Title. esseci Flame Treatment Technology for Converting Industry

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1 esseci Flame Treatment Technology for Converting Industry Title PRESENTED BY Name STEFANO MANCINELLI Presented by: Title SALES & PROCESS MANAGER Name Company esseci SRL -Italy Company

2 Located in Italy (1 hour from Rome). Established in st Flame Treater in the world for Bopp st Flame Treater in the world for bumpers for painting Over 950 installations in 48 Countries: 750 on films and paper 200 on car industry Pilot line running at 1000 mpm

3 Production Flame Treaters for Bopp Films Flame Treaters for Converting Flaming Systems for Automotive

4 After flame applications Printing Coating Metallization Lamination Extrusion Coating Painting

5 Flame Treated Products PAPER AND CARDBOARD IN DIFFERENT GRADES AND WEIGHT (< 80gsm; >450gsm) COATED PRINTED METALLIZED PAPER ALUMINUM FOILS IN DIFFERENT THICKNESS FILMS PP PLAIN COEXTRUDED- WHITE OPAQUE SYNTHETIC PAPER METALLIZED - PEARLIZED CPP PET/PE FILM THICKNESS FROM 3 µm TO HIGHER THAN 170 µm SPEED FROM 20 m/min TO 1000 m/min WIDTH UP TO MORE THAN 10 METERS TREATMENT LEVEL UP TO MORE THAN 72 DYNE/CM

6 EXAMPLE OF A COMPLEX LAMINATED PACKAGING (BOX) FOR JUICES 1st STEP PE + PAPERBOARD FLAME 2nd STEP PAPERBOARD + PE PE Al FLAME PAPERBOARD 3rd STEP PE PE Al PE FLAME +

8 EXTRUSION COATING FLAME BENEFITS INCREASED PRODUCTION SPEED RESPECT TO CORONA DECREASE POLYTHENE EXTRUDATE TEMPERATURE THICKNESS REDUCTION OF POLYTHENE LAYER CONTROL ON PAPER MOISTURE CONTENT. NO DRY PAPER EASY TO BREAK DECONTAMINATION FROM GREASE OIL WAX - DUST NO SMELL BURNING OF SMALL FIBRES NO PEELING BETWEEN PAPER AND FILM LAYER

9 What is staining? WHY WITH FLAME BETTER ADHESION THAN WITH CORONA? What is staining? Staining is an highly oxidized waxy build-up in the non engraved areas of the printing cylinder, that consists of the presence of ink in the nonprinted areas: - appears on the cylinder after several minutes of printing; - predominantly occurs with red ink, on the first or the second printing station; - can be washed off by water; - gets worst with corona boost treatment; - PEI content in the inks will worsen the phenomenon; - has never been observed on any of flame treated films.

10 What is staining? oxygen level vs Power WHY WITH FLAME BETTER ADHESION THAN WITH CORONA? 14 Threshold for formation of LMWOM in litterature = 8,3 Wmin/m² Oxygen level % 8 6 Anchored oxygen level = 4,8% 4 2 Threshold for formation of LMWOM= 9,8 Wmin/m² Power density (Wmin/m²)

11 THE CHEMICAL COMPOSITION OF A CORONA TREATED SURFACE CH3 CH3 PP SURFACE CH2-CH-CH2-CH-CH2 CH3 CH3 CH2-C-CH2-CH-CH2 CORONA TREATMENT CH3 CH3 OXYGEN CH2-C-CH2-C-CH2 OOH

12 THE CHEMICAL COMPOSITION OF A CORONA TREATED SURFACE CH3 CH3 CH2-C-CH2-C-CH2 OOH β-scission reaction C=O O CH2-C CH3 OOH Low molecular weight C-OH C=O O alkoxy radicals RO LMWOM

13 WHY WITH FLAME BETTER ADHESION THAN WITH CORONA? O/C RATIO IMWOM vs. LMWOM INCREASED SURFACE ENERGY Chain Scission behaviour/delamination/staining Aging behaviour Metallizing barrier effect & Improved surface properties

14 WHY WITH FLAME BETTER ADHESION THAN WITH CORONA? CORONA TREATED SLOW PEELING FLAME TREATED SLOW PEELING CORONA TREATED FAST PEELING FLAME TREATED FAST PEELING

15 WHY WITH FLAME BETTER ADHESION THAN WITH CORONA?

19 Bottom Treater

20 Top Treater

21 Mixture Generator

25 Touchscreen Operator Panel Easy and intuitive man/machine interface

26 (A/G)used Lambda (λ) = (A/G)stoichiometric λ = 1 mix stoichiometric; λ <1 mix gas rich; λ >1 mix gas lean.

27 ALARMS & WARNINGS Alarms banner, alarms buffer and help on line

28 Energy to the treater roll 35% 48 Kw FLAME TREATMENT PROCESS Energy to the web (1%) Energy to the exhausts 50% COMBUSTION ENERGY 137 kw 68,5 kw Energy to the burner 15% 20,5 kw FLAME TREATMENT DISTRIBUTION ENERGY MAP

29 FLAME TREATER PRELIMINARY DATA Max Natural gas consumption [m3/h; kg/h; l/h] 15 m3/h; 10,5kg/h; 23l/h Max Combustion energy Produced [kw] Heat Removal [kw] Burner 15% Roll 35% Air 50% Max burner net water consumption [m3/h] (Return temp.47 C) Max roll net water consumption [m3/h] (Return temp.35 C) , ,5 0,5 2,0

30 Cooling Unit Cooling Unit specs: Heat removal capacity: 66 BTU/s; Net water flow: 2,5 5 m3/h; Net water pressure: 4 bar; Loop (hot side) flow: m3/h.

32 References 1. LORI G. Aspetti chimico-fisici nell attivazione di superfici mediante il trattamento alla fiamma (1985). 2. STROBEL M.; BRANCH M.C; ULSH M.; KAPAUN R.S.; KIRK S.; LYONS C.S. Flame surface modification of polypropylene film. J. Adhesion Sci.Technol. Vol.10, No.6 (1996). 3. STROBEL M.; SULLIVAN N.; BRANCH M.C; JONES V.; PARK J.; ULSH M.; STROBEL J.M.; LYONS C.S. Gas phase modeling of impinging flames used for the flame surface modification of polypropylene film. J. Adhesion Sci.Technol. Vol.15, No.1 (2001). 4. S.Mancinelli, The Fundamentals of Flame Treatment Process and its Main Parameters, White Paper, EsseCI SRL, Via Flaminia Ternana, Narni, Italy, Nov M.Tuominen. J.Lahti, J.Lavonen, T.Penttinen, J.P.Rasanen, J.Kuusipalo The Influence of Flame, Corona and Atmospheric Plasma Treatments on Surface Properties and Digital Print Quality of Extrusion Coated Paper. J.Adhesion Sci.Technol. 24 (2010)

33 Thank you PRESENTED BY Name Stefano Mancinelli Company esseci srl

Corona Treatment of Paper Experiences and Findings. Dr. Ralf Weber

Corona Treatment of Paper Experiences and Findings Dr. Ralf Weber 12.1 + 7673 Content Current Status of Experiences Coating Trials with different Treatment methods. Test design Results Wetability improvement