Extrusion International 1-2024

41 Extrusion International 1/2024 changes (width and/or thickness adjustments), saving valuable production time and reducing scrap material. Setting target values is straightforward through the touchscreen on the HMI. Additionally, an included data analytics software package ensures a seamless re- cording of production parameters, such as production speeds, length, longitudinal and transverse profiles, av - erage values, and trends. Comprehensive analysis tools provide insights into the operational state (efficiency) of the system. The often-underestimated savings potential through the use of inline thickness gauges is illustrated in Picture 2. The table overview includes system parameters, ex- emplary for a PP thermoforming application, produc- tion costs, and the variance of the thickness profile (and achievable optimization through thickness measure- ment) as variable data. The program calculates annual material- and cost savings based on the achieved opti- mization. Practice shows that even with very small optimiza- tions in the micron range, annual savings are consider- able, and the return on investment of thickness mea- surement can be achieved well within one year. A comprehensive Program The Austrian company SBI Mechatronik and its global distribution network, covers various areas with its com- prehensive range of measurement technologies, includ- ing sheet for thermoforming applications, conductive and foamed films and sheets, cast and stretch films, as well as EVA films for solar panels and coating applica - tions. The company relies on the noted intelligent sensor and software technologies instead of radiation devices. From thermoforming sheets to landfill liners The globally successful KAPA system for films and sheets up to 3 mm (118 mils) thickness [in an extended version up to 6mm (236mils)] uses a combination sensor capacitive/eddy current and creates a thickness profile with a repeatability of +/- 0.5 µm (0.02 mil). Applications of this highly reliable and contactless measuring meth- od range from thermoforming films and sheets (PET, PP, HIPS, etc.) to 8.5 m (27.9 ft) wide geomembrane films for tunnel linings and landfill seals. Direct measurement for foam films and others For foamed films and sheets, as well as conductive materials up to a thickness of 3.5 mm (138 mils) (in a spe- cial version up to 8.5 mm (335 mils)), the SHADOW laser system is ideal. This direct measuring method uses a la- ser shadow/eddy current sensor and is manufactured up to maximum widths of 8 m (26 ft). Cast films For thin-walled films (cast & stretch film) up to ap - proximately 500 µm (19.7 mils), SBI offers a Soft X-Ray device, which measures the thickness and basis weight. Payback analysis SBI - thickness gauges The yellow highlighted boxes are values to input. The white boxes are the results based on the inputs. Working Hours hrs 24 No. of working days/ year days/yr 200 Machine output kg/hr 600 Target Thickness of Production micron 1000 Width of the film mm 950 Density of Polymer g/cm³ 0,92 Line speed of the machine mpm 11 Average thickness variation observed without thickness measurement system % 6 Average variation achieved with thickness measurement system % 4 Polymer % 96% Additive 1 % 4% Additive 2 % 0% Cost of Polymer/kg USD 1,02 € Cost of Additive 1/kg USD 2,00 € Cost of Additive 2/kg USD - € Cost of Production Recipe / kg USD 1,06 € Target Production Thickness micron 1000 Average Thickness achieved without thickness measurement system micron 1060 Average Thickness achieved with gauging system micron 1040 Excess thickness produced without gauging system micron 20,00 Raw material saving due to thickness measurement system g/m 17,48 Total annual Raw material saving per year according to production capacity kg/yr 57600 Total Monetary benefit per year USD 61 009,92 Input Parameters Production Details Production Recipe Return On Investment Analysis Variation Parameters Picture 1: Visualization Picture 2: Payback analysis