the European level two authorities deal with questions of food safety. One is the Council of Europe and the other is the European Union. While the decisions of the European Union are obligatory for national legislations, those of the Council of Europe are only a recommendation. For adhesives, the European Regulations are not harmonized. As is the case with all other materials, adhesives have to fulfill the requirements of the current framework regulation. In the framework regulation (EC)1935/2004 in annex 1 adhesives are listed for the first time, along with sixteen other groups of materials or articles for which special directives or regulations are planned. Although the draft of the so-called "Super Regulation" intends to include the migration contributions of the adhesives used in multilayer constructions it does not mention a specific regulation. High Clarity Linear Low Density Polyethelene for Packaging Applications Amy B. Hitchcock, Voridian Div Eastman Chemical, Speaker As packaging applications become more demanding, film extruders are searching for resins with a combination of properties, including strength, clarity and stiffness. Many conventional resins, such as high-pressure low density polyethylene are clear, but lack the overall balance of toughness and stiffness that many applications require. Linear low density polyethylenes provide increased toughness and stiffness, but most lack the high gloss and low haze required for clarity applications. To achieve better film clarity, some extruders use lower density linear polyethylenes or blend with high pressure polyethylenes, thus sacrificing stiffness and toughness. A new polyethylene that combines good stiffness, clarity and toughness is now available for these demanding applications. This polyethylene, a g/cc density linear low density based polyethylene can be used to produce stiff, clear films that can be used in a variety of applications including shrink wrap, and form, fill and seal applications.

14 9/28/2005 Session: :00 am :30 am :00 am :30 am 9/28/2005 Session: 13 8:00:a.m. - 10:00:a.m. Surface Treating for Flexography (Sponsored by FTA) The greater the demands put on the packaging for end use the greater the demands are for the printing of the material. Corona, flame and plasma are all treating methods used to improve the adhesion of ink on film, foil and even paper. Many factors will determine which process is preferred for one application verses another. Considering each of the treatment effects on the ink adhesion as well as the effect on the substrate is important. The economical aspects of one method over another may be more convincing for one process over another based on press width and speed. Selection of proper treating process and equipment is imperative for high quality flexo printing, laminating and coating. Rick Mix, Flexographic Technical Assn. Do All Substrates Need Surface Treatment? Steven Utschig, Fox Valley Technical College, Speaker A substrate supplier describes the requirements of their materials and what can negatively effect different substrates. Can accurately use a dyne pen to test chemically treated films? Find out why this is a problem. The Right Tools for the Right Job Michelle Stevens, MOCON Inc, Speaker Test methods, procedures and equipment for proper testing of substrate properties including but not limited to surface treatment. In addition to testing an implementation plan for testing programs will be presented. Comparison of Surface Treatment Equipment Rory A. Wolf, Enercon Industries, Speaker For a specific adhesion problem which method is best? The range of substrates, desired speeds and processes in your facility will determine the choice if you know the answers to look for. Chemical, flame, corona or plasma find out what you need to know to establish what is the best option for you? New Printing Adhesion Improvements Using Atmospheric Plasma Glow Discharge Technology Rory A. Wolf, Enercon Industries, Speaker Flexible packaging is experiencing a technological revolution aimed at increasing consumer convenience, enhancing consumer protection, and delivering new solutions for a host of challenges throughout the manufacturing and distribution chain. High performance film structures, package configurations and applications, and printing technologies continue to drive flexible packaging into existing as well as completely new markets. The Flexible Packaging Association has identified flexible packaging sales of US$12 billion within a packaging industry estimated to have total sales of about US$20.5 billion. While corona and flame surface pre-treatments have traditionally prepared finished traditional flexible packaging structures for graphic and coating enhancements, this paper presents evidence of new flexible packaging print adhesion performance benefits using atmospheric plasma treatment (APT) technology. 8:00:a.m. - 10:00:a.m. Cost Reduction and Efficiency Improvement Joseph D. DiGiacomo, Flynn Burner Corporation