ISIS 2011 Düsseldorf/Germany

Film Inspection: The Gel Count Standard

What resolution and defect detection
can be realised and make sense
- with practical examples

Presented by:
Oliver Hissmann
Sales Manager
OCS Optical Control Systems GmbH

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 Contents
¾ Introduction
¾ Definition Gel
¾ Inspection Standard of the Polymer Industry
¾ Defect Types and Resolution
¾ Practical Examples
(Optical, Pharma, Technical, Diaper, Food &
Surface Protection Films)
¾ Summary

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Web Inspection in Film Extrusion

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Web Inspection in Film Extrusion

100 % Optical Control of the Web

¾ Photo of every defect

¾ Position of every defect

¾ Database Interface

¾ Reports

¾ Alarms

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 Advantages of Web Inspection
¾ Process Control
(cleaning, waste, reduction of downtime)

¾ Raw Material
(control material + recipe)

¾ Product
(better quality, less claims, more competitive products)

Considerable Cost Savings!!

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¾ Definition Gel

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Gels & Defects

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¾ Inspection Standard of
the Polymer Industry

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Online „Closed Loop Control“-Concept

Additives

Process Production
Raw material
Sampling

Feedback On-line Quality

Assurance

Data (opt. measuring technique)

Determination of the Process computer

process parameters

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Online Laboratory at Kayan

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Online Quality Control at Sabic

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Online Lab at Basell

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Online Lab at Sasol

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 Start injection cleaning agent

Plant shut down

Online Anticipation of Plant Shut Down

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Online Transition Control
Stop injection cleaning agent

Stop extruder rinsing

Start extruder cleaning

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Online Control of Extruder Start Up
Extruder startup after plant restart, start extruder cleaning

Stop injection cleaning agent

Stop extruder rinsing

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 Benefits of Online Control

¾ Process Control
(Optimisation, capacity, cleaning, waste)

¾ Product
(better quality, customer satisfaction/relation, less claims,
more competitive products)

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¾ Defect Types & Origin

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 Defect Types
¾ Gels
¾ Black Specs
¾ Contaminations
¾ Die Lines
¾ Insects
¾ Calander Defects
¾ Oil Stains
¾ Air Bubbles
¾ etc.
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 Origin of Defects

¾ Extrusion Line 20 %
(screw geometry / dead zones)

¾ Resin 25 %
(contamination, recipe)

¾ Production Process 15 %
(extruder temperatures, screen change)

¾ Pellet Transport 40 %
(external/internal)

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¾ Practical Examples
- Optical Films & Sheets
- Pharma Films & Coatings
- Technical Films
- Diaper Films
- PET Food Films
- Surface Protection Films
- Extrusion Coating on Alu Boards

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 Optical Films & Sheets

¾ Product: Optical Film & Sheet & Coatings

¾ W = 1400 - 2500 mm
V = 3 - 80 m/min.
¾ Defects:
gels, black specs, fish eyes
optical distortions, lenses, flow/die lines, scratches
¾ Resolution Range: 25 – 100 µm
¾ Defects Specs: various

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Darkfield Inspection

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Optical Distortion Inspection

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Optical Distortion Inspection: Lens

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Closed Frame Optical Films 50 µm res.

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Closed Frame

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 Pharma Films & PVDC Coatings

¾ Product: PVC Pharma Films & PVDC Coatings

¾ W = 1400 - 2500 mm
V = 100 - 200 m/min.
¾ Defects:
gels, black specs, fish eyes, holes, insects
inclusions, coating voids, coating structure defects
¾ Resolution: 200 µm
¾ Defect Specs: 1 defect < 1 mm² per 10 m²
0 defect > 1 mm² per 10 m²

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Pharma Films & Coatings

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Inclusion

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Inclusion

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Coating Structure

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 Technical Films

¾ Product: Technical Films

¾ W = 1400 - 2600 mm
V = 100 - 200 m/min.
¾ Defects:
gels, black specs, fish eyes, holes, insects
¾ Resolution: 100 - 200 µm
¾ Defect Specs: various

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Closed Frame Blown Film

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Time History (Gel Level)

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Rolling Map / Die Defect

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 Diaper Films

¾ Product: Diaper Films

¾ W = 1400 - 2600 mm
V = 200 - 600 m/min.
¾ Defects:
gels, black specs, fish eyes, holes, insects
¾ Resolution: 500 µm
¾ Defect Specs: 1 mm

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Slit Alarm

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 PET Food Films

¾ Product: PET Food Films

¾ W = 1400 - 2600 mm
V = 200 - 250 m/min.
¾ Defects:
gels, black specs, fish eyes, holes, insects
¾ Resolution: 200 - 500 µm
¾ Defect Specs: visible

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PET Films

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Alarms / Repeating Defect

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Roll Stack Defect

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 Surface Protection Films

¾ Product: Surface Protection Films

¾ W = 1400 - 2600 mm
V = 100 - 250 m/min.
¾ Defects:
gels, black specs, fish eyes, holes, insects
¾ Resolution: 60 - 160 µm
¾ Defect Specs: 1 mm
¾ Defect Height: factor 1.1 – 1.5 times film thickness

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Surface Protection Films

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 Defect Results

Fish-eye
in a 3-layer Coex Film

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 Defect Results

Fish-eye marked in
aluminium sheet

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 Defect Results

Aluminium/Film
Laminate with
Contamination

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 Extrusion Coating on Alu Boards

¾ Product: PE Coated Aluminium Board

¾ W = 1400 - 2800 mm
V = 500 - 600 m/min.
¾ Defects:
PE spots, black spots, coating spots,
aluminium splices, missing coating,
aluminium peel-off, paper board creases
¾ Resolution: 350 µm

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High Power COB LED 3.000 mm
Extrusion Coating Alu

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Metal Splice

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Oil Drop

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Burst Bubble

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Wrinkle

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General Specifications (Resolution)

¾ PET Food Films: ∅ 200 - 500 µm

¾ Technical Films: ∅ 100 - 200 µm
¾ Surface Protection Films: ∅ 60 -160 µm
¾ Optical sheets + films: ∅ 25 -100 µm
¾ Extrusion Coating: ∅ 350 µm
¾ Diaper Films: ∅ 500 µm
¾ Pharma Films: ∅ 200 µm

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Thank you
PRESENTED BY

Oliver Hissmann
Sales Manager
OCS Optical Control Systems GmbH
hissmann@ocsgmbh.com

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