Clean
machine
16 November 2004
Deacro
slitter stars in cleanroom at Polyester ConvertersA
new state of the art cleanroom in the central London factory
of Polyester Converters is the first European installation
of the latest slitter rewinder from Canadian manufacturer
Deacro. Supplied by the company's UK partner TS Converting
Equipment, the model CL24 is a cantilevered centre winder
featuring laser guided core positioning and digital knife
set-up, and capable of running film at speeds of over 600m/min.
Lawrence Gardezi, managing director of Polyester Converters,
says the investment (totalling £300,000) will drive the company
forward, and allow it to enter new and innovative markets."We
spent a lot of time and effort looking at different machines but
felt that the Deacro slitter had the flexibility and efficiency we
required for expansion within our company," he remarks. "It
is geared up for extremely quick set-up and job change, which is
what we need. Everything is bespoke to our cleanroom's requirements.
It will be used for the conversion of medical, specialist trade conversion
and food grade packaging films.
Maximum
productivity
The
CL24 is the latest development of Deacro's C24A system – claimed
to be the most popular centre winder in North America. Designed
for maximum productivity at high production rates, in addition
to knife setting and core positioning, the machine's automatic
features include reel removal and packaging. Featuring an Allen-Bradley
PLC and Zicom touchscreen, the company says it offers simplicity
in machine set-up and minimal operator fatigue in operation.
The overhead web path facilitates machine access and provides
the operator with maximum visual inspection during the rewinding
process.
The
machine is designed for one-man operation and easy maintenance,
and has a compact footprint that is economic on floorspace.
It will handle web widths between 1,600-1,800mm. Maximum
unwind diameter is 1,300mm, and the rewind 610mm. Cantilevered
differential rewind shafts allow fast reel removal with no
shaft handling.
No vibration
The
machine frames are 50mm thick ground steel plate braced
with pre-stressed heavy duty torque members. This is said
to ensure frame stability and vibration-free operation. Control
Techniques drives are used. All driven systems are synchronous
timing belt drives to minimize noise, vibration and maintenance.
All idlers after the slitting section are tendency driven
to provide the required sensitivity for light gauge films.
The standard roller covering is cork rubber and upgrades
to neoprene, urethane, plasma or custom coverings are available.
Alternative, special roller coverings can be supplied based
on product requirements. All bearings are sealed for life
where applicable. Adequate guarding is provided along with
conveniently located access doors for servicing of the
drive train motors and all power transmission elements.
A
demo trim extraction unit set up by Kongskilde is attached
to the new slitter to control waste trim and dust in the
cleanroom. Polyester Converters is currently working towards
full BRC and ISO 1400 accreditation, and this system will
eventually be extended to link up with all the other slitting
machines located within the production facility.
"The profile and quality of the end reels produced
on the CL24A is phenomenal – second to none," enthuses
Lawrence Gardezi. "We've just done a job for a US customer – and
we were able to deliver it to them faster than their prime supplier
in the 'States. Consequently we have become their primary supplier.
"Polyester
Converters is part of the PSG Group, which also includes Plastic
Shims & Gaskets – the original operation founded by Lawrence
Gardezi's father in the 1960s. At its 13,333m2 premises not far from
Tower Bridge, the company stocks, distributes and converts polyester
films in thicknesses from 3.5-500 micron. It also offers a trade
conversion service on customer supplied products. 3M, ITW and Ford
are all major customers of the Group, which also has sales offices
in Germany and the USA.
The
operation in London stocks a range of films supplied by Saehan,
Toray, Du Pont, Hoechst, 3M and Agfa, including Excell, Terphane,
Lumirror, Melinex, Mylar and Hostaphan grades. Films are
also sourced from other leading manufacturers. "We
are independent – not tied to one supplier," Lawrence
Gardezi emphasizes. "We are increasing our stock in order to
offer price stability given the current fluctuations associated with
petroleum based products."Film types available include
clear, super clear, hazy, milky white, matt, opaque white,
black, metallized and coloured. Films can be supplied uncoated,
slip treated, anti static, corona treated, chemically pre-treated
for adhesion (to solvent as well as water based inks, adhesives
and resins), diazo coated, co-extruded (heatseal), dyed and
PvDC coated. Polyester Converters can service small and large
orders efficiently.
Converting
capabilities
The
ISO 9002 registered company's conversion service can produce
rolls from 10-1,600mm in width and sheets from 15mm square
to 1,270x1,524mm. In addition to the new Deacro in the cleanroom,
it has a variety of slitting machines, from 7-1,600mm
(with capabilities for slitting up to 2,200mm).
In addition to polyester film, other materials can be
converted, including paper, board and other films
from 6-1,000 micron. The slitting service will
convert materials to specification, producing coils from
6-1,600mm in width. Rolls are supplied on 76mm
or 152mm cores. The markets supplied are packaging -
carton windows, laminating, lidding for ready meals,
overwrap for bakery and aromatic products, and
metallizing; printing and stationery products; and industrial
items such as carrier/release films, adhesive tapes,
labels, holograms, stamping foil, thermal transfer
ribbons, and magnetic tape.
The
Polyester Converters armoury also has a complete range of
sheeting facilities to handle all types and thicknesses of
material. It claims to achieve tolerances of within 0.25mm
on sheets up to 1,500x1,650mm. Larger sizes may
be obtained, depending on type of material, up to 1,524x3,500mm,
where a tolerance is not so critical. Guillotining
is also used to produce sheets, maximum size
being 1,500x1,650mm at tolerances of 0.25mm. Finally,
die cut and cut components are manufactured and supplied
to any specification. Materials include polyester
paper, PP, PVC, and rubber.
PSG's
collaboration with TS Converting began in 1983, when it purchased
a new Cameron slitter, since refurbished in 2001. Such is
the close relationship between the two companies now, that
in addition to its main function, the new cleanroom will
be used as a sales tool for TS and Deacro – it
has been built with viewing windows for prospective customers. Significantly,
the 1,836m2 also has space available for a second machine to be installed "probably
next year", Lawrence Gardezi reveals. "It will be a wider
web model, to meet the growing demand for bigger reels."Tim
Self, director of T S Converting, comments: "The European introduction
of the Deacro range at the recent drupa exhibition was very encouraging.
We received over 100 enquiries for machines and expect further orders
shortly." Some 1,500 of the Canadian company's
machines are already in operation, mostly in North
America.
T
S Converting is also owner of Elite Cameron, whose range
includes automatic and manual core cutters, centre surface
slitter rewinders, and coating and laminating machines. The
company is actively promoting both the Deacro and Elite Cameron
ranges in the European market. It will open a fully operational
showroom early in 2005, providing a working facility for
potential customers to take their material for trials and
extended production runs.