www.convertingtoday.co.uk CONVERTING TODAY AUGUST 2006 PROGRESS Partners in COVER STORY psg London based PSG Group, whose new cleanroom facility was featured in our November, 2004, issue, has continued to improve its operational efficiency by installing an advanced Kongskilde waste removal system serving all of its converting machines. In addition to the tangible benefits this has achieved, the installation is representative of the close level of collaboration that exists between PSG and its suppliers. This is typified both by the work with Kongskilde UK - and by the converting company's long standing partnership with slitting machinery supplier TS Converting Equipment. The new bespoke waste handling system was commissioned last month. It removes continuous edge trim from the various machines in the factory (including the Deacro slitter in the cleanroom), chops it into small pieces for compaction, and conveys these through air ducts to a central collection point. Kongskilde UK sales manager John Kightley reflects: “Considering the layout, the number of different machines involved, and the types of material thicknesses, it is one of the most diverse systems we have installed. We have used several different items of equipment from our range within the installation.” The initial waste removal system supplied for the cleanroom slitter two years ago was designed by Kongskilde to extract two-edge trim up to a maximum width of 40mm, 250 micron thick, at a rate of 500m/min. It comprised two 60mm diameter flexible pick-ups feeding through an in-line twin blade Multicutter running at 2,800rev/min. A Multiair 215TR quiet pressure fan provided the air for an ITF100 Venturi to create the suction required to convey the chopped material into a roll-top container positioned under an air separator some 30m away. Now there are edge trim removal systems for all four of PSG's slitting machines, with provision to connect to a second Deacro slitter planned for eventual installation in the cleanroom. “We considered the various material parameters and line speeds for each of the machines and designed a specific edge trim removal system for each one,” reveals John Kightley. This was achieved using a computer programme designed by Kongskilde that calculates the required air speed and back pressure of each system, and confirms the most economic and power efficient method for each one. Three different methods of extraction are used to convey the chopped edge trim waste from the various slitter positions within the factory to a collection area outside. The two KU4000 air separators have been positioned within the roof structure of a small extension to the building which is close to the road, enabling easy access for collection of the waste containers. A 'through fan' system was selected to convey the material from the existing and proposed Deacro slitters in the cleanroom because of the long conveying distance required. It also generates the largest volume of waste material, due to the fast operating speeds. A Multiair 1075S with an RVS rotary separator operates in conjunction with single cutters on two of the machines handling the lighter gauge materials to convey the waste. Kongskilde was able to use the initial Multiair it had supplied for the first system at PSG in conjunction with an FVO Venturi and air return to extract the waste from the slitter dealing with the heavier gauge materials. Here it was considered prudent to use a cutter for each of the trims in this application to ensure longer blade life. Particular attention was paid to operational noise levels for the three systems. In-line silencers are positioned either side of the cutters, and at various points in the system to Below: trim pipe on Deacro C24 in cleanroom. Right: tailormade trim pipes lead to chopper motors on old Harnden slitters. Opposite, top: Multicutter in-line on C24. Below: Multiairs, rotary separator, Venturi system and air return. Far right: Air separators above waste trimstorage Converter PSG and suppliers Kongskilde and TS Converting Equipment co-operate closely CT Polyester p26_27 Aug 06 8/3/06 2:54 PM Page 26
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www.convertingtoday.co.uk CONVERTING TODAY AUGUST 2006
PROGRESSPartners in
COVER STORY psg
London based PSG Group, whose newcleanroom facility was featured in ourNovember, 2004, issue, has continued toimprove its operational efficiency by installing anadvanced Kongskilde waste removal systemserving all of its converting machines. Inaddition to the tangible benefits this hasachieved, the installation is representative of theclose level of collaboration that exists betweenPSG and its suppliers. This is typified both by thework with Kongskilde UK - and by theconverting company's long standing partnershipwith slitting machinery supplier TS ConvertingEquipment.
The new bespoke waste handling system wascommissioned last month. It removes continuousedge trim from the various machines in thefactory (including the Deacro slitter in thecleanroom), chops it into small pieces forcompaction, and conveys these through airducts to a central collection point.
Kongskilde UK sales manager John Kightleyreflects: “Considering the layout, the number ofdifferent machines involved, and the types ofmaterial thicknesses, it is one of the mostdiverse systems we have installed. We have usedseveral different items of equipment from ourrange within the installation.”
The initial waste removal system supplied forthe cleanroom slitter two years ago wasdesigned by Kongskilde to extract two-edge trimup to a maximum width of 40mm, 250 micronthick, at a rate of 500m/min. It comprised two60mm diameter flexible pick-ups feedingthrough an in-line twin blade Multicutterrunning at 2,800rev/min. A Multiair 215TR quietpressure fan provided the air for an ITF100Venturi to create the suction required to conveythe chopped material into a roll-top containerpositioned under an air separator some 30maway.
Now there are edge trim removal systems forall four of PSG's slitting machines, with provisionto connect to a second Deacro slitter plannedfor eventual installation in the cleanroom.
“We considered the various materialparameters and line speeds for each of themachines and designed a specific edge trim
removal system for each one,” reveals JohnKightley. This was achieved using a computerprogramme designed by Kongskilde thatcalculates the required air speed and backpressure of each system, and confirms the mosteconomic and power efficient method for eachone.
Three different methods of extraction are
used to convey the chopped edge trim wastefrom the various slitter positions within thefactory to a collection area outside. The twoKU4000 air separators have been positionedwithin the roof structure of a small extension tothe building which is close to the road, enablingeasy access for collection of the wastecontainers.
A 'through fan' system was selected toconvey the material from the existing andproposed Deacro slitters in the cleanroombecause of the long conveying distancerequired. It also generates the largest volume ofwaste material, due to the fast operatingspeeds. A Multiair 1075S with an RVS rotaryseparator operates in conjunction with singlecutters on two of the machines handling thelighter gauge materials to convey the waste.
Kongskilde was able to use the initial Multiairit had supplied for the first system at PSG inconjunction with an FVO Venturi and air returnto extract the waste from the slitter dealing withthe heavier gauge materials. Here it wasconsidered prudent to use a cutter for each ofthe trims in this application to ensure longerblade life.
Particular attention was paid to operationalnoise levels for the three systems. In-linesilencers are positioned either side of thecutters, and at various points in the system to
Below: trim pipe on DeacroC24 in cleanroom. Right:
tailormade trim pipes leadto chopper motors on old
Harnden slitters. Opposite,top: Multicutter in-line on
C24. Below: Multiairs, rotaryseparator, Venturi system
and air return. Far right: Airseparators above waste
trimstorage
Converter PSG and suppliers Kongskilde andTS Converting Equipment co-operate closely
CT Polyester p26_27 Aug 06 8/3/06 2:54 PM Page 26
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