Battenfeld Gloucester: New Slitters Contribute to Conversion Quality Trimless Rolls
Trimless rolls, those produced without removing the edge of the film before it is wound, can be a real challenge. The material and cost savings that result from the lack of edge trim, can make it an enticing niche to some film manufacturers. Producing quality film, at the highest possible first pass yield, for converting operations makes the difference between success and failure in many markets. The rolls need to be flat, smooth, compact, tight from end to end, and ready for high speed printing and converting. Reliable equipment and a stable bubble are critical. This is where Battenfeld Gloucester’s blown film lines contribute to this success.
Between the die and the top of the tower, a number of Battenfeld Gloucester technologies maintain the optimized quality of the film exiting the die. The user friendly UltraCool Air Ring is easy to adjust with repeatable settings. The system is very stable. Even with difficult to process materials and structures the end result is less bubble breathing and fewer wrinkles.
The automated start up function of the Digisonic™ IBC (Internal Bubble Cooling) Control System helps ease thread up and faster product changeovers. Optimized hardware configurations and sophisticated control algorithms enhance maximum bubble cooling while minimizing gauge variations (thick/thin areas).
A contact style Bubble Cage with fully teflon surfaced rollers and composite roller collapsers helps minimize layflat variation while minimizing the effects of friction and temperature for those products that will tolerate contact. BGE offers alternative non contact cages and collapsing frames for ultra critical products.
The Oscillating Hauloff at the top of the tower randomizes any remaining gauge imperfections.
Before actual winding, the film tube is slit by the Trimless Edge Slitter Station. The new high quality slitter design features a lower blade that faces upward towards the inner shoe. The film “walks” down the blade, pulling tension on the film, making for a better cut. The dimpled teflon-coated surface allows the film to float better with less air volume, preventing a “pillowing” effect above the blade holder. Less film pillows mean better layflat control and fewer edge wrinkles.
The precision and stability of the Model 1008 phantom axis dual turret winder with loadcell tension control is the final assurance of perfect edges and tight smooth rolls.
Advantages of producing trimless rolls:
• resin savings
• scrap elimination
• layflat accuracy
• scratch- and stretch-free films
• improved roll geometry
• higher converting speeds