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HANDBOOK

AD*STAR® Handbook
Appendix B
Film laminated AD*STAR® bags

08/2019 Language: English


original document
INTRODUCTION

Copyright
Drawings, installation plans and operating instructions as well as
designs, catalogues, brochures, diagrams etc. are the intellectual
property of STARLINGER. Duplication, reproduction, dissemination and
distribution to third parties are prohibited. Moreover, they must not be
used to produce or have produced machines or machine components.
Great care was taken in the creation of this documentation. However,
Starlinger reserves the right to make changes and improvements to
the documentation.

Warranty and liability


The individual contractual conditions pertaining to the liability and
warranty or the respective conditions of the general sales and delivery
terms of STARLINGER always apply. STARLINGER accepts no liability
for damage arising due to the owner failing to adhere to the intended
use.

©08/2019 - GW - Starlinger & Co. Gesellschaft m.b.H., Vienna – Austria

Appendix B 08/2019 PAGE 2 / 30


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TABLE OF CONTENTS

Intruduction .......................................................................................... 4
1 mode of operation.............................................................................. 6
1.1 Flat wPP laminated with flat film .................................................... 6
1.1.1 Pros & Cons ......................................................................... 6
1.1.2 Specification and quality requirements wPP: ............................. 6
1.1.3 Specification and quality requirements flat film: ........................ 7
1.1.4 Film and print position setup .................................................. 8
1.2 Circular wPP laminated with flat film .............................................. 9
1.2.1 Pros & Cons ......................................................................... 9
1.2.2 Specification and quality requirements wPP: ........................... 10
1.2.3 Specification and quality requirements flat film: ...................... 10
1.2.4 Film and print position setup ................................................ 11
1.3 Circular wPP laminated with two flat films ..................................... 13
1.3.1 Pros & Cons: ...................................................................... 13
1.3.2 Specification and quality requirements wPP: ........................... 13
1.3.3 Specification and quality requirements flat film: ...................... 14
2 Lamination process .......................................................................... 15
2.1 lamination without co-extruder and without special ink tie layer ...... 15
2.1.1 layer structure .................................................................... 15
2.1.2 Pros & Cons: ...................................................................... 16
2.1.3 Raw material specification and mixing ratio ............................ 16
2.2 Lamination with co-extruder and ink tie layer................................ 19
2.2.1 Layer structure ................................................................... 19
2.2.2 Pros & Cons ....................................................................... 19
2.2.3 Raw material specification and mixing ratio ............................ 19
3 lamination of ad*star® patches ......................................................... 23
3.1 Lamination of patches without ink tie layer ................................... 23
3.2 Lamination of patches with ink tie layer........................................ 23
4 settings .......................................................................................... 26
5 Ad*star® quality ............................................................................. 27
5.1 Quality standards ...................................................................... 28
5.2 General advice, testing frequency ................................................ 30
5.2.1 Raw material ...................................................................... 30
5.2.2 Printed, laminated fabric ...................................................... 30
5.2.3 Converted bag .................................................................... 30

Appendix B 08/2019 PAGE 3 / 30


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INTRODUCTION

INTRODUCTION

Dear Customer,

This manual is intended to contribute to your success in manufacturing


film laminated AD*STAR® bags.

Producing film laminated AD*STAR bags offers several benefits over


conventional AD*STAR bags, such as:

 premium appearance
 higher bag stiffness
 ability for full surface printing
 scratch-resistant printing (in case of reverse printed film)
 improved WVTR (moisture barrier)
 wide range of surface CoF values

The following chapters will provide you with an insight on required raw
materials, processing guidelines, limitations, quality requirements and
useful hints.

STARLINGER & Co. Gesellschaft m.b.H.

Appendix B 08/2019 PAGE 4 / 30


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INTRODUCTION

This document contains additional pictograms with various purposes.


The following table provides information on the pictograms which are
used and their meaning:

General warning

Important information

Before work on the plant/machine, the operation manual must be read


and known.
The AD*STAR® Handbook does not replace the operation manual.

The diagrams are example images, which may deviate from your
project slightly, depending on the particular application.
Safety regulations and safety instructions from the operation manual /
documentation must be followed without exception!

Appendix B 08/2019 PAGE 5 / 30


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1.Mode of operations

1 MODE OF OPERATION

Depending on market demands, availability of raw material as well


as different film printing technologies, it has been necessary to
develop different modes of laminating wPP with film (e.g. BOPP,
CPP). The most significant solutions are listed as follows:

1.1 Flat wPP laminated with flat film


The combination of flat wPP laminated with flat film is the most
common way of joining film to wPP.

1.1.1 Pros & Cons

advantage disadvantage

ability to print across the lateral need of fabric cutting device in


bag edges circular looms
need of additional tubing process
no need of register control
(additional machine)
no need of ceramic electrodes for need of longitudinal back seam
corona device (risk of bag breakage)
no over-coating on bag (coating
fins)
perfect alignment of front to
back side print
Table 1

1.1.2 Specification and quality requirements wPP:


cloth width 850 - 1500mm
(unwinder)
cloth width tolerance ±5mm
cloth weight 50-80g/m²
cloth weight ±3g/m²
tolerance
cloth construction plain fabric
tensile strength min. 4.5g/den (strip test based on DIN EN ISO 13934-1)
elongation 18-26% Fmax
weaving fault(s) crushed tapes and holes in the fabric may cause
reduction of efficiency and shutdown of the coating
line
roll diameter max. 1300mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform diameter
cloth core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 2

Appendix B 08/2019 PAGE 6 / 30


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1.Mode of operations

1.1.3 Specification and quality requirements flat film:


film type BOPP, OPP, CPP
film width (unwinder) 850 - 1500mm
film width tolerance ±2mm
film thickness 15-40 µm
film thickness ± 5%
tolerance
film composition 3 layers recommended
outer layer heat-sealable (for hot-air welding in conversion line)
centre layer transparent core
inner layer treated heat-sealable (for lamination/ink adhesion)
film CoF recommended 0,35 (film to film µd)
tensile strength min. 110N/50mm / min. 205N/50mm
MD/CD
elongation MD/CD 75-120% Fmax / 15-25% Fmax
roll diameter max. 1000mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform core/roll
diameter,
film core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 3

Reference materials film:

polymer manufacturer name type website


*
BOPP Treofan crystal GND20 http://www.treofan.com
Table 4

* STARLINGER reference materials (tested by STARLINGER)


** Customers reference materials

Composition of reference film:

Appendix B 08/2019 PAGE 7 / 30


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1.Mode of operations

1.1.4 Film and print position setup


Film unwinder setup:

image 1

Winder setup:

image 2

Appendix B 08/2019 PAGE 8 / 30


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1.Mode of operations

Unwinder of ad*starKON conversion line (after tubing)

image 3

1.2 Circular wPP laminated with flat film


The combination of circular wPP laminated with flat film is becoming
more popular as it doesn’t require an additional tubing process.
1.2.1 Pros & Cons
Advantage Disadvantage
no need of tubing process need of register control
no need of fabric cutting device in need of ceramic electrodes for
circular looms corona device
no longitudinal back seam over-coating on bag (coating fins)
no ability to print across the lateral
bag edges
risk of small variations in
alignment of front to back side
print

Appendix B 08/2019 PAGE 9 / 30


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1.Mode of operations

1.2.2 Specification and quality requirements wPP:


cloth width 400 - 720mm
(unwinder)
cloth width ±7mm
tolerance
cloth weight 50-80g/m²
cloth weight ±3g/m²
tolerance
cloth construction plain fabric
tensile strength min. 4.5g/den (strip test based on DIN EN ISO 13934-1)
elongation 18-26% Fmax
weaving fault(s) crushed tapes and holes in the fabric may cause
reduction of efficiency and shutdown of the coating
line
roll diameter max. 1300mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform diameter
cloth core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 5

1.2.3 Specification and quality requirements flat film:


film type BOPP, OPP, CPP
film width 850 - 1500mm
(unwinder)
film width ±2mm
tolerance
film thickness 15-40 µm
film thickness ± 5%
tolerance
film composition 3 layers recommended
outer layer heat-sealable (for hot-air welding in conversion line)
centre layer transparent core
inner layer treated heat-sealable (for lamination/ink adhesion)
film CoF recommended 0,35 (film to film µd)
tensile strength min. 110N/50mm / min. 205N/50mm
MD/CD
elongation MD/CD 75-120% Fmax / 15-25% Fmax
roll diameter max. 1000mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform core/roll
diameter,
film core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 6

Appendix B 08/2019 PAGE 10 / 30


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1.Mode of operations

Reference materials film:

polymer manufacturer name type website


*
BOPP Treofan crystal GND20 http://www.treofan.com
Table 7

* STARLINGER reference materials (tested by STARLINGER)


** Customers reference materials

Composition of reference film:

1.2.4 Film and print position setup


Film unwinder setup:

image 4

Appendix B 08/2019 PAGE 11 / 30


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1.Mode of operations

Winder setup:

image 5

Unwinder ad*starKON conversion line:

image 6

Appendix B 08/2019 PAGE 12 / 30


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1.Mode of operations

1.3 Circular wPP laminated with two flat films


The combination of circular wPP laminated with two flat films is
mainly due to limited availability of wide width films in certain
regions. In this case two narrow films are used, one for front side
and the other one for the back side of the tube.
1.3.1 Pros & Cons:
Advantage Disadvantage
need of two individual unwinder
no need of tubing process (machine has to be stopped for
roll change)
risk of small variations in
no need of fabric cutting device alignment of front to back side
in circular looms print (depending on film
elongation)
need of ceramic electrodes for
no longitudinal back seam
corona device
no ink tie layer applicable
over-coating on bag (coating fins)
no ability to print across the
lateral bag edges

Table 8

1.3.2 Specification and quality requirements wPP:


cloth width 400 - 720mm
(unwinder)
cloth width tolerance ±7mm
cloth weight 50-80g/m²
cloth weight ±3g/m²
tolerance
cloth construction plain fabric
tensile strength min. 4.5g/den (strip test based on DIN EN ISO 13934-1)
elongation 18-26% Fmax
weaving fault(s) crushed tapes and holes in the fabric may cause
reduction of efficiency and shutdown of the
coating line
roll diameter max. 1300mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform diameter
cloth core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 9

Appendix B 08/2019 PAGE 13 / 30


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1.Mode of operations

1.3.3 Specification and quality requirements flat film:


film type BOPP, OPP, CPP
film width (unwinder) 2x 400 - 720mm
film width tolerance ±2mm
film thickness 15-40 µm
film thickness ± µm
tolerance
film composition 3 layers recommended
outer layer heat-sealable (for hot-air welding in conversion line)
centre layer transparent core
inner layer treated heat-sealable (for lamination/ink adhesion)
film CoF recommended 0,35 (film to film µd)
tensile strength min. 110N/50mm / min. 205N/50mm
MD/CD
elongation MD/CD 75-120% Fmax / 15-25% Fmax
roll diameter max. 1000mm
(unwinder)
roll quality hard, without longitudinal or crosswise folds, no
(unwinder) telescopic shape, straight edge, uniform roll/core
diameter
film core (inside 76mm/3”, 102mm/4”, 152mm/6”, 203mm/8”
diameter)
Table 10

Reference materials film:

polymer manufacturer name type website


*
BOPP Treofan crystal GND20 http://www.treofan.com
Table 11

* STARLINGER reference materials (tested by STARLINGER)


** Customers reference materials

Composition of reference film:

Appendix B 08/2019 PAGE 14 / 30


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2.Lamination process

2 LAMINATION PROCESS

Depending on market demands, film structures, types of printing


technology as well as composition of printing inks different
lamination procedures are being performed.
2.1 lamination without co-extruder and without special
ink tie layer
2.1.1 layer structure
This structure is typically used for laminating surface printed film or
film with embedded print hence the print is not in contact with the
tie layer. Another typical application is reversed printed rotogravure
printing which uses inks that provide adhesion to PP. (e.g. vinyl-
based inks)

surface print embedded print

reverse print rotogravure

suggested tie layer application


weight: 20-30 gsm

Table 11
Appendix B 08/2019 PAGE 15 / 30
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2.Lamination process

2.1.2 Pros & Cons:


Advantage disadvantage
no need of Co-Extruder and no scratch-resistance of print
feedblock (surface print)
expensive film structure (embedded
no need of special ink tie layer
print)
solvent system prohibited in North
America and Europe (e.g. vinyl-
based inks)

2.1.3 Raw material specification and mixing ratio


PP 85%
LDPE 15%
Reference materials PP:
MFI
manufacturer name type MFI = g/10min. website
[230°C/2.16kg]
*
Borealis Daploy WF420HMS 22 www.borealisgroup.com
*
Sasol ESV 200 28 www.sasol.com
*
TVK Tipplen R959A 45 www.tvk.hu
*
APC Advanced PP 1101R 24 http://www.advancedpetrochem.com/
*
Braskem RP 144 40 www.braskem.com.br
*
Braskem Inspire 364 42 www.braskem.com.br
*
lyondellbasell Moplen RP3386 25 https://www.lyondellbasell.com/
*
lyondellbasell Moplen RP2380 48 https://www.lyondellbasell.com/
*
Sabic QR 674K 40 http://www.sabic.eu
*
Sabic RA12MN40 40 http://www.sabic.eu
*
TPC Cosmoplene FC9415G 30 https://www.tpc.com.sg/
*
Borealis WG341C 25 www.borealisgroup.com
**
Basell Moplen EP229S 32 https://www.lyondellbasell.com/
**
Tasnee PP H 2250 25 www.tasnee.com
**
Sasol HTV 145 50 www.sasol.com
**
Petroquim PH4040 40 www.petroquim.cl
**
Lukoil Buplen 6231 16-25 www.lukoil.bg
**
Indelpro Profax PL835N 34 www.indelpro.com
**
CPA CERTENE PHM-35 35 www.channelpa.com
**
Braskem CP 144 45 www.braskem.com.br
**
Arak Petr. Co. Moplen HP 552 R 25 www.arpc-ir.net
**
Reliance Polymers Repol H350EG 38 www.ril.com
**
Reliance Polymers Repol H350FG 35 www.ril.com
**
Sabic PP 511A 25 http://www.sabic.eu

***
lyondellbasell Adflex Z101H 27 https://www.lyondellbasell.com/
***
ExxonMobil Vistamaxx 3980 FL 8 vistamaxxelastomers.com
***
ExxonMobil Vistamaxx 3588 FL 8 vistamaxxelastomers.com
Table 12

Appendix B 08/2019 PAGE 16 / 30


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2.Lamination process

* STARLINGER reference materials (tested by STARLINGER)


** customers reference materials
*** PP modifier for improved adhesion performance. Dosage 0-
30% instead PP

Recommend MFI [230°C/ 2,16kg]:


20 - 50 g/10 min.

Reference materials LDPE:


MFI
manufacturer name type MFI = g/10min. website
[190°C/2.16kg]
*
lyondellbasell Lupolen 2420 K 4 https://www.lyondellbasell.com/
*
TVK Tipolen FD 243-51 4 www.tvk.hu
*
ExxonMobil LD 258 8.2 http://www.exxonmobilchemical.com/
**
Sabic HP 4023W 4 www.sabic.com
**
Sabic HP 2022J 2 www.sabic.com
**
DOW Plastics 722 8 http://plastics.dow.com
**
DOW Plastics PG 7008 7.7 http://plastics.dow.com
**
DOW Plastics PG 7004 4.1 http://plastics.dow.com
**
Qatar Petrochemical Lotrene FD 0474 4 www.qapco.com
**
Qatar Petrochemical Lotrene LA 0710 8 www.qapco.com
**
Braskem BC 818 8.1 www.braskem.com.br
**
IPPC LF0 200 2 http://www.petrochem-ir.net
**
Reliance Polymers Relene 1070LA17 7 www.ril.com
**
SCG Chemicals EL-Lene D777C 7 http://www.scgchemicals.co.th/
Table 13

* STARLINGER reference materials (tested at STARLINGER)


** Customers reference materials

The LDPE should not contain anti-blocking agents!

Appendix B 08/2019 PAGE 17 / 30


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2.Lamination process

Appendix B 08/2019 PAGE 18 / 30


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2.Lamination process

2.2 Lamination with co-extruder and ink tie layer


2.2.1 Layer structure
This structure is typically used for laminating flexographic reversed
printed film.

Co-Extrusion

image 7

suggested tie layer application weight:


15-30 gsm for fabric
5-10 gsm for film/printing ink
2.2.2 Pros & Cons
Advantage Disadvantage
scratch-resistance of print need of Co-Extruder and feedblock
minimum consumption of expensive
need of special tie layer
performance polymer (e.g. Lotader)
solvent system permitted in US and
Europe
Table 14

2.2.3 Raw material specification and mixing ratio tie layer for
woven fabric:
PP 85%
LDPE 15%

tie layer for film (ink)


performance polymer 100%

Appendix B 08/2019 PAGE 19 / 30


original document
2.Lamination process

Reference materials PP:


MFI
manufacturer name type MFI = g/10min. website
[230°C/2.16kg]
*
Borealis Daploy WF420HMS 22 www.borealisgroup.com
*
Sasol ESV 200 28 www.sasol.com
*
TVK Tipplen R959A 45 www.tvk.hu
*
APC Advanced PP 1101R 24 http://www.advancedpetrochem.com/
*
Braskem RP 144 40 www.braskem.com.br
*
Braskem Inspire 364 42 www.braskem.com.br
*
lyondellbasell Moplen RP3386 25 https://www.lyondellbasell.com/
*
lyondellbasell Moplen RP2380 48 https://www.lyondellbasell.com/
*
Sabic QR 674K 40 http://www.sabic.eu
*
Sabic RA12MN40 40 http://www.sabic.eu
*
TPC Cosmoplene FC9415G 30 https://www.tpc.com.sg/
*
Borealis WG341C 25 www.borealisgroup.com
**
Basell Moplen EP229S 32 https://www.lyondellbasell.com/
**
Tasnee PP H 2250 25 www.tasnee.com
**
Sasol HTV 145 50 www.sasol.com
**
Petroquim PH4040 40 www.petroquim.cl
**
Lukoil Buplen 6231 16-25 www.lukoil.bg
**
Indelpro Profax PL835N 34 www.indelpro.com
**
CPA CERTENE PHM-35 35 www.channelpa.com
**
Braskem CP 144 45 www.braskem.com.br
**
Arak Petr. Co. Moplen HP 552 R 25 www.arpc-ir.net
**
Reliance Polymers Repol H350EG 38 www.ril.com
**
Reliance Polymers Repol H350FG 35 www.ril.com
**
Sabic PP 511A 25 http://www.sabic.eu

***
lyondellbasell Adflex Z101H 27 https://www.lyondellbasell.com/
***
ExxonMobil Vistamaxx 3980 FL 8 vistamaxxelastomers.com
***
ExxonMobil Vistamaxx 3588 FL 8 vistamaxxelastomers.com
Table 15

* STARLINGER reference materials (tested by STARLINGER)


** Customers reference materials
*** PP modifier for improved adhesion performance. Dosage 0-
30% instead PP

Recommend MFI [230°C/ 2,16kg]:


20 - 50 g/10 min.

Appendix B 08/2019 PAGE 20 / 30


original document
2.Lamination process

Reference materials LDPE:


MFI
manufacturer name type MFI = g/10min. website
[190°C/2.16kg]
*
lyondellbasell Lupolen 2420 K 4 https://www.lyondellbasell.com/
*
TVK Tipolen FD 243-51 4 www.tvk.hu
*
ExxonMobil LD 258 8.2 http://www.exxonmobilchemical.com/
**
Sabic HP 4023W 4 www.sabic.com
**
Sabic HP 2022J 2 www.sabic.com
**
DOW Plastics 722 8 http://plastics.dow.com
**
DOW Plastics PG 7008 7.7 http://plastics.dow.com
**
DOW Plastics PG 7004 4.1 http://plastics.dow.com
** Qatar Lotrene
FD 0474 4 www.qapco.com
Petrochemical
** Qatar Lotrene
LA 0710 8 www.qapco.com
Petrochemical
**
Braskem BC 818 8.1 www.braskem.com.br
**
IPPC LF0 200 2 http://www.petrochem-ir.net
** Reliance Relene
1070LA17 7 www.ril.com
Polymers
**
SCG Chemicals EL-Lene D777C 7 http://www.scgchemicals.co.th/
Table 16

* STARLINGER reference materials (tested at STARLINGER)


** Customers reference materials
Reference materials performance polymer:
MFI
manufacturer name type MFI = g/10min. website
[190°C/2.16kg]
*
Arkema Lotader 4503 8 https://www.arkema.com/en/

Table 17

* STARLINGER reference materials (tested by STARLINGER)


** Customers reference materials

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2.Lamination process

Appendix B 08/2019 PAGE 22 / 30


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3. Lamination of AD*STAR® patches

3 LAMINATION OF AD*STAR® PATCHES

3.1 Lamination of patches without ink tie layer


In case of patch lamination without ink tie layer the front and back
side lamination process can be done in one step. Hence the flat wPP
will be laminated both sides via the turning bar and the film can be
attached to one side of the wPP at the same time.
wPP front & back side lamination in one step:

image 8

3.2 Lamination of patches with ink tie layer


In case of patch lamination with ink tie layer the front and back side
lamination process has to be executed in two steps. In the first step
one side of the wPP will be lamination coated with a standard coating
material blend of 85% PP + 15% LDPE. In the second step the wPP roll
will be laminated with the film using the ink tie layer to ensure proper
bonding strength.

Appendix B 08/2019 PAGE 23 / 30


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3. Lamination of AD*STAR® patches

wPP front & back side lamination in two steps:


first step: standard coating (without any tie layer)

image 9

second step: film lamination with ink tie layer

image 10

Appendix B 08/2019 PAGE 24 / 30


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3. Lamination of AD*STAR® patches

Appendix B 08/2019 PAGE 25 / 30


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5. Settings

4 SETTINGS

 Clean CORONA station frequently according to the


surroundings.
 Suction system (attention: flow switch in pipe)
 Set CORONA pre-treatment in a way to achieve 38 and 42
[dyn]
 Distance of ceramic electrodes to counter roller max. 2mm
 Distance of steel electrodes to counter roller max. 1.8mm
 Ceramic counter roller (use cleaning fluid only).
 Adjust the safety device for the CORONA electrodes exactly,
otherwise it will not work correctly.
 Coating edge/ fin should not exceed 5 mm on each side,
otherwise problems with the bottom fold will occur on the
conversion machine.
 Recommended chill roll temperature between 25° and 30°C.
 The lamination and film thickness should be the same on the
patches and on the main fabric.
 The melt curtain should not exceed the lateral edge of the
BOPP film, when using a special ink tie layer (Lotader)
 Positioning and calibration of print mark sensors
 Specification of print mark – tec. SPEC
 It is not recommended to refeed printed BOPP-Edgetrim

Appendix B 08/2019 PAGE 26 / 30


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5. AD*STAR® Quality

5 AD*STAR® QUALITY

A very important factor for success with AD*STAR is to check and


maintain the quality of all intermediate products on a regular basis.
 Carry out all the tests according to STARLINGER’s Laboratory
Handbook.
Chapter No. 5.2 “general advice, testing frequency”, gives some clues
for the implementation of the tests and what should be considered
during production. The frequency with which the tests should be
carried out is specified. Furthermore some forms are attached that
should be used to fill in the results of the tests. The filled form should
accompany the product from the first intermediate product to the final
product. This system guarantees good quality of the final product. It
helps to locate and minimise faults.

Appendix B 08/2019 PAGE 27 / 30


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5. AD*STAR® Quality

5.1 Quality standards


Laminated fabric (unperforated):
raw material as per specification above
tenacity min. 4.5g/den (warp and weft direction as well as
across the edge; strip test based on DIN EN ISO
13934-1)
elongation 18-26% Fmax (max. 5% less than uncoated fabric)
coating weight 17-30g/m²
coating weight ±3g/m²
tolerance
total weight ±4g/m²
tolerance (fabric +
coating)
coating adhesion min. 1.5N/cm – recommended 2N/cm
(according to STARLINGER test of adhesion in
fabric/film composites – ‘report of laboratory
findings’)
over-coating (circular min. 2mm; max. 5mm (on each side)
wPP)
back seam width 25-50 mm
(tubed)
cloth core (inside 203mm/8” (preferably on plastic cores – no
diameter) cardboard cores)
finished roll diameter min. 1200mm; max. 1500mm
roll quality hard, without longitudinal or crosswise folds, no
telescopic shape, straight edge, uniform diameter
max. edge 50mm (due to traverse motion unit, depending on
displacement (main machine speed and cutting length)
fabric)
Table 18

Fabric strips for valve/bottom patches:


finished roll diameter min. 800mm; max. 1000mm
cloth core (inside 203mm/8” (preferably on plastic cores – no
diameter) cardboard cores)
width of bottom bottom width – 5mm
patches
width tolerance ±1mm
roll quality hard, without longitudinal or crosswise folds, no
telescopic shape, straight edge, uniform diameter
Table 19

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original document
5. AD*STAR® Quality

Printed fabric:
repeat length tolerance ±1mm
fabric core (inside 203mm/8” (preferably on plastic cores – no
diameter) cardboard cores)
print design of main  no print 50mm in front of the printing mark
fabric  print mark width min. 10mm, length 30-50mm
print design of patch  no print 50mm in front of the printing mark
material  print mark width min. 6mm, length 30-50mm
finished roll diameter min. 1200mm; max. 1500mm
(main fabric)
finished roll diameter min. 800mm; max. 1000mm
(bottom and valve
patches)
roll quality hard, without longitudinal or crosswise folds, no
telescopic shape, straight edge, uniform diameter
max. edge displacement 50mm (due to traverse motion unit, depending on
(main fabric) machine speed and cutting length)
Table 20

Finished bags:
strength of welding Strip test related to EN ISO 13934 and according to
STARLINGER standard.
The tensile strength of the outer strip (front and
rear triangle) must not fall below 65% of the tensile
strength of the non-welded fabric in warp direction.
The individual tensile strength of the centre strips
(without front and rear triangle) must not fall below
75% of the tensile strength of the non-welded
fabric in warp direction.
elongation bottom min. 10% – recommended 12% Fmax
(strips)
fabric overlap 20mm (10mm on each bottom side)
(beneath the welded
bottom patches)
bottom width ±3mm
tolerance
length tolerance of the ±5mm
bag
air permeability/ According to filling station, in average 10-100m3/h
perforation for powdery goods. (testing pressure 50 mbar)
The perforation may reduce fabric strength and
elongation between 5% - 40%, according to the
needle density, the penetration intensity and the
condition of needle sleeves and counter roller,
therefore, regular maintenance is essential.
drop test minimum requirements:
(Starlinger recommendation)
Flat: min. 1,8m
Lateral : min. 1,4m
Upright: min. 1,2m
(The drop test height may vary due to filling

Appendix B 08/2019 PAGE 29 / 30


original document
5. AD*STAR® Quality

product, bag size and specific customer


requirements.)
Table 21

General:
production ´AD*STAR® handbook´ and ´report of laboratory
findings´ are the guiding documents and support for
the production
faults Weaving, coating and printing faults should be marked
on one side of the rolls with coloured tape (suitable for
the customer’s recycling machinery)
fabric Joining of two rolls by taping fabric ends is not allowed
and may create problems for the effective running of
the conversion line
Table 22

5.2 General advice, testing frequency


5.2.1 Raw material
 Visual check of the material at delivery (kind of packing) and
during filling into the dosing system.
 Check for: Moisture content, contamination.
 If there is a high possibility of contamination in the factory
(sand, dust) preventive steps should be taken.
5.2.2 Printed, laminated fabric
 Quality control check once per roll.
 The appearance has to be checked visually (e.g. roll quality
and diameter).
 During production on the coating line it is necessary to watch
for correct adjustment of the edge cutting device.
 Quality of printing has to be compared with the original
sample or photograph.
 Printing ink adhesion (tape test) in case of surface print only
5.2.3 Converted bag
 Quality control checks (full lab report) after each 2000 bags at
the beginning, afterwards it can be decreased to a frequency
of 4000 bags or more. (At the beginning it is very important
that the quality control is working well).
 Visual check of bag geometry (permanent)
 Check whether the valve is open. (permanent)
 Area of welding: Make sure that the hot air welding system is
adjusted correctly – see owner’s manual of the ad*starKON
conversion line. This affects the impact area of the hot air.
 Air permeability test

Appendix B 08/2019 PAGE 30 / 30


original document

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