2011 AIMCAL MARCH MANAGEMENT MEETING Speakers

for large-scale production applications.
All three can be customized for specific
flexible packaging applications.
The latest addition to the company’s
Davis-Standard developed its latest pelletizer range
to support new markets such as biopolymers as well
as debottlenecking projects and improved scrap
recovery.
range of surface and center winders, the
SLC (Sliding Lay-on Carriage) Series,
controls winding force with pneumatics
instead of hydraulics. Like the PAC
series, the SLC Series is capable of
wound roll diameters up to 1,500mm (60
in.). The AC-driven winder is available
in widths from 1,118 to 3,400mm (44 to
134 in.) and capable of winding rolls on
75- or 150mm (3- or 6-in.) cores. Several
unique engineering features improve
performance. Bearings located close to
the wound roll edge support the weight
of the roll, while a horizontal linear rail
enhances shaft performance. Winding
force is controlled via pneumatic cylinders
with control feedback and taper
capabilities. The finished roll unloading
system is independent from the winding
transfer cycle sequence, shortening
and streamlining roll changes. Roll carts
and shaft handling are available to add
automation to fit each plant’s needs.
Other features include a horizontal flat
bed design, high-capacity shaft bearings,
high-speed pneumatic traversing
knife assembly, web tension control,
touch screen controls for winder settings,
and two center slitters for multiple lane
production. Options include additional
slitters, a center drive feature, gap winding,
shaft accelerator, cord expander roll
and shaft extractor/cart.
A range of coaters and coating
heads are available with more than
50 coating configurations. Innovative
accessories include the patented CAS
(coating air separation) system, the
Steamex re-humidification system, and
the patented pressurized gravure head
(PGH) system. Liquid coating and laminating
machines are equipped for window
protection and optical films, release
22 Holiday 2010 www.aimcal.org
and adhesive tapes, photography products,
and solar and battery applications.
C-P Flexible Packaging (C-P), York,
Pennsylvania, installed a lamination
line from Davis-Standard primarily to
produce snack food packaging. “Over
half of our business is in extrusion lamination,
so the addition of this line was
essential,” reports Mike Takis, engineering
manager at C-P. “Not only did Davis-
Standard address our technical needs,
but they achieved an ambitious timeline.”
Davis-Standard supplied the line
with custom profile control between the
gauging system and flex lip die to attain
very flat profiles across the web and in
the machine direction. The line is also
wider to better match the company’s
flexo printing capabilities. Installed late
in 2009, the line features new Integrator
control technology and a regenerative,
shaftless turret unwind splicer. It produces
laminated structures comprised
of extruded polyethylene between two
films including oriented polypropylene
and polyethylene terephthalate. The
films can be clear, printed in up to 10
colors or metallized. Prior to the expansion,
C-P was running all extrusion
laminations on a Black Clawson line,
which has run continuously for almost
20 years. C-P is AIB (American Institute
of Baking) rated and one of the few certified
Sustainable Green Printers in the
United States.
For more information, visit www.
(left-right) Steve Tusing, Extrusion Department
manager, Mike Takis, engineering manager, and
Greg Collins, vice president of Manufacturing, stand
before C-P Flexible Packaging’s new Davis-Standard
lamination line with Integrator control technology.
noel-automation.com, www.davisstandard.com,
www.bc-egan.com, www.
cpflexpack.com.
***
Tullis Russell Coaters, Bollington,
United Kingdom, has won the prestigious
Northwest Business Environment
Awards in the Small and Medium
Enterprise category for fully integrating
environmental performance into its business
practices. As a result, the company
has reduced its carbon footprint 17%,
realized £374,000 (US$588,535) in annual
cost savings, and is eligible for an energy
efficiency discount from the annual
Climate Change Levy. The judges noted:
“Their plans for the future are innovative
- including solar panels and a growing
eco range. Their commitment to community
engagement and work with schools
shows they have gone the extra mile,
making them deserving winners.”
Measures included simple steps
such as turning down thermostats,
implementing routine power-downs of
equipment, and installing low-energy
lighting. Energy use has been further
reduced by insulating the factory’s
steam pipes, and adding heat exchangers
to the coating machine ovens and
an economizer to the boiler. A waste
paper compactor and tipper bins have
been installed, and waste is now segregated
for pretreatment and recycled, to
reduce the amount diverted to landfill.
The firm has reduced annual carbon
dioxide emissions 46% and water use by
74 cubic meters. During the past three
years it has reduced landfilled waste
81%. In addition, the facility meets the
ISO14001 standard for Environmental
Management Systems and holds Forest
Stewardship Council (FSC) accreditation
for sustainable use of raw materials.
The Bollington manufacturing facility
produces and supplies coated security
paper and films for a global market and
employs 110. Support from Groundwork
Cheshire, the Carbon Trust, Defra and
Envirowise helped the firm make a wide
range of resource efficiency improvements
and gain the full support of all
employees. For more information, visit
www.trcoaters.co.uk.
***
CARESTREAM Flexx transparent
conductive films from Carestream
Advanced Materials, Rochester, New
York, provide an alternative to indium
tin oxide (ITO) films for touch panels.
Patented silver nanomaterial technology
enables exceptional conductance
and superior optical performance.
Coating the nanomaterial onto resilient
polyethylene terephthalate (PET) creates
a film that is more flexible and less
expensive to produce than ITO-based
offerings. “Device manufacturers have
been limited by the drawbacks of ITO for
a long time, including brittleness, high
cost, relatively low durability, and occasional
scarcity of product,” says Bruno
Merry, general manager for Carestream
Advanced Materials, noting, “Our
Flexx films exceed standards for optical
transparency and offer customers many
benefits that were not previously available.
Our PET-based product—which is
manufactured using a high-yield, rollto-roll
precision coating process—is also