Brückner ServtecCompany Profile

© Brückner

About Us

Established in 2003 as individual legal entity within the Brückner Group

Today 50 employees with many years of experience in biax business

Solid back-up by our sister company Brückner Maschinenbau

Supported by a number of service locations around the world

We provide service for …... any Brückner line, regardless whether it is 3 or 30 years old!... all lines built by Cellier, Proctor & Schwartz and Barmag extruders.... a growing number of lines supplied by Brückner competitors.

© Brückner

Complete Service Offered Out of One Hand

Production optimization

Line upgrading & conversion

Process optimization

Spare parts

Service contractsPersonnel service

Line inspection

Mediation of used equipment

Clip & chain refurbishment Condition monitoring

Measuring service

Line relocation

Teleservice24-h hotline

Consultancy

TrainingRepair

© Brückner

Upgrade Your Line and Stay Competitive

From resin to mill roll, from hardware to software: get the latest and proven technology for your existing line!

Improvements, which pay back in short time

Solutions provided by people, who understand your business:

● Punctual shipment

● Precise installation schedule

● Short interruption of your production

● Fast start-up

● One face to the customer

© Brückner

Upgrading TopicsTruck and big bag feeding Gravimetric Dosing

Multilayer film extrusion

High speed pinning system

MDO roll direct drives

MDO stretching unit with automatic roll bend protection

High efficiency film heating

Minimized lubricant consumptionHeat recovery

Integrated process control (IPC)

Programmable resin supply

Closed loop die bolt control Chill roll direct drive

High efficiency water removal Digital drives

High speed chain track system

Surface treatment

Thickness control integrated tension controlActive damping via linear motor technology

Roll handing system

Cut optimization (CUT)

© Brückner

Highlights in Upgrading I

Speed upgrade: the world‘s fastest BOPP line - 525 m/min

7-Layer film production with high barrier EVOH capability

Upgrades of non-Brückner lines, e.g. 5-layer special film production with thickness control

Line conversion to shrink film production (OPS or OPVC)

Electrical and automation upgrades

© Brückner

Highlights in Upgrading II

Special MDO for optical film, 100% direct drive controlled and with automatic roller cleaning

TDO heat recovery and condensate absorption system

Thickness measurement by controlled infrared heaters in TDO

Fully integrated web scan systems for maximum quality control

Winder contact roll system upgrade (LIWIND), ultra-fast response and highest accuracy

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Service Highlights: Professional Line Inspection

Unscheduled line stops or process problems caused by:

Failures

Unavailable spare parts

Misalignment and maladjustment

can be avoided with regular line inspections by our service specialists

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Service Highlights: Mobile Service Assistant

Expert support available within minutes

Saving of travel expenses and travel time

Problems can be discussed directly on site

Suitable for any mechanical, electrical or process issue

Training

Easy troubleshooting, maintenance and increased uptime

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Service Highlights: On-Site Roller Surface Repair

Damage: Step 1:

Step 2: Finished!

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Service Highlights: CLIPFITClip & Chain Refurbishment

Not new –but perfectly overhauled

by Brückner Servtec!

Unprofessionalcleaning, no

quality inspection!

© Brückner

Service Highlights: Energy Audit

Experienced auditors Assessment for the complete plant● Material supply ● Stretching line● Electrical system● Utilities and surroundings, e.g. energy supply,

air conditioning, production hall illuminationReport with customised energy saving solutions

More efficient use of energy

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Condition Monitoring and Measuring SystemsKeep your fingers on the pulse of your machine!

IR-Camera inspection:Electrical equipment, cast film, insulations and mechanical parts

Online and offline Machine Condition Monitoring (MCM):Gearboxes, bearings and other rotating components with alert function and statistical evaluation

© Brückner

Condition Monitoring and Measuring SystemsKeep your fingers on the pulse of your machine!

Oil Inspections:Verification of oil condition, evaluation of condition of the concerning machine part

Measuring services:Speed synchronization, TDO air distribution, check of the wear condition

© Brückner

Mediation of Used Equipment

Finding potential buyers foryour used equipment

We take care of a safe transfer of payments and goods

Valuation of your equipment

Finding economical spare parts solutions for older lines

On demand: professional overhaul

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Training & Seminars: The Brückner Academy

Sharing knowledge and experience

Increase your profitability

Qualification and motivation of your staff

Increase safety level

© Brückner

Upgrading the Process Control System

Good Reasons for Investing in a …… New Process Control System:

Avoid spare-part problemsIncrease reliabilityIncrease productivityIncrease and ensure product qualityTransparent production

© Brückner

IPC, Overview

S7-416

I / O Drives

Ethernet TCP/IP Profibus

MS - Windows Workstations

Fiel

d-Le

vel

Linux Server

• Central data- & event handling• Open architecture (expandable)• Reliable: RAID, UPS, Redundant Power...• Thickness control, roll- and process-data

Brückner Integrated Process Control System - powered by PVSS-II

Supe

rvis

ory-

Leve

l

DieboltControl

Options: - Integrated Thickness Control- Integrated Web-Inspection

Internet

Upgrading the Process Control System

DSL-Router

• Online-support• Trouble-shooting

© Brückner

MMSManufacturing

ManagementSystem

Information Flow

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MMS – Efficiency Boost for Old and New Lines

Brückner´s MMS is the solution to control film production processes right from the start to the very end.

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MMS – What You Get

You Save ● Set-up time● Waste (e.g. CUT 0,5% - 4%)● Inventory

You Improve● Product to market time

You Gain● Increased market share

Fast Return on Investment (ROI)

© Brückner

Heat Recovery System for TDOIncluding Condensate Absorption

Easy upgrade with short delivery time● Max. 10 weeks

Short installation period● Max. 1 week

Easy and cheap maintenance of the system● Max. 2 times per year

Higher quality of the filmHigh profitability

Average amortization within less than 1,5 years !

© Brückner

Heat Recovery System for TDO – Advantages

Reduced energy consumption by returning existing heat energy● Up to 270 kW per hour

Improvement of film quality by preheated fresh air● Less temperature differences● Less pressure differences

Higher air conformity in the TDO oven

© Brückner

Condensate Absorption – Advantages

Less maintenance in the TDO● By controlled absorption of condensate ● By easy collecting ● By easy removing

Less emission to the environmentLess condensate at slots, holes and cold bridges by● Reduced flow of cold air● Controlled overpressure in the oven

Improvement of film quality

Condensate hose

Condensate tray

© Brückner

Linear Motor Winding System (LIWIND®)Mechatronic Damping System for the Contact Roll at the Winder

© Brückner

LIWIND® – Perfect Mill Rolls for All Film Types

© Brückner

Web Inspection – Basic Principle

High speed cameras

Embedded PCs with low heat processors

High power fluorescent lighting

100 MB Ethernet data transfer

Evaluation software

1

2

4

5

3

© Brückner

Web Inspection – Detectable Defects

SpotsContaminations (dust)Cracks and holesCoating defectsOil and condensate dropsFluff balls

Die linesBurned granulesScratchesInsects and/or gel inclusions and similar appearancesFlow marks

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Web Inspection – Advantages

Comprehensive quality inspection records

Avoidance of unnecessary and expensive complaints

Optimization of the production by online detection and correlation to the process

Improved sales argument by optimized and recorded quality

Possibility of partitioning for each roll in different quality segments

Waste reduction by automatic online alarm

Quicker set-up of new products by online quality observing

© Brückner

7 Layer Upgrade

Output increaseNewest products with the latest developed resinsAbility to produce highest grade films with special recipes Be prepared for future marketsReturn to competitiveness

Skin layer (Co- or Terpolymer)Core layer (Homopolymer)Tie layer (Adhesive layer)EVOH (Barrier layer)Tie layer (Adhesive layer)Core layer (Homopolymer)Skin layer (Co- or Terpolymer)

7 Layer high barrier film

© Brückner

Upgrade TDO Chain TrackFOK 4.4.2 to FOK 4.7 System

Speed up of the chain system up to 300 m/min

The existing chain track will be reused

No more exchange of sliding bars after modification

Less maintenance cost by special plastic runners

Save more than 50% of lubrication on the sliding parts

Reduced down time due to minimized maintenance stops

One of our standard upgrades – done already several

times!

© Brückner

Upgrade TDO Chain TrackFOK 4.4.4 speed up to 400 m/min

High-speed sliding chain

Excellent sliding properties

Precision cast clips

Magnetic clip closer and opener

Speed up to 400 m/min

© Brückner

Upgrade TDO Chain TrackFOK 5.1 to FOK 5.3 System

Speed up to 250 m/min

Lubricant free chain

Much less oil on mono rail

6 roller bearing system for smoother running

Magnetic clip closing

Special bearings for increased lifetime, grease filled, sealed for lifetime

Overhaul at Brückner Servtec facility

Easy & economic maintenance

© Brückner

Upgrade TDO Chain TrackCellier to FOK 5.3 System

Speed up to 250 m/min

Lower oil consumption

Lubrication free

Less wear due to better sealing

Pneumatical clip pre-opening at film break

Magnetic clip closing

We also do upgradings of non-Brückner lines!

UpgradingLatest References

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Upgrading – Latest References ICountry Customer Project Upgrading

Year of Installation

Japan 1201 TOC IPC / PVSS upgrading

2008

Japan 1250 LOC Modification MDO

Spain 3341 NAV Various upgradings of a relocated line

Finland 272 AHL Cross cutter, safety upgrading contact roll

Italy 248 ISEA Replacement of TDO electrical heatingto oil heating

Republic of Korea 1092 ROK New electrical system with new cabinets PLC and

process control system including thickness TCE

Czech Republic

0268 TECH Web inspection system

2007

Czech Republic

0268 TECH Dedusting system

Czech Republic

0268 TECH

Complete revamp to 3 layer line with twin screws, direct drives, new TDO chain, new winder, IPC with

PVSS II / S7

Turkey 3343 ISA 5-layer and thickness gauge modification

© Brückner

Upgrading – Latest References IICountry Customer Project Upgrading

Year of Installation

Canada 231 BORD Raw material supply

2007

Netherlands 1255 KEY Modification of extruder

Chile 1227 SIG Magnetic clip opener system for FOK 4.7 -300m/min

Chile 1227 SIG Die bolt temperature control system, network upgrade

Republic of Korea Ja Kang Industrial Co.Ltd. 1111 LAD Corona generators and new electrodes

Greece 1278 HEL Version update integrated process control system, new die bolt temperature control system

Greece 1270 EKO Version update integrated process control system, new die bolt temperature control system

Greece 1278 HEL Magnetic clip opener and closer system for FOK 4.4.4. - 360m/min

Greece 1270 EKO Magnetic clip opener and closer system for FOK 4.4.4. - 360m/min

Italy Axial s.r.l. 3342 AXI TDO for shrink film

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Upgrading – Latest References IIICountry Customer Project Upgrading

Year of Installation

Germany 1072 EFO Long term roll based data archiving analysis and reporting – RDH extended

2007

USA Confidential 1289 OTA Electrical control system for KARO IV

USA Confidential 1242 HUT Line relocation

USA Confidential 1241 TAPInterchangeable configuration plates for adapter

block to achieve different layer configurations with the same adapter block

Confidential Confidential Confidential IPC upgrading PVSS II/S7, new DC drives, change distribution I/O’s from ET100 to ET200

Belgium Treofan Group 1165 NIE Gravimetric dosing

Malaysia Confidential Confidential Modification of extrusion system / adding screen changer unit

Belgium Treofan Group 1165 NIE Digital drive system

Malaysia Stenta Films 1168 MASIntegrated process control with PVSSII/S7 and

distributed I/0’s, digital drives and winder modification

Malaysia Stenta Films 1205 SAM Modification die bolt control system

www.brueckner.com // servtec@brueckner.com // tel. +49 8662 63 0 // fax +49 8662 63 9370

Brückner Servtec GmbHThank you very much for your attention.