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min

atin

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2008

Ext

rusi

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empe

ratu

re,

line

s pee

d, o

utpu

t rat

e an

d di

e pr

essu

rep

,p

pE

quip

men

t geo

met

ry s

uch

as s

crew

des

ign,

air

gap

and

die

lip g

ap

Di

Piti

Ld

Die

Posi

tion

Lead

Lead

ont

o ei

ther

su

bstra

te fo

r im

prov

ed

adhe

sion

Issu

esS

ubst

rate

bur

n th

roug

hgW

eb c

ontra

ctio

n on

hea

vy

coat

wei

ghts

Line

spee

d w

ill e

ffect

Wor

k ne

eds

to b

e do

ne

to o

ptim

ize

loca

tion

Chi

llR

llT

tS

ttiC

hill

Rol

lTem

pera

ture

Setti

ngTo

oC

old

prod

uces

rapi

dqu

ench

rate

Too

Col

dpr

oduc

esra

pid

quen

chra

teR

educ

ed a

dhes

ion

Rol

l may

sw

eat i

n hi

gh h

umid

ityy

gy

Too

War

m p

rodu

ces

slow

er q

uenc

h ra

teP

olym

er m

ay s

tick

to ro

llB

ond

issu

es o

r tea

ring

with

sub

stra

teC

an w

rap

chill

roll

Une

ven

Tem

pera

ture

Une

ven

Tem

pera

ture

Poo

r or u

neve

n st

rippa

bilit

yFl

ow m

arks

in p

rodu

ctp

Indi

catio

n th

at c

hill

roll

may

be

foul

ing

Chi

llR

llSt

iP

itiC

hill

Rol

lStr

ipPo

sitio

n

If R

oll t

o H

igh…

.…

Chi

ll R

oll S

urfa

ce C

anno

t R

ecov

erC

Rec

over

C L

C L

If R

oll t

o Lo

w…

....

Poo

r Stri

pabi

lity

Res

ultin

g in

C LL

C LCh

ill R

oll

Qua

lity

Def

ects

L

A m

isal

igne

d or

Wor

n Ro

ll Ca

n Re

sult

in W

rinkl

es in

the

Pro

duct

Chi

ll R

oll R

ecov

eryy

600°

F M

elt T

emp.

100°

F90

°F

120°

F

AB

75°F

AB

75°F

The

Chi

ll R

oll n

eeds

tim

e an

d di

stan

ce to

Dav

is S

tand

ard

reco

ver c

oolin

g of

its

surf

ace

( A to

B )

Ni

Ii

Nip

Impr

essi

onA

mou

ntof

impr

essi

onA

mou

ntof

impr

essi

onde

term

ined

by:

Rol

l Har

dnes

sIm

pres

sion

Rol

l Dia

met

erN

ip P

ress

ure

Wid

erni

p

Impr

essi

onW

idth

Wid

erni

pIm

prov

ed a

dhes

ion

For h

eavi

er s

ubst

rate

sC

ti

hl

Can

cre

ate

pinh

oles

Eve

n ni

p ac

ross

the

roll

isim

porta

nt!!!

roll

isim

porta

nt!!!

Qui

ck C

alcu

latio

n fo

r Chi

ll W

tG

PMW

ater

GPM

mwxC

pwx

T w=

mp(

Cpp

xT p

+hf p

) x E

ff

mw

= M

ass

Flow

Wat

er, l

b/hr

mp=

Ext

rude

r Out

put,

lb/h

rC

pw=

Spe

cific

Hea

t Wat

er,

BTU

/lb-°

FC

pp=S

peci

fic H

eat P

olym

er, B

TU/lb

-°F

T w=

Tem

pera

ture

Ris

e W

ater

, °F

T p=

Tem

pera

ture

Cha

nge

Pol

ymer

, °F

hfp

= he

at o

f Fus

ion

Pol

ymer

, BTU

/lbp

y,

U/

Eff

= E

ffeci

ency

of S

yste

m

GPM

= [(

mp

x 0.

75 x

T p

)/(T w

x 50

0)] x

1.2

How

muc

h w

ater

do

we

need

to p

ump

thro

ugh

our c

hill

roll

if w

e ha

ve a

rate

or 1

000

lb/h

r LD

PE,

Mel

t Tem

pera

ture

600

°F, a

Stri

p Te

mpe

ratu

re o

f 100

°F, a

nd 3

°F W

ater

Tem

pera

ture

Ris

e?

GPM

= [(

1000

x 0

.75

x (6

00-1

00)/(

3 x

500)

] x 1

.3 =

325

gpm

GPM

= 1

000l

b / hr (0

.55B

TU/ lb

-°F

x (6

00-1

00°F

)+0.

48Bt

u / lb)

/ (1

BT

U/ lb

x 3°

F x

480)

* 0

.7 =

275

gpm

*Ass

umin

g C

hill

roll

is o

f ade

quat

e si

ze**

Incr

ease

GPM

to a

llow

for

Nip

and

Bac

king

Rol

l Flo

w

Qui

ck C

alcu

latio

n fo

r Coo

ling

TTonn

age

Ton

= [m

px0.

75x

T p/1

2,00

0] x

1.2

Mp

= E

xtru

der O

utpu

t, lb

/hr

p

p,

T p=

Tem

pera

ture

Cha

nge

Pol

ymer

, °F

Ton

= To

nnag

e of

Ref

riger

atio

n re

quire

d or

ava

ilabl

e at

50°

F1.

2 =

Effi

cien

cy o

f 80%

How

muc

h co

olin

g is

requ

ired

if w

e ar

e ex

trudi

ng 1

000l

b/hr

of 6

00°F

LD

PE w

ith a

strip

ping

Tem

pera

ture

of 1

00°F

.

Ton

= [1

000

lb/h

r x

0.75

x (6

00-1

00)°

F /1

2,00

0] x

1.2

= 3

7.5

Ton

Chi

llR

llC

ttT

iC

hill

Rol

lCon

tact

Tim

eC

alcu

late

Con

tact

an

d R

ecov

er T

ime

and

Len

gth

for

a E

xtru

sion

Lin

e

CR

Di

tW

%gH

avin

g a

24

inch

Ch

ill R

oll w

ith

a 2

20°

Wra

p at

a L

ine

Spee

d if

50

0fp

m.

CR

Dia

met

er x

Wra

p%Li

ne

Spee

d x

22

.93

Con

tact

Tim

e, s

ec =

24 x

220

500

x22

93=

CR

Dia

met

erx

(1-W

rap%

)R

ecov

ery

Tim

ese

c=

500

x22

.93

=

0

.46

sec

CR

Dia

met

erx

(1W

rap%

)Li

ne

Spee

d x

22

.93

Rec

over

yTi

me,

sec

=

24 x

(36

0-22

0)50

0 x

22.9

3= =

0.2

9 se

c

Chi

llR

llC

ttL

thC

hill

Rol

lCon

tact

Leng

thC

alcu

late

Con

tact

an

d R

ecov

er T

ime

and

Len

gth

for

a E

xtru

sion

Lin

e

CR

Dia

. x W

rap%

Con

tact

Len

gth

ft=

gH

avin

g a

24

inch

Ch

ill R

oll w

ith

a 2

20°

Wra

p at

a L

ine

Spee

d if

50

0fp

m.

p1

37

6C

onta

ctLe

ngt

h,f

t=

24 x

220

1376

=

Rec

over

y Le

ngt

h,f

t =

CR

Dia

. x 3

.14

/12

–C

onta

ct L

engt

h

=

3

.84

ft

yg

g

=24

x3.1

4/12

-3.8

4

=

2

.44

ft

Trou

bles

hoot

ing

–Pr

oble

ms

Rl

td

tth

Li

tR

elat

edto

the

Lam

inat

or

Apr

oble

mw

ithit’

sca

uses

will

belis

ted

Apr

oble

mw

ithit

sca

uses

will

belis

ted

Sol

utio

ns a

re b

ased

on

wha

t we

have

gon

e i

thi

tti

over

inth

is p

rese

ntat

ion.

Aud

ienc

e w

ill gi

ve a

nsw

ers

by fi

lling

out w

ork

bk

hbl

ii

book

as

each

pro

blem

is g

iven

.G

roup

dis

cuss

ion

and

revi

ew o

f sol

utio

ns.

Sl

tiW

kbk

Solu

tions

Wor

kboo

kPr

oble

m#1

#2#3

#4#5

#6Pr

oble

m#1

#2#3

#4#5

#6S

olut

ions

Incr

ease

Air

Gap

DA

iG

Dec

reas

eA

irG

apC

hill

Rol

l to

Die

(Lef

t/Rig

ht)

Incr

ease

Chi

ll R

oll T

empe

ratu

reD

ecre

ase

Chi

ll R

oll T

empe

ratu

reIn

crea

se N

ip P

ress

ure

Dec

reas

eN

ipP

ress

ure

Dec

reas

eN

ipP

ress

ure

Cha

nge

Stri

pper

Pos

ition

Chi

ll R

oll F

oule

d (C

lean

)C

all B

eth

Pbl

#1Pr

oble

m#1

Poo

rAdh

esio

nof

Ext

ruda

teto

base

orP

oorA

dhes

ion

ofE

xtru

date

toba

seor

lam

inat

ed s

ubst

rate

.D

ueto

:Ina

dequ

ate

oxid

atio

non

lyD

ueto

:Ina

dequ

ate

oxid

atio

non

lyTh

ere

are

two

solu

tions

rela

ted

to th

e la

min

ator

fort

his

prob

lem

lam

inat

orfo

rthi

spr

oble

m

Pbl

#2Pr

oble

m#2

Poo

radh

esio

nof

the

poly

mer

toth

eP

oora

dhes

ion

ofth

epo

lym

erto

the

subs

trate

.D

ueto

:Pre

mat

ure

Coo

ling

Due

to:P

rem

atur

eC

oolin

gTh

ere

are

thre

e po

ssib

le s

olut

ions

to th

is p

robl

em

Pbl

#3Pr

oble

m#3

Poo

rAdh

esio

nof

the

Pol

ymer

toth

eP

oorA

dhes

ion

ofth

eP

olym

erto

the

Sub

stra

teD

tS

tiki

tth

Chi

llR

llD

ueto

:Stic

king

toth

eC

hill

Rol

lTh

ere

are

two

poss

ible

sol

utio

ns to

this

pro

blem

Pbl

#4Pr

oble

m#4

Exc

essi

veO

dor

Exc

essi

veO

dor

Due

to O

ver-

Oxi

datio

nTh

il

il

ih

li

fTh

ere

is o

ne s

olut

ion

rela

ting

to th

ela

min

ator

for

this

pro

blem

Pbl

#5Pr

oble

m#5

Poo

rHea

tSea

labi

lity

Poo

rHea

tSea

labi

lity

Due

to: O

ver-

Oxi

datio

nTh

il

il

dh

li

fTh

ere

is o

ne s

olut

ion

rela

ted

to th

ela

min

ator

for

this

pro

blem

Pbl

#6Pr

oble

m#6

Poo

rAdh

esio

nA

cros

sth

eW

ebP

oorA

dhes

ion

Acr

oss

the

Web

Adh

esio

n is

goo

d in

som

e ar

eas

and

poor

in

thothe

rsD

ue to

: Red

uced

The

rmal

Con

duct

ivity

Ther

e ar

e tw

o po

ssib

le s

olut

ions

rela

ted

to th

is

prob

lem

and

one

is tr

icky

!!

Cl

iC

oncl

usio

n

Ei

td

PE

quip

men

t and

Pur

pose

Chi

ll W

ater

Sys

tem

Des

ign

dC

tl

and

Con

trol

Bas

ics

of P

roce

ssC

alcu

latio

nsTr

oubl

esho

otin

ggTh

anks

to O

ptex

Pro

cess

S

olut

ions

, LLC

,