Productivity versus Profitability in Vacuum Web Coating

Transcription

1 Productivity versus Profitability in Vacuum Web Coating Liz Josephson, Applied Films Corp. Longmont CO Dirk Hoffmann, Gerard Loebig Applied Films GmbH & Co. KG, Alzenau, Germany

2 Market requirements Quality versus Productivity Technical Innovations Investment Risk

3 Changes in the Market

4 Supplier Support Machine manufacturer Metallizer World markets September 2004 COC WEB 4

5 Innovations for the Future Process Flexibility Winding Systems for increased production Higher product quality Better Off Line Performance Faster Speeds Improved measurement Systems September 2004 COC WEB 5

6 Market requirements Quality versus Productivity Technical Innovations Investment Risk

7 What s New in the Metallizing World

8 New Market Demands Meeting New Market Demands requires: Cutting Costs Expanding product portfolio

9 Expanding Markets Window film Anti-Static Security Food Decorative Capacitors

10 Solutions for Flexibility Window film Anti-Static Various Substrates Equipment Innovations Food Decorative Flexible ECBs Capacitors

11 Market requirements Quality versus Productivity Technical Innovations Investment Risk

12 Price versus Quality $/m 2 Increasing Quality Decreasing Price

13 Faster Machines 20% more production m/s m/s 20% increase

14 Faster Machines For increased line speed, the impact on Annual production = An additinal 900 tons per machine = > $ 330,000/year

15 Faster Machines: Benefits Higher Production capacity Faster payback Increased profit

16 Evaporation Quality Boat Controlling Components Operation System Data Input/Output PLC Data Transfer Thyristor Controller Power Control Evaporation Station Transformer Power Supply

17 Evaporation Quality Reduces splashing effects in boat Minimizes pinholes results in a better layer film quality Extends Boat Life up to 30 % More Coating Cycles with same boat means longer coated film length. Lower boat costs Improved Power Consumption Lower Energy Cost

18 Process Control Products of Variable OD

19 Differences in Layer Structures Food Paper Electronics and decorative metallizing Packaging Window New capacitors film

20 Comparison of Monitoring Systems Method Substrate / Application Eye All Resistance All Eddy All (no window film) O D All Measuring range 0.1 x OD Ω/ Ω/ OD Accuracy +/-0.5 OD (< 2OD) +/- 1% +/- 4 % +/- 2% Control No cross, no length Closed loop No cross Closed loop All All September 2004 COC WEB 20

21 Substrates Transparent film A thin coating Transparent film printed Opaque film onto a substrate Paper Paper board

22 Monitoring Options Operator Eyes Experience Resistivity Point-to-Point Eddy Current Optical Density

23 OD Measuring Principle Transmitter Receiver

24 Typical Optical Density Plot for Opaque Film Using opaque film with 0.5 OD adsorption + Layer Thickness Uniformity LMS OD or ohm/sqr 2,8 2,7 2,6 2,5 2,4 2,3 2,2 2,1 2 1,9 1, single values measured value O.D over 8% under 8% calculated average = Results in 3.0 OD for product (film + layer)

25 Process Flexibility Large range of materials Metallic Semi- Conductors (ITO) Abs.Dielectric + Semi-Con. (TiN, (TiN, SiO SiO 2 ) 2 ) Pure Pure Dielectric (Optical (Optical Tio Tio 2, 2, SiO SiO 2 ) 2 ) Various coatings Various Substrates September 2004 COC WEB 25

26 Definition of Barriers

27 Functional Requirements for Barrier Functional Packaging Requirements Environmental friendly Barrier against moisture, oxygen,.. Protect filled goods Increase shelf time of goods Technical applications requires higher barriers Suitable for all converting processes

28 Barrier Applications Oxygen Transfer Source: Fraunhofer IVV Water Vapor Transfer

29 Improved Barriers Barrier Improvement Factors Film type Film thickness Lamination Metallization - Higher OD of Al layer Pre-Treatment to increase layer density Transparent barrier coatings

30 Barrier Dependency on Film Thickness OTR [cm3/m2/d] 20µ 2,000 25µ 1,500 35µ 30µ 1, µ 40µ Barrier improvement by increasing substrate thickness is not efficient! WVTR [g/m2/d]

31 Barrier of 20µm BOPP Al and Plasma Pre-treatment OTR [cm3/m2/d] 10,000 plain OD OD + pre-treatment WVTR [g/m2/d]

32 Process Factors Low density Higher density Defects Minimized defects Al thickness OD value 2.3 OD value 2.3 Al thickness Without Pre-treatment With Pre-treatment

33 Transparent Barrier Coating Barrier against O 2, Water Vapor,... Environmentally friendly Optical clear, packaging content visible Microwave transparent Heat resistant for boiling applications Process ability: direct printing, lamination,... Metal free: ability to check food with metal detectors Al 2 O 3, SiOx and Mixtures

34 Stoichiometry vs Coating Length 65nm on 20µ BOPP 40nm on 12µ PET 1,60 1,50 Stoichiometry 1,40 1,30 1,20 1,10 1, Coating length in km

35 Barrier vs Coating Length 3 OTR* in cm3 / m2 / day 2,5 2 1,5 1 0,5 2,6 2,63 12µm PET approx. 40nm SiO 0 * at 23 C, 50% rh 10.5 km 19 km Film length

36 Barrier Uniformity for SiO x 20µ BOPP 65nm SiO 12µ PET 40nm SiO OTR in cm3/m2/day 10 2,9 2,3 2,1 2,2 1, OTR at 23 C, 50%rH Position in mm

37 Plasma Pre-Treatment Impact on Barrier 6 No Plasma-Treatment OTR in cm3 / m2 / day Plasma-Treatment 2,875 5,03 12µ PET 40nm SiO 0 OTR at 23 C, 50% r.h. WVTR at 38 C, 90% r.h. 12,43 12,86 WVTR in gr / m2 / day

38 ZnS Applications: Decorative, Security,Transparent layer on hologram Requirements Transparent Thickness 40-50nm Refractive index n=2.3 High reflectance over wide visible range High productivity3m/sec Actual: High productivity achieved Modular concept Temperature controlled Thickness uniformity 10% (adjustable) Quck and easy installation

39 ZnS Thickness Uniformity 8kW 3m/s no Treatment 9kW 3m/s with Treatment 8kW 3m/s with Treatment 10kW 3m/s with Treatment Thicnkness in nm Position in mm

40 SEM picture of ZnS layer ZnS layer Embossing layer PET film

41 Refractive Index of ZnS 2,8 Refractive index 2,7 2,6 2,5 2,4 2,3 2,2 2, Wavelength in nm 50nm ZnS on 12µm PET

42 Reflectance Hologram Wavelength in nm 12µ PET 55nm ZnS uncoated coated Reflectance in %

43 Reflectance Hologram Wavelength in nm 12µ PET 55nm ZnS uncoated coated Reflectance in %

44 Flexibility: SiO / ZnS Modular Design for transparent layers have been developed High productivity and low scrap rate Product requirements for SiO x and ZnS layers can be fulfilled Low cost thickness measurement tool still needs to be developed to enable closed loop control Ease of fast upgrade to new processes leads to shorter Time to Market Increase of product flexibilities Strengthen our customers competitiveness

45 Ability for Quick Change Paper Non aluminium coating CPP BOPP

46 Machine Flexibility Masking Systems

47 Winding Innovations Edge control Reduction of waste from telescoping and heavy edge Reductions in surface damage Scratches star effect Slitting during winding Reduce further production steps

48 Web Winding Edge Guiding System (EGS) Problem Solution

49 Web Winding Heavy Edge 20 mm Waste for worst case: 40 mm = 80 t/a Waste =$ 200,000 /year

50 Web Winding Savings with edge control ( EGS ) 30 mm Waste for worst case: 60 mm = 120 t/a =$ 300,000 /year

51 Web Winding Surface quality improvements To avoid film damage: Modify winding system No Star Effect

52 Web Winding In-chamber-slitting Rewinder with integrated slitting operation to decrease further production steps

53 Potential for Metallizing Machines Masking Process Modules EGS Rewinder System Solutions

54 Market requirements Quality versus Productivity Technical Innovations Investment Risk

55 Increasing Off Line Performance Turn around times Cleaning Roll Changes Accessiblity Roll Changes Less down time Maintenance Better accessibilty Employee Safety Integrated Tools

56 New Capabilties Equate to: Increase productivity X Box Process Flexibility Winding features Decreased turn around times

57 Economics of metallizing Minimized investment risk Sell Buy The Production Unit For the flexible market

58 Achievable Parameters Increased production with faster machines = impact on profit Flexible processes from a single machine = increased market share Improved Web handling and logistics = operational costs Multiple functions pattern/striping = increased market share Better layer control and measurement = improved quality

59 Added Value versus Flexibility Flexibility

60 Supplier Support - Increase flexibility - Increase value-added - Minimize risk Machine manufacturer Metallizer World market September 2004 COC WEB 60

61 September 2004 COC WEB 61

62 CLICK TO RETURN TO LIST OF PAPERS AND PRESENTATIONS March 04 COC WEB 62