Critical Role of On-Line Gauging System in Extrusion Coating Troubleshooting, 2006 PLACE Conference

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Computer-based on-line gauging system plays a critical role in trouble-shooting of Extrusion Coating process during various stages of manufacturing. The system monitors a multitude of process variables continuously and trends the data for process monitoring. Time-based trends of various temperatures, pressures and speeds can be displayed continuously, along with coating thickness to show cause and effect. The high degree of process visibility is of tremendous value to the Line Operators and Process Engineers to setup the equipment at start-up and product changes, as well as to monitor production continuously. System ensures full-width coating gauge uniformity through effective process controls in the cross and down web directions, while monitoring substrate variability. Software features such as Process Variance Analyzer and FFT provide efficient process analytical tools for trouble-shooting of uncontrolled high frequency short-term machine direction variations caused by worn-out process equipment. Other sensors (such as visual inspection system) can be integrated to show ultra-high resolution display for troubleshooting defects.

Alarm history provides critical information on coated rolls for downstream processes such as slitting. The impact of timely trouble-shooting on improved Product Quality and Process Economics derived from material savings, scrap reduction and faster start-ups/ product change-overs can be significant.