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
Market requirements Quality versus Productivity Technical Innovations Investment Risk
Changes in the Market
Supplier Support Machine manufacturer Metallizer World markets September 2004 COC WEB 4
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
Market requirements Quality versus Productivity Technical Innovations Investment Risk
What s New in the Metallizing World
New Market Demands Meeting New Market Demands requires: Cutting Costs Expanding product portfolio
Expanding Markets Window film Anti-Static Security Food Decorative Capacitors
Solutions for Flexibility Window film Anti-Static Various Substrates Equipment Innovations Food Decorative Flexible ECBs Capacitors
Market requirements Quality versus Productivity Technical Innovations Investment Risk
Price versus Quality $/m 2 Increasing Quality Decreasing Price 1990 2010
Faster Machines 20% more production 15 0 10 5 14 m/s 15 0 5 10 17 m/s 20% increase
Faster Machines For increased line speed, the impact on Annual production = An additinal 900 tons per machine = > $ 330,000/year
Faster Machines: Benefits Higher Production capacity Faster payback Increased profit
Evaporation Quality Boat Controlling Components Operation System Data Input/Output PLC Data Transfer Thyristor Controller Power Control Evaporation Station Transformer Power Supply
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
Process Control Products of Variable OD
Differences in Layer Structures Food Paper Electronics and decorative metallizing Packaging Window New capacitors film
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 0.5 100 Ω/ 0.5 50 Ω/ 0 5.2 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
Substrates Transparent film A thin coating Transparent film printed Opaque film onto a substrate Paper Paper board
Monitoring Options Operator Eyes Experience Resistivity Point-to-Point Eddy Current Optical Density
OD Measuring Principle Transmitter Receiver
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 1,8 0 5 10 15 20 25 30 single values measured value O.D over 8% under 8% calculated average = Results in 3.0 OD for product (film + layer)
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
Definition of Barriers
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
Barrier Applications Oxygen Transfer Source: Fraunhofer IVV Water Vapor Transfer
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
Barrier Dependency on Film Thickness OTR [cm3/m2/d] 20µ 2,000 25µ 1,500 35µ 30µ 1,000 500 1 50µ 40µ Barrier improvement by increasing substrate thickness is not efficient! 0.6 0.7 0.8 0.9 1.1 1.4 WVTR [g/m2/d]
Barrier of 20µm BOPP Al and Plasma Pre-treatment OTR [cm3/m2/d] 10,000 plain 1000 100 2.3 OD 10 2.3 OD + pre-treatment 1 0.15 0.35 0.55 0.79 5.4 7.97 WVTR [g/m2/d]
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
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
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 1,00 1 10 21 Coating length in km
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
Barrier Uniformity for SiO x 20µ BOPP 65nm SiO 12µ PET 40nm SiO 100 54 43 67 OTR in cm3/m2/day 10 2,9 2,3 2,1 2,2 1,8 1 100 200 300 400 500 OTR at 23 C, 50%rH Position in mm
Plasma Pre-Treatment Impact on Barrier 6 No Plasma-Treatment OTR in cm3 / m2 / day 5 4 3 2 1 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
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
ZnS Thickness Uniformity 8kW 3m/s no Treatment 9kW 3m/s with Treatment 8kW 3m/s with Treatment 10kW 3m/s with Treatment 45 40 35 Thicnkness in nm 30 25 20 15 10 5 0 50 150 250 350 Position in mm
SEM picture of ZnS layer ZnS layer Embossing layer PET film
Refractive Index of ZnS 2,8 Refractive index 2,7 2,6 2,5 2,4 2,3 2,2 2,1 2 350 400 450 500 550 600 650 700 750 800 850 Wavelength in nm 50nm ZnS on 12µm PET
Reflectance Hologram 1 45 40 35 30 25 20 15 10 5 0 300 327 354 381 408 435 489 462 705 516 543 570 597 624 651 678 732 759 786 813 840 Wavelength in nm 12µ PET 55nm ZnS uncoated coated Reflectance in %
Reflectance Hologram 2 45 40 35 30 25 20 15 10 5 0 300 326 352 378 404 430 456 482 508 534 560 586 612 638 664 690 716 742 768 794 820 846 Wavelength in nm 12µ PET 55nm ZnS uncoated coated Reflectance in %
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
Ability for Quick Change Paper Non aluminium coating CPP BOPP
Machine Flexibility Masking Systems
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
Web Winding Edge Guiding System (EGS) Problem Solution
Web Winding Heavy Edge 20 mm Waste for worst case: 40 mm = 80 t/a Waste =$ 200,000 /year
Web Winding Savings with edge control ( EGS ) 30 mm Waste for worst case: 60 mm = 120 t/a =$ 300,000 /year
Web Winding Surface quality improvements To avoid film damage: Modify winding system No Star Effect
Web Winding In-chamber-slitting Rewinder with integrated slitting operation to decrease further production steps
Potential for Metallizing Machines Masking Process Modules EGS Rewinder System Solutions
Market requirements Quality versus Productivity Technical Innovations Investment Risk
Increasing Off Line Performance Turn around times Cleaning Roll Changes Accessiblity Roll Changes 9 0 6 3 Less down time Maintenance Better accessibilty Employee Safety Integrated Tools
New Capabilties Equate to: Increase productivity X Box Process Flexibility Winding features 9 0 6 3 Decreased turn around times
Economics of metallizing Minimized investment risk Sell Buy The Production Unit For the flexible market
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
Added Value versus Flexibility Flexibility
Supplier Support - Increase flexibility - Increase value-added - Minimize risk Machine manufacturer Metallizer World market September 2004 COC WEB 60
September 2004 COC WEB 61
CLICK TO RETURN TO LIST OF PAPERS AND PRESENTATIONS March 04 COC WEB 62