Tape Manufacturers Can you survive the competition

February 2017February 2017By Shrikant AthavalePrathith Consultants , PUNE MS [email protected]

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Tape manufacturesTape manufacturesCanCan youyou survive thesurvive thecut throatcut throat CompetitionCompetition ??

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Tape manufacturesTape manufacturesCanCan youyou survive thesurvive thecut throatcut throat CompetitionCompetition ??

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This is a general comment / remark , today

All the Industries are facing this issue.

especially the Adhesive Tape Industry isfacing a very stiff competition , withinlocal manufacturers , as well as ChineseManufacturers

So the question is how to tackle this ?

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This is a general comment / remark , today

All the Industries are facing this issue.

especially the Adhesive Tape Industry isfacing a very stiff competition , withinlocal manufacturers , as well as ChineseManufacturers

So the question is how to tackle this ?

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eed YesYes

The answer is we have to be cost effective.But is it sufficient to be just cost effective ?

NONO

We have to be cost effective , with no compromise inWe have to be cost effective , with no compromise inquality , quantity .quality , quantity .YesWe can face stiff competition by offering qualityproduct and also in huge quantity

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eed YesYes

The answer is we have to be cost effective.But is it sufficient to be just cost effective ?

NONO

We have to be cost effective , with no compromise inWe have to be cost effective , with no compromise inquality , quantity .quality , quantity .YesWe can face stiff competition by offering qualityproduct and also in huge quantity

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Now

How to be cost effective ?cost effective ?

We will try and see the ways and means to be costeffective.

This is big challengeBut we can accept this and achieve it

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Now

How to be cost effective ?cost effective ?

We will try and see the ways and means to be costeffective.

This is big challengeBut we can accept this and achieve it

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eed We all know

That for the manufacture of any kind of adhesive tapeWe need basically

1. The Necessary raw materials2. The machinery or equipment , for coating, slitting ,

packing3. The testing equipment4. Energy , like Electricity , Fuel5. Manpower to operate the machines6. A place , shop floor to install the machines

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eed We all know

That for the manufacture of any kind of adhesive tapeWe need basically

1. The Necessary raw materials2. The machinery or equipment , for coating, slitting ,

packing3. The testing equipment4. Energy , like Electricity , Fuel5. Manpower to operate the machines6. A place , shop floor to install the machines

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eed Knowing this we can understand that the cost of the

adhesive tape product can be basically divided intobelow mentioned heads

1. Raw Material cost2. The Packaging Material cost3. The Manufacturing Cost4. The last but the most important one is the Profit

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eed Knowing this we can understand that the cost of the

adhesive tape product can be basically divided intobelow mentioned heads


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So now the question isHow to be cost effective in


Here we all will agree that thequality and quantityquality and quantitywill play a major role in controlling the cost.

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So now the question isHow to be cost effective in



How ?Let us analyze the same one by one.

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1.1. Raw Material costRaw Material cost

The Cost of Raw Materials will remain the samemore or less for anybody.ButButBuying larger quantities can help us in gaining extradiscounts , and hence some cost saving is possible.Buying quality raw materials will it help to save cost ?YesYesBuying quality raw materials could be , look to beexpensive , at its face value , but will prove to be costeffective , at a later stage .

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The Cost of Raw Materials will remain the samemore or less for anybody.ButButBuying larger quantities can help us in gaining extradiscounts , and hence some cost saving is possible.Buying quality raw materials will it help to save cost ?YesYesBuying quality raw materials could be , look to beexpensive , at its face value , but will prove to be costeffective , at a later stage .

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Let us analyze now , how quality can control the cost ?Let us analyze now , how quality can control the cost ?

Let us consider we buy , seconds quality , or stock lots , orLet us consider we buy , seconds quality , or stock lots , oradhesive / coatings , with lower solids content ?adhesive / coatings , with lower solids content ?

We pay less while buying ,We pay less while buying ,but ?but ? Pay more ultimately , due to more wastages , morePay more ultimately , due to more wastages , moreconsumption , heavy rejections.consumption , heavy rejections.How ?How ?Just consider the facts mentioned belowJust consider the facts mentioned below

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Let us analyze now , how quality can control the cost ?Let us analyze now , how quality can control the cost ?

Let us consider we buy , seconds quality , or stock lots , orLet us consider we buy , seconds quality , or stock lots , oradhesive / coatings , with lower solids content ?adhesive / coatings , with lower solids content ?

We pay less while buying ,We pay less while buying ,but ?but ? Pay more ultimately , due to more wastages , morePay more ultimately , due to more wastages , moreconsumption , heavy rejections.consumption , heavy rejections.How ?How ?Just consider the facts mentioned belowJust consider the facts mentioned below

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eed Let’s consider ,

Case study no. 1Case study no. 1

Consider we buy Stock lot Paper / filmsThe cost per kg will be very attractive , no doubt . But thenwhere do we lose money ?

Non standard width , non standard gram mage , non standardthickness , reworking or recoating , gauge or gram magevariation across the width , or along the length are thefeatures of the stock lots. These variations will lead to morerejections , or extra consumption of , backing material oradhesive or any other similar coating.

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Consider we buy Stock lot Paper / filmsThe cost per kg will be very attractive , no doubt . But thenwhere do we lose money ?

Non standard width , non standard gram mage , non standardthickness , reworking or recoating , gauge or gram magevariation across the width , or along the length are thefeatures of the stock lots. These variations will lead to morerejections , or extra consumption of , backing material oradhesive or any other similar coating.

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Let’s consider ,Case study no. 2Case study no. 2

Consider we buy adhesive or coating with lower solidsThe cost per kg will be very attractive , no doubt . But thenwhere do we lose money ?

To get / achieve the desired adhesive coat weight ( dry ) onehas to coat higher adhesive coating weights. Hence the costbenefit by buying at lower price is compensated by coatingextra adhesive.The second disadvantage of higher coating weight resultsinto lower drying speeds, lower physical properties offinished product . So as a matter of fact the cost per suaremeter increases and the same will reflect in the companiesBalance sheet at the end of the year.

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Consider we buy adhesive or coating with lower solidsThe cost per kg will be very attractive , no doubt . But thenwhere do we lose money ?

To get / achieve the desired adhesive coat weight ( dry ) onehas to coat higher adhesive coating weights. Hence the costbenefit by buying at lower price is compensated by coatingextra adhesive.The second disadvantage of higher coating weight resultsinto lower drying speeds, lower physical properties offinished product . So as a matter of fact the cost per suaremeter increases and the same will reflect in the companiesBalance sheet at the end of the year.

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Consider we buy backing films/ fabrics / foam / foils etc .From stock lots ?

The cost per kg will be very attractive , no doubt . But thenwhere do we lose money ?

The stock lots are invariably , having gauge variation , andhence , you compensate for this by coating extra adhesive tomatch the total thickness of the product .This is a unwanted variation in the final product and willresult in uneven , peel , shear and Tack , adhesion properties, across the widths. This can result into major rejections .

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Consider we buy backing films/ fabrics / foam / foils etc .From stock lots ?


The stock lots are invariably , having gauge variation , andhence , you compensate for this by coating extra adhesive tomatch the total thickness of the product .This is a unwanted variation in the final product and willresult in uneven , peel , shear and Tack , adhesion properties, across the widths. This can result into major rejections .

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Consider we buy backing paper , films/ fabrics / foam / foilsetc . From stock lots ?


The mismatching widths , the gauge variation across thewidth can result into a lot of wastage , in an effort tomatching , by trimming .

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Consider we buy backing paper , films/ fabrics / foam / foilsetc . From stock lots ?


The mismatching widths , the gauge variation across thewidth can result into a lot of wastage , in an effort tomatching , by trimming .

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To sum up

after the above case studies you will realize thatIn an effort to reduce the cost of raw materials , bychoosing the sub standard ones,You land up into spending extra money , extra timefor manufacture , and some time a bad reputation.

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To sum up

after the above case studies you will realize thatIn an effort to reduce the cost of raw materials , bychoosing the sub standard ones,You land up into spending extra money , extra timefor manufacture , and some time a bad reputation.

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The Packaging Material cost

The Cost of Raw Materials will remain the samemore or less for anybody.



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The Packaging Material cost

The Cost of Raw Materials will remain the samemore or less for anybody.



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eed Try and buy in large quantity to avail special

quality discountsHere you could save on cost at the same time youcan get consistent quality .

Quantity purchases can also help in reducing thehandling and transportation cost .

This will also avoid last moment running aroundfor want of packaging materials.

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eed Try and buy in large quantity to avail special

quality discountsHere you could save on cost at the same time youcan get consistent quality .

Quantity purchases can also help in reducing thehandling and transportation cost .

This will also avoid last moment running aroundfor want of packaging materials.

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The Manufacturing Cost



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The Manufacturing Cost



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More the quantityquantity you produce , lesser will be thechange over's , and hence the wastage incurred will alsobe low

Similarly , the good qualityquality material that is processedwill certainly incur lower wastages.

Here too the variables are

Raw MaterialPackaging MaterialProcessing EquipmentThe Man Power

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More the quantityquantity you produce , lesser will be thechange over's , and hence the wastage incurred will alsobe low

Similarly , the good qualityquality material that is processedwill certainly incur lower wastages.

Here too the variables are

Raw MaterialPackaging MaterialProcessing EquipmentThe Man Power

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Raw Material

Packaging Material

Quality

Quantity

Quality

Quantity

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Man Power

Processing Equipment Quality

Quality

Quantity

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Raw Material

QualityQualitySuch as uniform gauge, weight per sq. mtrs, width etc.Will reflect in the quality of the finished productBetter the quality of raw material better will the finished product ,and lower will be the wastagePlease find some illustrations non the next slide

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QualityQualitySuch as uniform gauge, weight per sq. mtrs, width etc.Will reflect in the quality of the finished productBetter the quality of raw material better will the finished product ,and lower will be the wastagePlease find some illustrations non the next slide

QuantityQuantityWill also play a vital role in the quality of the end product . LargerWill also play a vital role in the quality of the end product . Largerthe quantity that is processed will result in consistent quality of thethe quantity that is processed will result in consistent quality of thefinished product and will keep the wastage on lower sidefinished product and will keep the wastage on lower side

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Un uniform thickness orsalvage group createshigher wastage

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WebWebAdhesiveAdhesiveLinerLinerWidths notWidths notmatchingmatching

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Mismatching width of websresult into higher wastage

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Packaging Material

QualityQualityEspecially the quality of paper cores can reduce the wastage to agreat extent. Poor quality paper cores , might result into , corecollapse and unwanted but very expensive rejection.For example , just for the sake of saving some money the paper corewall thickness or the quality of paper , or the quality of paper glue iscompromised . No doubt there is some saving , but this is a shortterm saving. The value of the Adhesive tape wound on this papercore is almost 10 times of the value of paper core . Hence theoutcome is there is loss incurred to the tune of more than 10% , dueto wrong select of paper core.Same is the case with packaging cartons. A 3 ply carton , in place of5 ply might save some money , but the same will result in hugewastage of quality product packed inside , at the end

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eed QualityQuality

Especially the quality of paper cores can reduce the wastage to agreat extent. Poor quality paper cores , might result into , corecollapse and unwanted but very expensive rejection.For example , just for the sake of saving some money the paper corewall thickness or the quality of paper , or the quality of paper glue iscompromised . No doubt there is some saving , but this is a shortterm saving. The value of the Adhesive tape wound on this papercore is almost 10 times of the value of paper core . Hence theoutcome is there is loss incurred to the tune of more than 10% , dueto wrong select of paper core.Same is the case with packaging cartons. A 3 ply carton , in place of5 ply might save some money , but the same will result in hugewastage of quality product packed inside , at the end

Quantity , will also be contributing to the wastage

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This is a Typical Example of total rejectionThis is a Typical Example of total rejectionof a good quality Adhesive tape , just dueof a good quality Adhesive tape , just dueto inferior quality of paper core . Hence ato inferior quality of paper core . Hence asaving of mere 5% in the coat of papersaving of mere 5% in the coat of papercore can result into very ejection ofcore can result into very ejection offinished productfinished product

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This is a Typical Example of total rejectionThis is a Typical Example of total rejectionof a good quality Adhesive tape , just dueof a good quality Adhesive tape , just dueto inferior quality of paper core . Hence ato inferior quality of paper core . Hence asaving of mere 5% in the coat of papersaving of mere 5% in the coat of papercore can result into very ejection ofcore can result into very ejection offinished productfinished product

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This is a Typical Example ofThis is a Typical Example oftotal rejection of a good qualitytotal rejection of a good qualityAdhesive tape , just due toAdhesive tape , just due toinferior quality of corrugatedinferior quality of corrugatedbox . Hence a saving of merebox . Hence a saving of mere5% in the coat of paper core can5% in the coat of paper core canresult into very ejection ofresult into very ejection offinished productfinished product

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Processing Equipment

QualityQuality

Plays a very vital role and depends on theAccuracy of the machine , especially the Coating Heads, theLamination , the unwind and rewind tension ability to handle varies substrates types of coatings that can be handled the ease of handling the ease of change over's the machine control panel user-friendly or complicated ? coat ability, the coating methods available , faulty or unsuitable coatingmethods mismatching rollers , in terms of width , in terms of diameter mismatching coating trays machine drying tunnel effeciencyAll these factors add to the Quality of the finished product . How ?You will see some illustrations in the next slideW

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d QualityQuality

Plays a very vital role and depends on theAccuracy of the machine , especially the Coating Heads, theLamination , the unwind and rewind tension ability to handle varies substrates types of coatings that can be handled the ease of handling the ease of change over's the machine control panel user-friendly or complicated ? coat ability, the coating methods available , faulty or unsuitable coatingmethods mismatching rollers , in terms of width , in terms of diameter mismatching coating trays machine drying tunnel effeciencyAll these factors add to the Quality of the finished product . How ?You will see some illustrations in the next slide

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QualityQuality

Accuracy of the machine ,

The accuracy of the machine plays a very crucial role in thequality of the finished product and there by the amount ofrejection or wastage.

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QualityQualityAccuracy of the Coating Heads,

Uniformity of theNip , or the Gapbetween thecoating rolls ,The dynamicbalancing of thecoating rollsSurface evennessof the coatingrolls contribute tothe good qualityof final product

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Uniformity of theNip , or the Gapbetween thecoating rolls ,The dynamicbalancing of thecoating rollsSurface evennessof the coatingrolls contribute tothe good qualityof final product

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QualityQuality

Accuracy of the unwind and rewind tension

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eed Many a times a compromise is done on the Rewind and

Unwind tension control systems.A relatively old clutch and brake system is preferred inplace of auto tension controlling devices.No doubt you save some Money in terms of low capitalInvestment

But the result ?But the result ?

You keep losing money every day in terms of wastageYou keep losing money every day in terms of wastageand rejection, and sometimes may be the reputation orand rejection, and sometimes may be the reputation orloss of the customerloss of the customer

Why this happens ?Why this happens ?

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eed Many a times a compromise is done on the Rewind and

Unwind tension control systems.A relatively old clutch and brake system is preferred inplace of auto tension controlling devices.No doubt you save some Money in terms of low capitalInvestment

But the result ?But the result ?

You keep losing money every day in terms of wastageYou keep losing money every day in terms of wastageand rejection, and sometimes may be the reputation orand rejection, and sometimes may be the reputation orloss of the customerloss of the customer

Why this happens ?Why this happens ?

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eed Why ?Why ?

Because the rewind tension set at the beginning of thecoating is say “ X ”As the coating progresses and the diameter at the rewindend increases , there is a increase in the tension. Thisaffects the line speed. As a matter of fact the line speedincreases , andThis results in improper drying, increase in residualsolvent , unwanted wrinkles and creases , which ultimatelyresults in higher wastage or some times rejections.

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eed Why ?Why ?

Because the rewind tension set at the beginning of thecoating is say “ X ”As the coating progresses and the diameter at the rewindend increases , there is a increase in the tension. Thisaffects the line speed. As a matter of fact the line speedincreases , andThis results in improper drying, increase in residualsolvent , unwanted wrinkles and creases , which ultimatelyresults in higher wastage or some times rejections.

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QualityQuality ability to handle varies substrates

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types of coatings that can be handled

Water borneOrSolvent borneOrsolvent lessOrhot melt

High viscosityOrLow viscosity

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Water borneOrSolvent borneOrsolvent lessOrhot melt

High viscosityOrLow viscosity

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QualityQuality the ease of change over's

Product Change over's can contribute to the quality offinal product

Too many change over's can contribute to a huge lossof raw materials, time , and manpower hours

Ultimately resulting intoUnwanted wastage of Raw Material, preciousproduction time, electrical energy , fuel and moreexpensive manpower hours

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Product Change over's can contribute to the quality offinal product

Too many change over's can contribute to a huge lossof raw materials, time , and manpower hours

Ultimately resulting intoUnwanted wastage of Raw Material, preciousproduction time, electrical energy , fuel and moreexpensive manpower hours

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QualityQuality the machine control panel user-friendly orcomplicated ?

A user friendly Control panel can save a lot’s oftime , and energy as well as man power hours .That’s how the wastage can be under control

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QualityQuality the machine control panel user-friendly orcomplicated ?

A user friendly Control panel can save a lot’s oftime , and energy as well as man power hours .That’s how the wastage can be under control

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QualityQuality

coat ability, the coating methods available ,faulty or unsuitable coating methods

For sake of convenience let us consider water borneand solvent borne coating that are more commonlyused.

The viscosityThe solids contentThe rheological property of the coating

Play a important role in the coating processA proper coating method is responsible for lowerwastageW

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dW

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d

For sake of convenience let us consider water borneand solvent borne coating that are more commonlyused.

The viscosityThe solids contentThe rheological property of the coating

Play a important role in the coating processA proper coating method is responsible for lowerwastage

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CoatingMethod

Viscosityin CPS

MaxSpeedper Min

Coating Wt .gm per sq. mtr

700Mtrs.

The most common Coating Methods

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Gravure 100-2000700

Mtrs. 3.-20.

Comma 1000-6000 300 10-200

ReverseRoll Nip 1000-6000 300 10-200

ReverseRoll Pan 200-6000 100 10-200

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It is clear from the Chart thatGravure coating is meant for lower Viscosity ( 100 to 2000cps ) or free flowing viscosity coatings or Adhesives.Generally the Packaging Tapes based on Water Based Acrylicadhesive , with an average solids content of 50-52 %OrThe release coating based on Silicone or non silicone withorganic solvent ( Toluene , Ethyl Acetate or Alcohols ) , withsolids content of 1 to 3 %Are the examples of the coatings done by Gravure Method

Now in case if someone tries to coat higher viscosity adhesivesby this method than the coating will not be even or it willresult into very coat weight.The result isWastage of adhesive ( excess weight of adhesive ), andImproper drying , resulting into adhesive transfer and rejectionW

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dIt is clear from the Chart thatGravure coating is meant for lower Viscosity ( 100 to 2000cps ) or free flowing viscosity coatings or Adhesives.Generally the Packaging Tapes based on Water Based Acrylicadhesive , with an average solids content of 50-52 %OrThe release coating based on Silicone or non silicone withorganic solvent ( Toluene , Ethyl Acetate or Alcohols ) , withsolids content of 1 to 3 %Are the examples of the coatings done by Gravure Method

Now in case if someone tries to coat higher viscosity adhesivesby this method than the coating will not be even or it willresult into very coat weight.The result isWastage of adhesive ( excess weight of adhesive ), andImproper drying , resulting into adhesive transfer and rejection

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Similarly

Comma , reverse Roll coating is meant for higher Viscosity( 1000 to 6000 cps ) coatings or Adhesives.Generally the specialty Tapes / or tapes with release linerbased on Solvent based adhesive or Water Based Acrylicadhesive , with an average solids content of 50-52 %Are coated by this method.

Now in case if someone tries to coat lower viscosityadhesives by this method than the coating will not be even orit will result into low coat weight.The result is Wastage of adhesive coated product ( lowweight of adhesive ), and Excessive drying , resulting intoanother rejection.Even while attempting to coat the adhesive will tend to leakout from the check plates at the sides of the coating roll.W

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dSimilarly

Comma , reverse Roll coating is meant for higher Viscosity( 1000 to 6000 cps ) coatings or Adhesives.Generally the specialty Tapes / or tapes with release linerbased on Solvent based adhesive or Water Based Acrylicadhesive , with an average solids content of 50-52 %Are coated by this method.

Now in case if someone tries to coat lower viscosityadhesives by this method than the coating will not be even orit will result into low coat weight.The result is Wastage of adhesive coated product ( lowweight of adhesive ), and Excessive drying , resulting intoanother rejection.Even while attempting to coat the adhesive will tend to leakout from the check plates at the sides of the coating roll.

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QualityQuality

mismatching rollers , in terms of width , interms of diameter

RUBBER ROLLERRUBBER ROLLER

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GRAVURE ROLLER

THE WEBTHE WEB

Above is a typical Example of mismatchingroller width as well as the web to be coated.This will result into lot of wastage andRejection

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RUBBER ROLLERRUBBER ROLLER

GRAVURE ROLLER

THE WEBTHE WEB

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GRAVURE ROLLER

Above is another Example of mismatchingroller diameters as well as the web to becoated. This will result into lot of wastage andRejection

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eed QualityQuality

mismatching coating traysAll these factors add to the Quality of the finished product .How ?You will see some illustrations in the next slide

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eed QualityQuality

mismatching coating traysAll these factors add to the Quality of the finished product .How ?You will see some illustrations in the next slide

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RUBBERRUBBERROLLERROLLER

GRAVUREROLLER

THE WEBTHE WEB

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GRAVUREROLLER

Too big or too deeptoo deep trayAlso leads to more wastage or rejection

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RUBBERRUBBERROLLERROLLER

GRAVUREROLLER

THE WEBTHE WEB

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GRAVUREROLLER

Too bigToo big or too deep trayAlso leads to more wastage or rejection

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QualityQuality

machine drying tunnel efficiency

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Correct designCorrect design of dryer tunnel , ( with a gap ofapprox 12 mm between the web and the AirNozzle )

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Wrong designWrong design of dryer tunnel , ( with a gap ofapprox 20 mm or more between the web and theAir Nozzle )

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Wrong designWrong design of dryer tunnel , ( with a gap ofapprox 6 mm or less between the web and the AirNozzle )

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QualityQuality


Also depends on lower capacity Heating Source , Hot Air Generator, orThermo pack improper air distribution absence of exhaust system air leakage from sides too large or too small drying tunnel correct air velocity

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QualityQuality


Also depends on lower capacity Heating Source , Hot Air Generator, orThermo pack improper air distribution absence of exhaust system air leakage from sides too large or too small drying tunnel correct air velocity

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QualityQuality

Lower CapacityLower Capacity Heating Source , Hot Air Generator, orThermo pack

Hot air / Thermo pack are available in various capacitieslike 50000 cal / 100000 cal/ 200000 cal / 400000 cal etc. more the capacity more is the fuelfuel consumption ( like diesel,LDO, furnes oil etc. ) in order to keep the fuel consumption lower , generally thelower capacity Hot Air generator or Thermo pack is chosen. This is the reason the expected coating speeds are notachieved , oror the coating is done at higher speeds without efficient dryingand results into adhesive transfer and huge wastages.

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QualityQuality

Lower CapacityLower Capacity Heating Source , Hot Air Generator, orThermo pack

Hot air / Thermo pack are available in various capacitieslike 50000 cal / 100000 cal/ 200000 cal / 400000 cal etc. more the capacity more is the fuelfuel consumption ( like diesel,LDO, furnes oil etc. ) in order to keep the fuel consumption lower , generally thelower capacity Hot Air generator or Thermo pack is chosen. This is the reason the expected coating speeds are notachieved , oror the coating is done at higher speeds without efficient dryingand results into adhesive transfer and huge wastages.

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QualityQuality

Improper air distribution

The air distribution Nozzles play a important role in thedrying process . Improper air distribution results in creatingair pockets inside the tunnel and that is how the dryefficiency is adversely affected.

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QualityQuality

Absence of exhaust system

in some of the cheaper designs of drying tunnel , theexhaust system is missing. Actually for efficient drying theexhaust is necessary just to replace the air . The air withwater of solvent vapor saturation needs to be replaced withfresh air so that more water or solvent vapor could beabsorbed.Incase if the exhaust system is missing then the air insidethe drying tunnel is always saturated and no fresh vaporcan take place efficiently.

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QualityQuality

Absence of exhaust system

in some of the cheaper designs of drying tunnel , theexhaust system is missing. Actually for efficient drying theexhaust is necessary just to replace the air . The air withwater of solvent vapor saturation needs to be replaced withfresh air so that more water or solvent vapor could beabsorbed.Incase if the exhaust system is missing then the air insidethe drying tunnel is always saturated and no fresh vaporcan take place efficiently.

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QualityQuality

Air leakage from sides

Sometime the Drying tunnel design is faulty and leakagesare noticed form the sides of the tunnel. This ultimatelyresults in loss of Heat energy . Hence the coating speed isreduced or the coated web contains residual solvent( water or organic solvent ) , and hence rejections at a laterstage due to adhesive mass transfer.

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QualityQuality

Air leakage from sides

Sometime the Drying tunnel design is faulty and leakagesare noticed form the sides of the tunnel. This ultimatelyresults in loss of Heat energy . Hence the coating speed isreduced or the coated web contains residual solvent( water or organic solvent ) , and hence rejections at a laterstage due to adhesive mass transfer.

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QualityQuality

Too large or Too small drying tunnel

InsufficientArea for properair circulation

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InsufficientArea for properair circulation

Too large AreaResulting intoloss of heatand insufficientdrying

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QualityQuality

correct air velocity

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Air at very high velocity can disturb the coatedadhesive on the web , resulting into unwantedunevenness and lots of wastage or rejection

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Any compromise or deviation in drying efficiency isgoing to result in unwanted wastage of heat energy,electricity . Man power cost .

This will ultimately increase the cost of manufacture , andresult into lower , or sometimes NO ProfitsNO Profits at all

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Man Power

Quality

Quality of manpower , or well trained man power willproduce a good quality product , with lower rejectionsor lower wastage

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QuantityIt found some times that , just to replace a qualitymanpower / operator , two or more people are employed.But it’s a fact that quality of operators cannot be replacedby quantity or more numbers of un trained operators.

This results into more rejections and wastages.

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The last but the most important one is the Profit



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The last but the most important one is the Profit



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Another major issue with many tape Manufactures ?

Give a guess ??????Give a guess ??????

YesYou are right

There is no testing facility.There is no testing facility.Lack ofQuality ControlAndQuality Assurance Testing

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Another major issue with many tape Manufactures ?

Give a guess ??????Give a guess ??????

YesYou are right

There is no testing facility.There is no testing facility.Lack ofQuality ControlAndQuality Assurance Testing

I am sure some of you might be shocked to know this ,I am sure some of you might be shocked to know this ,but trust me I have seen some manufacturers , wherebut trust me I have seen some manufacturers , wherethere is no other testing equipment except a merethere is no other testing equipment except a mereThickness gauge and aThickness gauge and a GSMGSM balancebalance

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eed QualityQuality ControlControl

Quality can be monitored and controlled whilemanufacturing. The Product will have good quality and thewastage will be below 2-3 % or Rejection will be avoided.

The basic tests as mentioned below can help you to producea right product .1. Web Thickness and GSM2. Adhesive thickness and GSM\3. The residual solvent / water under 0.2 %4. Web shrinkage under control5. Proper rewind tension ( the rewound roll is never rock

hard , etc.

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eed QualityQuality ControlControl

Quality can be monitored and controlled whilemanufacturing. The Product will have good quality and thewastage will be below 2-3 % or Rejection will be avoided.

The basic tests as mentioned below can help you to producea right product .1. Web Thickness and GSM2. Adhesive thickness and GSM\3. The residual solvent / water under 0.2 %4. Web shrinkage under control5. Proper rewind tension ( the rewound roll is never rock

hard , etc.

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eed Quality AssuranceQuality Assurance

Quality cannot be rectified or altered after the coating orslitting process is over.Quality Testing is only possible , but the properties cannotbe altered. The reworking , in many a cases is impossible ,And the same is very expensive if possible .

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eed Quality AssuranceQuality Assurance

Quality cannot be rectified or altered after the coating orslitting process is over.Quality Testing is only possible , but the properties cannotbe altered. The reworking , in many a cases is impossible ,And the same is very expensive if possible .

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ConclusionConclusion

Tape manufactures Can you survive the cut throatCompetition ?

The answer is : YES: YES

You canYou can

How ?How ?

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ConclusionConclusion

Tape manufactures Can you survive the cut throatCompetition ?

The answer is : YES: YES

You canYou can

How ?How ?

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Aim atminimumminimum Wastage and NoNo Rejection.

Choose ,Choose ,

Right quality Raw Materials , A correct machine Trained manpower Bare minimum Testing equipment Draw product specifications, process parametersand follow them strictly

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Aim atminimumminimum Wastage and NoNo Rejection.

Choose ,Choose ,

Right quality Raw Materials , A correct machine Trained manpower Bare minimum Testing equipment Draw product specifications, process parametersand follow them strictly

We

Pro

mis

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att

end

your

Tec

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eed

We

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end

your

Tec

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eed Contact us for more DetailsContact us for more Details

PrathithPrathith ConsultantsConsultantsPUNEPUNE , MS, INDIA, MS, INDIA

WhatsappWhatsapp : 0091 9850242282: 0091 9850242282

Email : [email protected]

website : http://www.psadhesive.com http://www.adhesivelabtesting.com

Linkedin Profile : https://www.linkedin.com/in/shrikantathavale4adhesiveconsu

We

Pro

mis

e to

att

end

your

Tec

hnic

al n

eed

We

Pro

mis

e to

att

end

your

Tec

hnic

al n

eed Contact us for more DetailsContact us for more Details

PrathithPrathith ConsultantsConsultantsPUNEPUNE , MS, INDIA, MS, INDIA

WhatsappWhatsapp : 0091 9850242282: 0091 9850242282

Email : [email protected]

website : http://www.psadhesive.com http://www.adhesivelabtesting.com

Linkedin Profile : https://www.linkedin.com/in/shrikantathavale4adhesiveconsu

Technology

Tape Manufacturers Can you survive the competition