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2009 PLACE Conference November 10-14, 2009
Mubai and New Dehli, India
Recent Advances in FSIR On-Line Measurement of Coating Weights in Complex Extrusion Coating Process
for Aseptic Packaging
Presented by: Name Mr. Vinay Verma Title Regional Sales Manager Company Thermo Fisher Scientific
2
AGENDA
Problem Statement
Principles of Measurement: IR Ratiometric vs Full Spectrum Infrared
Discussion of Results: Contribution of HR-FSIR
Discussion: HR-FSIR vs. Conventional IR
Selecting the Right Sensor for the Application: Technology Comparison
Case Study #1: Results
Case Study #2: Results
Conclusion
3
PROBLEM STATEMENT
Challenges of on-line measurement of complex fast moving webs
• Paperboard with Top & Bottom PE Coatings• Aseptic packaging product structure:
• Printed paperboard with Decorative PE layer, PE Laminate, Aluminum Foil, Tie and Barrier layers
Need to measure extruded coatings close to edges of substrates
Need to minimize or eliminate effects of printing, fillers etc. on coat weight measurements
Which sensor technology or technologies are optimal for my application?
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FSIR/IR Measurement Principles
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Principle of Ratio-Metric IR Measurement
Select One Wavelength With High Absorption - “A”Select One Wavelength With Low Absorption – “R”This Ratio “A”/“R” is Proportional to Weight
“A”“R”
“R”
“A”
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Ratio-metric IR Measurement
Measurement Limitations:Limited spectral information provides limited measurement capability
Optics degrades the signal-to-noise ratio
Measurement of new materials requires new filters and re-calibration
Sources of Measurement Error:Colorants and pigments such as titanium dioxide may cause measurement error
Light scattering from voided films
Optical interference from thin films
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FSIR Sensor
Source Spectrum
Vector
Absorption Spectrum
Optics
MSP
Filter Matrix
FixedDetector Array
Optics
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Infrared Coat Weight Measurement
Each Material Has Unique Absorption Pattern
weaker
STRONGER
Absorption is StrongerAt Certain Wavelengths
Compared to Others
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Chemometric Analysis
Full Spectrum Array Accurate Calibration ForClear, Pigmented or
Voided Films
ChemometricAnalysis
Chemometric Analysis: Intelligent Calibration Recognition
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Lamp and Filters Response
Lamp Response
Material "Signature"
Full Spectrum Array
Absorption
Intensity
Absorption
Trans
Intensity
FSIR Conventional Optics
#1
#2
SIGNAL
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Comparison of FSIR vs IR Sensors
Comparison of FSIR vs other sensor technologies
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Effect of Coatings on Infrared Measurement
Comments:Polyester base materialNote changes in the 1.4 to 2.5 μm rangeFSIR are looking at the shape, not the absorbance
Pigmented Coating Clear Coating Metal Surface Effect
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Foil/Adhesive/Top Coat Polymer Breakdown
Spectrum shows the same material with varying foil, adhesive and polymer composition
FSIR is able to separate and measure the:
• Top coat polymer• Adhesive polymer
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Foil/Adhesive/Top Coat Polymer Calibration
Calibration results for:• Top coat polymer• Adhesive polymer
… for a foil/adhesive/polymer structure
Top coat polymer Adhesive polymer calibration
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FSIR: Standard vs. HR Spot Size
19 mm diameter
6 mm x 25 mm
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0
10
20
30
40
50
60
2.0 1.9 1.8 1.7 1.6 1.5 1.4 1.3 1.2 1.1 1.0 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0.0 -0.1
-0.2
-0.3
-0.4
-0.5
-0.6
-0.7
-0.8
-0.9
-1.0
Inches from edge
Coa
t wei
ght a
t edg
e
Original
SpectraBeam-HR
Poly CoatingBoard Edge
0.25" Wide Poly Strips
FSIR HR Provides High-Resolution Edge MeasurementResult: Additional bolt on each edge for APC
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Results: Pigments and Black Body Absorbers
Titanium dioxide, and carbon black
Tran
smis
sion
With TiO2 Scattering
With Carbon Black
100908070605040302010
01.3 3.4Wavelength (Microns)
Polymer only
Comments:Carbon is a black body absorber. The sample contains a trace of carbon that severely reduces the transmissionTiO2 acts as an opacifier, both scattering and reducing the % transmission (blue end scatters, higher wavelength scattered less)FSIR can measure the polymer content in the presence of opacifiers and black-body absorbers
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Results: Effect of print
Printed & Unprinted Surface Spectra
3.02.0
30
20
40
Scanning on Printed Materials
Tran
smis
sion
Ratiometric measurement somewhere in here
Ratiometric reference somewhere in here
Comments:Print, like TiO2, will act as an opacifier and reduce the % transmissionRatiometric gauges takes time-spaced measurements both on and off the printed area, leading to significant errors: Profile accuracy, APC performanceFSIR measures the entire spectrum on the same spot, eliminating measurement error
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Printed Substrate Measurement Conventional IR
Print creates4 + GSM
weight shift
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Printed Substrate Measurement on FSIR Sensor
FSIR removes4+ GSM
print effect
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FSIR SpectraBeam Signal Processing
MeasuredStandardized
Spectrum
Composition #1
Composition #2
Effect #1(Surface)
Effect #2
Residual
Absorption
Chill roll gloss
Moisture
Polymer Color
Whatever’s left
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FSIR vs Ratio-Metric IR Sensors
Feature Scanning Spectrometer Beam Splitter Spinning Filter
Wheel
Noise Characteristics Best Good Good
Dynamic Repeatability Best Good Good
Sensitivity to Printing No Yes Yes
Sensitivity to Additives No Yes Yes
Exact SpotMeasurement Yes Yes NoCalibration Flexibility Yes No NoCalibration Complexity Moderate Easy Easy
Optical Interference No Yes Yes
PolymerDiscrimination Best Limited LimitedMoving Parts No No Yes
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FSIR vs Other Sensor Technologies
Criteria FSIR Conventional IR X-Ray Beta
Noise Characteristics Good Good Good Nuclear Statistic
Noise Degradation over time None None None 1.5% increase/month
Tolerance to Web Flutter Best (+/- 5mm) Best (+/- 5mm) Good (+/- 3mm) Fair (+/- 1mm)
Temperature Sensitivity No No Yes Yes
X,Y,Z Sensitivity No No Yes Yes
Composition Sensitivity No No Yes Some
Dynamic Repeatabilty Best Best Good Good
Mulitlayer Coating Calibration Complexity Moderate Moderate High High
PolymerDiscrimination Possible Possible No No
Mulit-Component Measurement Yes Yes No No
Exact Same Spot Yes No No No
Substrate Effect Minimal Some Yes Some
Printing Additive Effects Minimal Yes Yes Yes
24
Solution: HR-FSIR On-Line Sensor
Illustrated with 2 Case Studies:Case Study #1
• PE extrusion coatings on paperboard (PE- unfilled & with CaCO3)• Top(14gsm)• Bottom(26gsm)
• Sensors: Dual HR-FSIR (6x25mm aperture) with scan speed of 15 cms/sec
• Replacing Ratiometric IR sensors with scan speed of 3.75 cms/sec
• Coating width range: 2.2 to 2.6 meters• Line speed range: 200 to 340 meters/min • Production: 8400 hours/year
25
Case Study #1 Results: Sensor to Lab Correlation
Sensor Vs. Lab Correlation of PE with CaCo3 Correlation Coefficient R2=0.9898
26
Case Study #1 Results
Profile (CD) variations Reduction • Average of 45% reduction in both Top & Bottom PE coatings
Yield Optimization (in Target Management Control)• Resin Savings on Top PE coat = 2.4%• Resin Savings on Bottom PE coat = 4.5%
Annual economic savings is ~ $750,000
27
Solution: HR-FSIR On-Line Sensor
Illustrated with 2 Case Studies:Case Study #2:
• Multilayer co-extrusion of PE & Barrier resins on printed paperboard for aseptic packaging Applications
• Sensors: Top & Bottom HR-FSIR (6x25mm aperture)
• Scan speed of 15 cms/sec replacing Ratiometric IR sensors with scan speed of 3.75 cms/sec, for measurement of Decorative PE & co-extruded Barrier layers
Coating width range: 1.2 to 1.6 meters
Line speed range: 500 to 600 meters/min
Production: 8400 hours/year
28
Case Study #2 Results
Sensor to Lab correlation: R2= 0.98 to 0.99 (various layers)
Profile (CD) variations Reduction • Average of 50% to 60% reduction in various coatings in APC
Yield Optimization (in Target Management Control)• Average Resin Savings on various coatings coat = 3.5%
Annual Economic Savings is ~ $900,000
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Case Study #2 Results: Auto Profile Control
76% Reduction in 7 Mins Approx.
43% CD Reduction in 3 mins approx.
66% Reduction in 7 Minutes Approx.
Faster Response
30
Case Study #2 Results: Auto Profile Control
APC Performance on various coating layers
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Case Study #2 Results: Product Uniformity
High Product Quality and Uniformity
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Results Summary
HR-FSIR solution offers best results as shown in the two Case Studies, where it replaced conventional IR sensors:
• Better dynamic on-line measurements of various coatings
• Full-width measurement, closer to the edges, resulting in less edge scrap
• Enhanced electronics & faster data collection and processing allow for faster scan speeds (four times faster than conventional IR)
• Faster scan speed leads to more frequent controls
• Faster APC response & better APC performance results in increased savings, less scrap, higher productivity
• Substantial Economic Savings
33
CONCLUSION
•High-Resolution FSIR is the optimal and proven choice for measurements of various full-width coatings in a complex extrusion coating process for aseptic packaging
Thank You
PRESENTED BY
Name Mr. Vinay VermaTitle Regional Sales MangerCompany Thermo Fisher Scientific
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