FILM STRETCHING PRODUCTION LINES AND COMPONENTS SPECIALTY MACHINERY. Quality creates value

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Patricia Dawson
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1 PRODUCTION LINES AND COMPONENTS FILM STRETCHING Quality creates value SPECIALTY MACHINERY

Film stretching lines ahead of standard with custom-made systems Sheets for solar panels, capacitor and battery films, flexible circuits, electrical insulations, graphic films and packaging films.

2 Film stretching lines ahead of standard with custom-made systems Sheets for solar panels, capacitor and battery films, flexible circuits, electrical insulations, graphic films and packaging films. All these products represent the DORNIER film production technology. DORNIER has supplied about a third of all film stretching lines installed all over the world. The Lindauer DORNIER GmbH has developed and manufactured film stretching lines since Today Lindauer DORNIER GmbH supplies complete film production lines as well as machine components. DORNIER polypropylene film production line for three-layer BOPP film with a thickness range of µm and a trimmed width of 8,200 mm Average annual output of the production line is 29,400 tons DORNIER film stretching lines The manufacturing program includes Raw Material Handling and extrusion systems, chill roll units, pinning systems, longitudinal stretching machines, single- and double-sided coaters, transverse stretching and heat setting machines, post stretchers as well as take-up and transfer sections. Other components for complete production lines, such as winders and slitters, cutters as well as reclaim recycling systems are procured in close cooperation from other leading European suppliers. Most DORNIER film stretching lines are supplied for the production of polyester (BOPET) and polypropylene (BOPP) film. Other applications include the processing of PS, PA, PVC, PE, PEN and different thermoplastic materials. DORNIER stretching equipment is also used for manufac turing geo textiles and biaxially oriented nets, e.g. for road construction. The production range and the design of the equipment as well as the whole line configuration depend on the individual application. Machine specifications can there fore vary considerably. However, all the lines, without exception, have one thing in common: a high design and manufacturing quality standard combined with an outstanding reliability.

FILM STRETCHING LINES AND EQUIPMENT Reliable line components for highest availability The Raw Material Handling engineered by DORNIER ensures a constant and reliable supply of chips.

All extruders are very constant with respect to output and temperature uniformity. The extruders will be combined with filters, melt pump, melt pipes and a die plus control equipment, etc.

3 FILM STRETCHING LINES AND EQUIPMENT Reliable line components for highest availability The Raw Material Handling engineered by DORNIER ensures a constant and reliable supply of chips. Crystallizing and drying of polyester chips is carried out with minimum creation of dust. DORNIER extrusion systems are available as single extruder with melt pump or as cascade extrusion system. All extruders are very constant with respect to output and temperature uniformity. The extruders will be combined with filters, melt pump, melt pipes and a die plus control equipment, etc. to form an extrusion system. For co-extrusion twin screw extruders are used to provide maximum flexibility with regard to raw material changes. The DORNIER proprietary controls together with DORNIER s vacuum system and gravimetric feeding ensures a melt flow at constant output pressure. The superior DORNIER proprietary controls also allow the use of twin screw extruders for main extrusion in polyester film production lines. From the extrusion system the hot melt is cast on the chill roll to form a sheet. In a polypropylene production the casting drum is normally arranged in a water bath. After controlled cooling the primary film passes through the longitudinal stretching machine, where the film is stretched in machine direction. DORNIER polyamide film production line for BOPA film Following longitudinal stretching, the film can be coated with water based coating solutions. The DORNIER coater is operating according to the kiss coating principle with coating chamber and gravure roll. The gravure roll can be exchanged quickly and easily to provide maximum flexibility regarding coating application. The coater includes corona treatment to activate the film surface before coating. The coater can be supplied for single or double side treatment. High transverse loads and low film thicknesses a firm grip with the DORNIER clip Up to 2,400 clips are incorporated in a transverse film stretching machine. They run linked in special monorail guides. The clips have to securely hold the edges of different plastic films of a wide thickness range, while these are passed through the transverse stretching machine to be heated, stretched and stabilized. DORNIER is the pioneer in the field of modern roller clips running on continuous flexible steel belt guides. DORNIER s know-how guarantees an almost maintenancefree operation of the film stretching machine with minimized lubrication. This results in a clean production of high-quality film. Each individual clip has to meet the high demand of the film manufacturing process. Clip closing device of the DORNIER high speed SSDC-clip Chain track and clip are designed for speeds up to 600 m/min 2 3

DORNIER PET film production lines tailored to your needs View of a DORNIER take-up and transfer section of a high speed production line for BOPET film In the following transverse stretching machine

Material and mechanism have to withstand temperatures in the range of 100 to 280 C at production speeds between 100 and 500 m/min according to output and film thickness.

4 DORNIER PET film production lines tailored to your needs View of a DORNIER take-up and transfer section of a high speed production line for BOPET film In the following transverse stretching machine the film is gripped with clips at both edges and stretched widthwise at a given temperature. Cross loads of up to 3,500 N per clip can occur. Material and mechanism have to withstand temperatures in the range of 100 to 280 C at production speeds between 100 and 500 m/min according to output and film thickness. Therefore the utmost precision in the manufacture of these clips is a must. Manufacturing tolerances in machining of the clips are in the micron range. Therefore DORNIER clips can stand long periods of production almost certainly maintenancefree. After the film has been oriented in both directions, the stretched film is guided from the TDO by a take-up system to View of a DORNIER transverse stretching and heat setting machine of a BOPET line for film thicknesses from µm

5 FILM STRETCHING LINES AND EQUIPMENT the winder. In this area the film is chilled further and the edges are cut off. At the same time the thickness uniformity is checked and the results of this measurement is used for control of the die. The film wound on cores with a length up to 50 km is slit in a rewind and slitting machine later on. DORNIER PET film production lines tailored to your needs The Lindauer DORNIER GmbH supplies film production lines for the production of biaxially oriented polyester and polypropylene film, which are designed in accordance to customers requirements. The necessary systems and components, such as single screw extruders, melt filters and melt pipes, chili roll unit, longitudinal stretching machine, coater, transverse stretching and heat setting machine as well as take-up transfer section are designed and built by DORNIER - Made in Germany. Affordable flexibility with the multi drive and control plus process automation system DORNIER supplies custom-made PLC systems for control of single machines, such as a longitudinal stretching machine for the production of monoaxially oriented film as well as for control of turnkey plants for biaxially oriented film. For a complete production line single PLCs for the different machine components respectively grouped machine components will be used, which are communicating via a bus system. This kind of control guarantees a high flexibility at reasonable costs. On request, the control system also can be connected to a host computer system. Hard- and software of the controls are based on the world wide Siemens standard. Control system visualisation of a cascade extrusion system of BOPET film production line 4 5

speeds up to 130 m/min DORNIER twin screw extruder

6 DORNIER film stretching lines tailored to your needs High performance DORNIER pinning system for chill roll speeds up to 130 m/min DORNIER twin screw extruder control and gravimetric feeders for highest melt pressure constancy

optimum air/film heat transfer DORNIER chain track system with 9 roller clips suitable

7 Airing system for DORNIER transverse stretching and heat setting machine designed for minimum energy requirement and highest temperature and air flow constancy as well as optimum air/film heat transfer DORNIER chain track system with 9 roller clips suitable for line speeds up to 600 m/min with a minimum oil lubrication requirement of only 70 cm3 per day

8 FILM STRETCHING LINES AND EQUIPMENT DORNIER take up and transfer machine with a frame design for line speeds up to 600 m/min 6 7 8

FILM STRETCHING LINES AND EQUIPMENT Material engineering laboratory MAV-Services measuring, analyzing, value adding Testing laboratory for films and polymers In this laboratory, DORNIER uses a number

This proves to be extremely useful for the layout and optimization of processes and materials as well as for troubleshooting.

9 FILM STRETCHING LINES AND EQUIPMENT Material engineering laboratory MAV-Services measuring, analyzing, value adding Testing laboratory for films and polymers In this laboratory, DORNIER uses a number of highly sophisticated testing equipment of the latest state of the art which enable its experienced laboratory engineers to analyze a wide range of polymer and film parameters. This proves to be extremely useful for the layout and optimization of processes and materials as well as for troubleshooting. Especially the high precision 3D microscope and REM are vital for a detailed surface and structural analysis. And DSC and FTIR permit the checking of all relevant polymer parameters. For optimizing the on-site process, mechanical testing devices such as tensile testers come in handy. 3D microscope surface analysis of films DSC analysis of PET chips

Lindauer DORNIER GmbH Rickenbacher Str. 119 88131 Lindau, Germany Telephone +49 8382 7030 Telefax +49 8382 703 1378 American DORNIER Machinery Co

10 Lindauer DORNIER GmbH Rickenbacher Str Lindau, Germany Telephone Telefax American DORNIER Machinery Corp. P.O. Box Charlotte, N.C , USA Telephone Telefax DORNIER Machinery India Private Limited 201-A, Sangeet Plaza Marol Maroshi Road Andheri (East) Mumbai , India Telephone Telefax DORNIER Makina Ltd. Sti. Oruç Reis Mahallesi Giyimkent Sitesi 6. Sokak B64 No Esenler/Istanbul, Turkey Telephone Telefax DORNIER Machinery (Shanghai) Co. Ltd. WaiGaoQiao Tax Free Zone 299 FuTeZhong Road Area B G/F Block 45 Shanghai , China Telephone Telefax sales.sm@lindauerdornier.com 13019/w3/ All rights reserved! Quality creates value

Sheet &foil 50 YEARS AT THE TOP OF THE EXTRUSION TECHNOLOGY EXTRUSION LINES FOR THE MANUFACTURE OF CLEAR SHEET AND FOIL OF HIGH OPTICAL QUALITY

Sheet &foil 50 YEARS AT THE TOP OF THE EXTRUSION TECHNOLOGY EXTRUSION LINES FOR THE MANUFACTURE OF CLEAR SHEET AND FOIL OF HIGH OPTICAL QUALITY PROCESSING. A COMBINATION OF WINNING FACTORS. AN ASSURED RESULT: QUALITY AND EFFICIENCY 11 For more than 40 years we have been designing and manufacturing complete extrusion and coextrusion lines for the