The benefits of a Sussex Integrated Film Control
system for Blown Film Extruders
without IBC control
The IFC System:
a. The Sussex Film thickness Controller with Patented Air Cushion Head.
b. Ultrasonic Bubble Diameter Control System.
c. Gravimetric blender or Loss in Weight hopper.
This system is greater than the sum of its component parts.............
How it improves the Film line!
The Sussex FT+ production recipe sets the target Thickness, Limits, Width and controls Line-speed to automate and optimise width and thickness control from start-up through to continuous production. It leads to the following material cost savings:-
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4% saving through Optimising!
The FT+ measures Kg/Hr via a gravimetric batch blender or Loss-In-Weight hopper.
A blender on its own rarely controls the line and just improves the quality of the plastic mix. A loss in weight hopper on its own can control and stabilise the average thickness but not save material through optimising. Either type of Gravimetric hopper Linked to the FT+ enable the FT+ to optimise the process and typically save 4% of the material through controlling to near minimum gauge. The FT+ shows the film thickness profile and location of high or low areas, enabling the operator to make accurate adjustment of diebolts.
The flatter the film profile, - the higher the savings !
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+2% saving through width control!
The width gauge uses three Ultrasonic Sensors just above the Freeze line and the layflat width is displayed on the FT+ indicator. An inflate/deflate system pulses air into or out of the bubble to maintain width within +/-2mm. On Start-up it inflates the bubble automatically to the correct size using high pressure air changing to low pressure pulses near correct size. The control system is fast enough to prevent bubble collapse when the bubble is holed.
More accurate width control typically saves 2% of material through reduced edge trim.
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+3% saving through scrap reduction!
Further savings are achieved by the quicker Start-Up achieved by the IFC system and by the automatic linespeed change when changing product width and/or thickness. 1.5 minutes on start-up and 2 minutes on every product change leads to a scrap reduction equal to about 3% with 2 Hr production batches.
The shorter the producton runs, - the greater the saving !
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+X% through better quality!
The FT+ on the line is a quality window on the process and enables a higher quality to be maintained, and recorded on a remote computer. This should lead to improved customer satisfaction and fewer returns. Only the user can estimate how much money will be saved every year by avoiding these losses.
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= Total Savings 9% + X%!
The total savings are 9% from the above, which will pay for the IFC system in under 6 Months on a machine producing 100Kg/Hr. After that it starts saving for your next machine!
Using the Sussex IFC system for two years - your next Film line can be FREE !
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"If you need a machine and do not buy it
You will finish up paying for the machine and not own it"
Henry Ford
 
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