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

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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

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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

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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

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Case Study #1 Results: Sensor to Lab Correlation

Sensor Vs. Lab Correlation of PE with CaCo3 Correlation Coefficient R2=0.9898

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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

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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

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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

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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

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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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