Non-Stop Design Change

UK Headquarters
Wallcovering Machinery Division
USA Facility
Emerson and Renwick Ltd’s UK head office and manufacturing plant
The use of control technology to
enhance the product and to reduce
energy and production costs.
USA
United Kingdom
Emerson & Renwick USA Inc
Emerson & Renwick Ltd
4906 IDA Park Drive
Peel Bank Works
Church
Lockport
New York 14094
Accrington
USA
Lancashire
BB5 4EF
England
Telephone: 001 716 438 0747
Presented by
Fax:
David Miskin and Martin Sinker
Emerson & Renwick Product Ranges
001 716 438 0749
Telephone: 44 (0) 1254 872727
Web site: www.eandr.com
Fax:
email address:
[email protected]
44 (0) 1254 871109
email address:
[email protected]
Emerson & Renwick Development Milestones
Design, Development, Manufacture and Installation
of
Late 1960’s:
Wallcovering Machinery
Automotive Machinery
Radiators, Heaters, Condensers etc.
Dixon Division Machinery
Coating & Laminating
Special Purpose Machinery
16 Hot Embossers, ICI Vymura
1970’s
Duplex, PVC Coating etc.
1980
In-Register Duplex
1982
In-Register Hot Emboss
1986
Shaftless Rotary Screen Press
1990
In-Line Production
1995
Shaftless “Advantage”Gravure Press
2000’s
Screen / Gravure Combinations
Medical, Embossing, Bagging Machinery.
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Emerson & Renwick Wallcovering Machinery
Paper
Emerson & Renwick Wallcovering Machinery
PVC (Paper or Non-Woven Backed)
• Colour, Washable and Prepaste Coating
• Plastisol and Prepaste Coating
• Surface, Flexo, Gravure and Screen Printing, Embossing
• Screen, Gravure and Combination Printing
• In-Register Hot Embossing
Flexo / Gravure In-Line
• Blown Vinyl and Chemical Emboss
• Duplex Laminating and Embossing
In-Register Emboss
Also Full Turn-Key Projects, Machine Rebuilds etc.
• Also Processing of Non-Wovens
What does the Market want from
the Machine Builder ?
What does the Market
want from
the Machine Builder ?
• Less scrap (paper, inks, PVC)
• Lower manning levels
• Less down-time
• Less pollution
• Lower energy costs
• Reduced ink use
• Reduced work-in-progress
2
What does the Market want from
the Machine Builder ?
• Better quality
• Higher output
• Quicker manufacturing time
• Quicker design and colour change
• Safer, quieter
From Line-shaft to
Data-Highway
• Cheaper (update old machines)
• “New Looks”
From Line-shaft to Data-Highway
From Line-shaft to Data-Highway
The last 30 years have seen technological change at
an unprecedented rate, many industries have either
totally disappeared or changed beyond recognition.
Leander Flexo Press 1975
Whilst wallpaper has not fundamentally changed, the
digital revolution has enabled new products and
allowed more efficient production of traditional
products.
All of the prints are line-shaft
driven and registeradjustments made by handwheels.
The next few slides illustrate the evolution of our
machines.
Simple electronics is used to
vary the speed of the main
motor (Pye Tasc Unit).
Still in production in China.
3
From Line-shaft to Data-Highway
In-Register Emboss 1982
The availability of
microprocessor-based
control-systems allowed us
to manufacture our first
high speed In-Register Hot
Embosser in 1982.
Since then we have sold
nearly 100 units.
The digital-system allowed
much more flexibility and
precision.
From Line-shaft to Data-Highway
Shaftless Flexo Press 1985
Still in production in Russia.
This is very similar to the
Leander press made 10 years
earlier, but digital controls have
replaced the hand-wheels and
gear trains.
Adjustment and setting inregister is easier.
From Line-shaft to Data-Highway
From Line-shaft to Data-Highway
Coating – Printing – Embossing 1990
Coating – Printing – Embossing 2004
Digital technology has further
matured.
Digital technology
has matured
allowing the
integration of
previously separate
processes into one
in-line machine.
Control and drive functions are
carried out using massproduction programmable
building blocks. Cost is
reduced, performance and
reliability increased. Advanced
SCADA systems allow better
Human-machine interface, and
allow integration of machine into
plant IT system.
4
Process Integration
Off-Line Production.
COAT
Process Integration
PRINT
EMBOSS
WIND & WRAP
Process Integration
Process Integration
In-Line Production.
Off-Line Production
COAT
WIND & WRAP
PRINT
EMBOSS
Enabling Factors
• Electronic Lineshaft
• Good Tension and Register Controls
• Quick or Non-Stop Design Change
For:
• Economy of Mass Production (PVC Coating)
• Production Flexibility
• Some Speed Advantages
• Use Existing Plant
Against:
• Processing Time
• Space and Value of Work-in-Progress
• High Manning Levels
• High Scrap Levels
• Video Monitoring
5
Process Integration
Process Integration
In-Line Production
In-Line Production
For:
• See End Product at Once
• No Work-in-Progress
• Low Manning Levels
• Low Scrap Levels
• Lower Energy Costs
Against:
• Capital Cost (but can link existing plant)
• One Break Stops All
• Fear
Non-Stop Design Change
Non-Stop design-change-over is especially desirable for complex coatingprinting-embossing lines. If the line is stopped to change designs:
Non-Stop
Design Change
• All of the paper ‘in the line’is wasted,
• Scrap is made while slowing down and speeding up,
• Machine productivity is reduced.
The down side is that a lot of scrap can be generated if many ‘fine-tuning’
adjustments need to be made with the line running at full production speed.
I will now describe two important aspects of Non-Stop machines.
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Non-Stop Design Change
Non-Stop Design Change
Production planning and recipe systems
This is the way it works
1. The operator loads the NEXT job into the machine from the
production planning system. The loaded recipe includes job details
(i.e.; which unit uses which screen) and machine set-up (i.e.; oven
temperatures).
For Non-Stop to work well the production runs need to be carefully
planned. The operators need:
•
•
•
•
Configuration (which unit prints which colour),
Set of rotary screens for the new design,
Inks,
Recipe settings. i.e.:
• Speed
• Tensions
• Oven and hood temperatures
• Squeegee settings.
2. The operator can now change any of the settings, load rotaryscreens and prepare to run the next job.
3. When preparation is complete and all of the new screens are ticking
over the operator can select TRIAL (print a short run for colour and
quality checks) or CHANGE (permanently go to next product).
The SCADA system display a mimic diagram to show progress of
the change-over.
Machines have included recipe systems for some time, but TCP/IP
connectivity can now be included so that the machine can be connected
to the plant IT system, and recipes can be stored in the production
planning system, rather than the machine SCADA system.
Plant IT
System
Jobs
Data-base
5. During the run machine information (i.e.; speed, status) is available
to the plant IT system via the TCP/IP link.
External
Support
Production
planning
Telecomms
Strike-off
Machine
Control Desk
Machine
SCADA
System
68 m/min
Strike-off
Information about
machine operation
‘NEXT’Job
when requested by
operator
4. At the end of the run the operator can send an ‘as run’copy of the
recipe to the planning system.
Touch
Screen
1
Change
2
3
Cancel
4
5
6
7
Web
Video
Information about
machine operation
Machine re-configured
after ‘CHANGE’or
‘TRIAL’selected
Machine
Strike-off 60 m
U
Running Job
Next Job
R
7
68 m/min
Strike-off
Strike-off
1
Change
2
3
Cancel
4
Strike-off 60 m
5
6
Running Job
Strike-off
Change
2
3
Strike-off 60 m
5
6
Running Job
Change
2
7
4
5
6
7
Running Job
Next Job
68 m/min
Strike-off
Strike-off
1
Next Job
3
Cancel
Strike-off 60 m
Next Job
Cancel
4
Strike-off
1
68 m/min
Strike-off
1
7
68 m/min
Strike-off
Change
2
3
Strike-off 60 m
Cancel
4
5
6
Running Job
7
Next Job
8
68 m/min
Strike-off
Strike-off
1
Change
2
3
Cancel
4
Strike-off 60 m
5
6
Running Job
Strike-off
Change
2
3
Strike-off 60 m
5
6
Running Job
Change
2
7
4
5
6
7
Running Job
Next Job
68 m/min
Strike-off
Strike-off
1
Next Job
3
Cancel
Strike-off 60 m
Next Job
Cancel
4
Strike-off
1
68 m/min
Strike-off
1
7
68 m/min
Strike-off
Change
2
3
Strike-off 60 m
Cancel
4
5
6
Running Job
7
Next Job
9
Non-Stop Design Change
68 m/min
Strike-off
Strike-off
1
Change
2
3
Registration systems
Cancel
4
5
6
When running Non-Stop it is especially important that the new
design goes straight into register. Four solutions are available:
7
• Open-loop preset
• Web – Web register control
• Web – cylinder register control
• Web – cylinder register control with dedicated key-mark
Strike-off 60 m
Running Job
Next Job
Non-Stop Design Change
Non-Stop Design Change
Registration systems
Open-Loop preset
Registration systems
Web-Web register control
A register-eye measures the distance between printed marks.
This is the system most often used on screen–printing lines.
The new design is pre-registered based on web paths
between prints, and then manually adjusted to production
tolerance. Pre-registration is normally to within 20mm, but
cannot be exact due to variation of machine and raw material
conditions.
Web-Web systems can give the most accurate register, but
there may be problems when used on screen-printing lines
•Careful set-up is needed to work with very pale marks
•Pad-coats may cause problems because of colour or edge
•If pre-register is not within 10mm (gate-size) manual
adjustment is needed
•Sophisticated mark-sensors result in expensive system
•Skilled operators required to get best results
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Non-Stop Design Change
Non-Stop Design Change
Registration systems
Web-cylinder register control
Registration systems
Web-cylinder register control with dedicated key-mark
A register-eye detects the mark printed by a previous unit.
The control system measures the print-cylinder-angle at the
instant that the mark was detected. Because the print-cylinder
always prints its mark at the same angle, registration error can
be calculated without having to detect the mark printed by the
unit.
This mode is available as a fall-back in conventional web-web
systems, and is used when a unit is printing very difficult
marks. There are, however, two problems:
We have developed a system in which all of the prints register
to a master print-mark printed on the back of the paper.
This has several advantages:
• Not influenced by colour being printed or pad-colour
• Uses simple mark-sensor
• Requires virtually no extra operator skill
1. There must be a good mark printed by a previous unit
• So long as screens are keyed at witness-cross no
configuration is needed
2. Operator intervention is needed to set the system up
• ‘New’design is pre-registered to within about 1mm
before it begins printing
Non-Stop Design Change
Registration systems
Web-cylinder register control with dedicated key-mark
The system is not quite as accurate as a Web-Web system, a
small adjustment to register may be required after, for
example, a change of squeegee-setting. However, register is
accurately maintained during steady running, drift due to
change of Web tension, oven temperature or cooling-drum
temperature being eliminated.
Cleaner Machines
The system is ideal for Non-Stop rotary-screen printing lines.
• It is very easy to use
• It gives accurate registration of ‘new’design before
Non-Stop change
• It is cost effective
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Cleaner Machines
Cleaner Machines
What is in the Plastisol ?
Heating Methods
24%
17%
5%
43%
3%
PVC Resin
Plasticiser
Filler
Tioxide
Additives
White Spirit
Gas Oven
Hot Oil Oven
Drum Gelling
•Cheaper Plant
•Good for Heat
Recovery
•Good Surface
Finish
•Good Temp. Control
•Needs Curing
Downstream
•Quick Warm-Up
•Lower Heat Loss
•Less Exhaust
(LEL’s)
8%
Cleaner Machines
Cleaner Machines
How much Exhaust ?
Evaporation is Expensive
EN 1539 : Safety Requirements
How Much Plasticiser Evaporates and Where:
• Gelling and Curing ?
• Reheat for Hot Embossing ?
• Expansion and Blowing ?
• Loss of Plastisol Weight : 5 to 15%
• Latent Heat of Evaporation : Energy
• Condensation : Drips, fire risk, cleaning costs
• Big Fume Treatment Plant : Expensive
• Replacement Air to Factory : Energy
WE DO NOT KNOW !
Energy Costs, Carbon Taxes, Climate Change Levy
So we have to allow for the worst case.
IT WILL GET MORE EXPENSIVE !
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Cleaner Machines
Some Possible Savings
• Auto-Thermal Fume Treatment, Heat Recovery
(CHP: waste heat to power)
Wallcovering Machinery Division
• Fume Monitoring and Feedback
(Every hood and zone)
• Variable Speed Fans
• Energy Saving Motors
• Localised Fume Treatment ?
• Improved Plastisols
(SCL)
• Low Evaporation (non-phthalate) Plasticisers
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