Optical Control Systems

®

Optical Control Systems for the highest Standards

B e s t Q u a l i t y C o n t r o lf o r t h e

P e t r o c h e m i c a lI n d u s t r y

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OCS Optical Control Systems

As one of the world’s leading manufacturers of opti-cal testing systems for quality control, OCS suppliescustomised and complete solutions in the fields ofdigital image processing, optical measurement andautomation.

Our systems ensure maximum product quality control.With the aid of precision cameras in conjunction withhigh performance online image processing, even thesmallest defects in polymer products are detected,located and analysed in detail.

The applications for OCS systems range from labora-tory use to complete integration into the productionprocess.

Leading manufacturers in the petrochemicals andpolymer industries benefit from these features.Everywhere in the world, our system solutions aresuccessfully in service.Already, most of the raw material producers are OCS’customers, and are highly satisfied. A reference list isavailable on demand.

With a highly expert and innovative team of develop-ment and production engineers, OCS supplies toplevel technology and know-how worldwide - alwaysat the leading edge with our systematic research anddevelopment work. Our manufacturing processes,delivery, installation and user training are also stateof the art. Service to our clients is our paramountaim: in no time we will repair damaged systemsworldwide - guaranteed.

A Mission Statement

Our continued goal is to provide the polymer industrywith quality control systems that are optimised withregard to production and purpose, and to offer com-plete solutions with solid and up-to-date technologyat reasonable prices.To achieve this we constantly improve our productionexpertise and technical knowledge, and widen ourall-round understanding of functional requirements.

OCS is committed to provide quality products andservices to its customers within the agreed deliverytime.OCS will strive to continuously improve quality, deli-very and responsiveness to assure customer satisfac-tion.OCS strives to widen its world-wide market share tobe the world-leader in providing the highest valueproducts and services to our customers.

Innovation Award

In 2005 OCS won the German Innovation Prize fortheir successful introduction of outstanding innovationand their business conception. They have determinedto establish new technologies, devise innovative ideasand extend the high-tech equipment.OCS has a unique selling point in the world market.Through the progress of different processes of qualitycontrol for the production of polymers both in thepetrochemical industry and with processors, OCSbecame successful and an evergrowing market leader.Its measuring method became the standard for thequality control in the plastics industry.

November 2005

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Y o u r p a r t n e rt o b e w i t h

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A p p l i c a t i o n s

ARKEMA

BASELL

BASF

BAYER

BOREALIS

INEOS

BP CHEMICALS

CLARIANT

DEGUSSA

DOW CHEMICAL

DUPONT

EASTMAN CHEMICAL

EMS CHEMIE

EQUISTAR

EXXONMOBIL CHEMICAL

HUNTSMAN

HYDRO

JAPAN PE

JAPAN PP

MITSUBISHI CHEMICAL

NOVA CHEMICALS

PHILLIPS CHEMICAL

QATAR PETROCHEMICAL

REPSOL

SABIC

SASOL

SHELL CHEMICAL

SOLVAY

TOTAL PETROCHEMICALS

BOROUGE

BRASKEM

DSMEQUATE

FAR EASTERN IND.

FORMOSA

GE PLASTICS

HANWAH

HOECHST TREVIRA

LVM

M&G

MITSUI ELASTOMERS

OMAN PP

SUMOTOMO DOW

THAI PE

ADVANCED POLYPROPYLENE COMPANY

CABOT

CHINA JINSHAN

FIRESTONE

KANEKA

MERCK

PETLIN

PETROCHINA

PETROKEMYA

PETROMONT

RASCO

ROHM & HAAS

ROMPETROL PETROCHEMICALS

SAMSUNG TOTALSAUDI EUROPEAN PETRO

SAUDI YANBU PETROCHEMICAL

SCHULMAN

SHIN-ETSU

SINOPEC

SAUDI POLYOLEFINS COMPANYSTERLING

TETRA PAK

THAI PETRO. IND.

TITAN

TORAYTOSCO

THE POLYMER COMPANY

TVK

UBE

VINYTHAI

YANSHAN

YANSAB

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Applications

Plastics have become indispensable nowadays, andthe areas of application are constantly broadened.The level of the requirements has risen in equal measure.

The industry demands for high quality raw material,that needs appropriate “online controls” to guaranteebest properties for the fields of polymerisation, pro-cessing and application. Therefore it is essential thatthe extrusion process is checked for function anddocumented, as the polymer film should be clear ofcontamination and gels. It is important to detectinhomogeneties as soon as possible so the cause canbe eliminated at an early stage of the process.

The rheological behaviour of the polymer melt is defined by the molecular structure and allows conclusions to the extrusion process.

The quality of the granules, e. g. the size and shape,has an influence on the pneumatic conveyance andof course also on the material flow in the feedingprocess and extruder during high performance extrusion.

For further processing the frequency and size of gelsand black specks in the film must be determined.These affect the optical appearance of the film andreduce the mechanical stability and ability for treat-ment, e. g. printing, laminating etc.

The surface quality is also an important QC criterionwhen producing glossy and transparent films.Most thermoplastic material contains additives forprocessing and preservation, the content of whichhas to be analysed during quality inspection.

OCS has developed a modular conception of testingsystems and optional devices which can be combinedaccording to requirements:

Pellet /Powder puritySize & Shape distributionGels & ContaminationAdditives MeasurementRheologyHaze, Gloss, Thickness MeasurementPellet Transport System

The various systems are described on the followingpages, showing all options for a fully automatedtesting line. With these instruments all quality controlrequirements in modern plastic production and plasticconversion are fulfilled, offering tools for flawlesshistory tracking of all critical parameters, for effectiveprocess control and for root cause analysis, creatinga solid basis for process improvement.

AGFA

KEMYA

FUJI

HMC

J S R

SABIN

SHARQ

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P o w d e ra n d L i q u i d s

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Powder Testing System PT2C

The Powder Testing System PT2C, equipped with a 3-CCD-chip colour camera, counts and classifies con-taminations. Colour classes can be defined with the"teaching" tool to detect discolorations and foreignbodies which are different in colour from the bulkmaterial, such as PVC, PP, PE etc.

The system is capable of detecting contamination anddiscoloured powder particles (pink, yellow, brown, black,etc.). These irregularities are sorted into different classsizes which are completely user definable.Furthermore, it is possible to define alarm limits. If theseare exceeded, a potential-free contact is activated.

The PT2C can be used for laboratory purposes aswell as for online inspection. The powder can be sub-mitted as a sample or it can be withdrawn from theproduction line by creating a bypass. Using a bypasssystem gives the user the advantage of direct inspec-tion of the material during the production process.This allows faster response in order to prevent off-spec production.

P e l l e t I n s p e c t i o n

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S y s t e m s

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Pellet Scanning System PS25C

The PS25C Scanning System is used to analyse trans-parent, opaque and colour pellets. The pellets are in-spected with a high-resolution colour camera for con-tamination, discolouration and foreign particles. Thetesting material is fed into the appliance through thehopper. The pellets are conveyed separately to the in-spection zone via a vibrating channel. After the opticalevaluation, the contaminated pellets can be separatedinto a different container (sorting unit option).Measuring errors are eliminated by use of numerousadditional optical components. After definingcolour/size classes and alarm limits the recorded dataare stored in a test report to enable future analysis.Also the recorded images and measured data can beobserved on a screen during the measuring process.Installation in the bypass guarantees production,monitoring and rapid reaction to any occurrences.The material throughput is approx. 40 kg/h.

High Speed Pellet Scan System PS200C

Another new development of OCS is the High-SpeedPellet Scanning System PS200C. This system is fordetection of contamination, discolouration and foreignparticles on transparent and opaque pellets. ThePS200C is an advanced version of the PS25C and hasthe same features, only the throughput of both devices is different.The PS200C has a throughput of approx. 250 kg/hand is applicable, especially for the online qualitycontrol during a production process.

Pellet Size and Shape Analyser PSSA

The PSSA is a modular inspection system for the pre-cise analysis of size and shape of transparent andopaque granules (e.g. twins, triples, dog-bones, tails,fines) for the polymer industry. The pellets are separa-ted on a vibrating surface and transported to themeasurement zone. The recorded data are stored in atest report to enable a future analysis of the results.The features of the granules e.g. size, shape, elongation,roundness, roughness and convexity can be presentedgraphically or in tabular form and printed as well. Thissystem assures a continuous process pelletizer moni-toring including pellet weight /count (optional).

Pellet Size and Shape Distribution PSSD

The PSSD is a modular inspection system for the rapidanalysis of the size and shape distribution of transpa-rent and opaque granules (e.g. twins, triples, dog-bones, tails, fines) for the polymer industry. The pel-lets are transported by the vibrating channel and aremeasured individually in the free fall between thecamera and the light source. This principle enablesthe system to analyse up to 50 kg/h. The results aregraphically presented as particle size and shape dis-tribution, time history of the measurement as well asin tabular form.

Pellet Analyser PA66

The PA66 is a combination of the highly sensitivePSSD, PS25C and real Colour Measurement CM(optional). These systems are working at the sametime to assure the highest quality of the polymers.

B l o w n F i l m T o w e r

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Blown Film Tower BFT300/400

The blown film towers BFT 300/400 with film haul-off, extruder and spiral die are used to produce high-quality blown film for carrying out optical and physicalmeasurement on the film. The mechanical design cor-responds to a production system in laboratory scale.All settings and configuration parameters are storedby the system (touch panel), which means that thefilm quality can be reproduced at any time. This isparticularly important for optical on-/offline measure-ment, such as gels, contamination, haze, gloss, etc.Reproducible film qualities are also important for on-/offline density and additive measurement.

The tower height is electrically driven, free adjustableand can therefore be set optimally for all extrudedmaterials.

The take-off nip rolls are driven pneumatically andthe temperature is optionally controlled.

The film bubble can be stabilised with additional gui-ding rolls, adjustable wooden grids and Teflon-coatedrolls are leading the film bubble into a flat layer film.

The guiding rolls are made of stainless steel. Someguiding rolls are special designed to prevent wrinkles.

The blown film tower is operated via a colour LCDtouch panel. All parameters, e.g. haul-off speed, filmtension, winding force, winder diameter, cooling air,film width, etc. can be set and stored as a configurationfile.

An optical device measures the width of the flattenedfilm and controls the diameter of the film bubble.In this way, the desired film width remains constant.The film width is recorded and shown graphically onthe touch panel.

The complete operation is visualised on the touchscreen.

C a s t F i l m

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Chill Roll & Winder Unit CR9/WU9

The Chill Roll & Winder Unit has been specially devel-oped to meet the requirements of the polymer rawmaterial producers.

The CR9/WU9 can contain an FTIR for Online Spec-troscopy, Haze-, Gloss- and Thickness Measurementand they can be used in the laboratory or online,serves the production of cast film/winding blow film.The system consists of two chill rolls with controlleddrive, temperature, speed several guidance rolls,haul-off station with two rubber-nip rolls followed bya central pneumatically expandable winder. The winderis regulated via the tension control.

The CR9/WU9 consists of a TFT Touch Control Panelwhich improves the visualisation of user and equip-ment parameters, a digital and manual rotationadjustment, film tension control and speed control.

A speed indication for chill rolls and nip rolls is availableand the winder is pneumatically expandable.The CR9/WU9 is equipped with a film break sensorand a detector for film direction as an alarm function.An electrostatic discharging of the winder with ionisedair is available.

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FilmSurface Analyzer FSA100

FSA100 is a modular surface inspection system foruse in laboratories and production. The film quality isassessed optoelectronically through the use of high-resolution line cameras and the appropriate illumina-tion technology. The measurement data are stored inan inspection report so that later analysis is possibleat any time.The modular concept permits the use of differentcamera and illumination constellations and can there-fore be optimally used for transparent and opaquefilms. Optimum adaptation in laboratory work and inencapsulated measuring stations is a major contribu-tion towards quality control.In addition to the recognition and classification ofdefects, the system can also be used for analysis,recording, archiving and documentation purposes.Every defect detected is transferred with the defectimage to the measurement protocol together with itsfeature vector (position, size, shape ...).

The system can be modified exactly to suit the res-pective requirements.

Sample Tester ST4

The Film Quality Scanning System ST4 is designed forthe precise inspection of surfaces with a small area.Transparent materials such as films (PP/ PE, PS, etc.),plates (Polycarbonate), glass etc. and non-transpa-rent/opaque materials like paper, metals or textilesetc. can be examined. The system detects impurities,holes, scratches and other surface irregularities.It is suitable for laboratory use and for research anddevelopment.

T e s t i n gF i l m

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R h e o m e t e r

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The New OP5 online Rheometer

A system for plant optimisation and improved productquality

OCS have acquired the Porpoise technology and bringyou the new OP5 rheometer.

The function of the OP5 is to make certified measure-ments of the Melt Index and/or Polydispersity of smallsolid polymer samples. The primary duty of these mea-surements is overall control of many types of polyme-risation processes, to ensure that the product is madeto the correct specifications. The secondary duty isQuality Control of the customer product. The OP5 islogically situated in the plant analysis laboratory, whichensures best reliability, calibration and maintainabilityfor these important measurements.

Representative samples of each reactor (and finishedproduct) are therefore transported to individual analy-sers. In simple plant configurations, such as LDPE, PS,PET and Nylon this usually means one OP5. In com-plex plants such as PP, HDPE and LLDPE two or moreOP5 analysers would be required and in the case ofpowder sampling the associated analyser would havedegassing and catalyst deactivation stages. Sampleextraction is to be via the OCS PTS system which isindividually configured to minimise reactor to analysisdelay time.

Melt flow measurements are performed after the solidsample is melted and conditioned to the appropriatetest temperature. In the OP5 the rapid melting processminimises any changes to the structure of the polymerand substantially avoids any shear damage, cross-lin-king, thermal degradation and other degradation pro-cesses. This sample preparation removes the last tracesof any trapped air or gas and overall makes an impor-tant contribution to making the sample at the point ofmeasurement fully representative of the process. Inthis unique way the OP5 makes control through rheo-logy as reality.

The melt flow is regulated by a sealed gear pump, whichtransports a metered quantity through a shaped diewhich has the normal MI die L/D. The shaping of thedie is to minimise the delay in the slow moving poly-mer near the walls, without deviating the actual rheo-logy relationships too far from the standard MI die.

Measurements of pressure and flow rate are used toderive the standard Melt Index. Many features of theapparatus are covered in the following current patents.The patent, Melt Flow determination in Polymer pro-cess, has the following grants, EU 989 45440, GB233 4958 and US 09/622558. These patents also haveintegrated process control application. Systematic cor-relations are applied to compensate for the relationshipbetween the OP5 die and the lab test die and testmethodology thus covering both ASTM D1283 andISO 1133 methods. Once established the correctionsdo require regular verification, which is suppliedthrough the OP5 operating software. The IPR of theoperations are described in the EU CTM, RegistrationCertificate No 002729309. The methodology of cali-bration and measurement gives the OP5 class leadingaccuracy, which can be used to certify the finishedproduct and thus completely replace routine testingusing the Lab Melt Indexers, whether manual or com-pletely automatic. It is normal to certify these calibra-tions through a third party specialist. SGS, who arerespected globally for such duties and have now con-tract approval with major polymer producers for suchonerous tasks.

The OP5 measurement of Melt Index is performed ina batch process, termed a cycle. The MI result is basedon a tiny part of the sample, which gives the OP5 apin point accuracy. The result shows every small varia-tion in the polymer product and which can be used tosteer polymer reactions in a way not possible by longterm averaging or less than adequate sample prepa-ration. The delay, from reactor to measurement result,is comfortably small enough to achieve tight reactioncontrol. The measurement qualities are of coursevaluable for Quality Control and will thus maximisethe added value to the production.

The unique features of the OP5 equipment open up thehuge opportunity process control through rheology.

Scrap make (with OCS/Porpoise rheometer)

Scrap make (without OCS/Porpoise rheometer)

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Online FT-InfRared Spectrometry APLAIRS®

Replacing your QC-methods with only onetechnique

APLAIRS® (Analysis of PLAstics by InfraRed Spectro-metry). With this concept, conventional quality con-trol methods can be replaced with only one spectros-copic technique. Additives, physical properties,co-polymer and multi-layer composition, thickness aswell as degree of polymerisation can be measuredsimultaneously. A continuous flow of film runsthrough a special construction of the APLAIRS®

system, which is equipped with an FTIR spectrometerand specially designed software. APLAIRS® focuseson film measurements, although infrared spectroscopycan also be applied to melted samples.

Application

APLAIRS® can be applied to a whole range of poly-mers, co-polymers and blends to determine the chemical composition in the resins, varying from functional group analysis to co-polymer compositionanti-oxidants, UV absorbers, slip agents, stabilisers,fillers, extenders, impact modifiers, speciality modifiers,processing aids, flame retardants and any other addi-tives the extruded film thickness, and the thicknessof separate films in multi-layered structures physicalproperties like density, splittyness, etc.

A d d i t i v e M e a s u r i n g A p l a i r s

F i l t r a T e s t

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P e l l e t i z i n gLab scale strand pelletizer consists of:

Extruder 20/25D V3, strands die, water bath andstrand pelletizer with adjustable speed.The extruder has a TFT touch panel with 4 heatingzones, 4 micro processor temperature controls andtemperature sensors.• High/ low- temperature alarm with driving-stop• Alarm signal and alarm-quitting• Torque indicator• Torque alarm• Rotation speed indicator 0….150 rpm• Rotation adjustment with up/down button• Strand die with heating, 3 mm and 4 mm diameter• Sample hopper with “hopper empty” alarm• 3 zone-screw 4:1 with mixing zone

Filtra Test ME FT 20 according to DIN EN13900-5

The system can determine the Filter Pressure ValueFPV as well as other parameters. Furthermore rheological data can be acquired.A sieve package can be installed behind the gearpump. For every maintenance an automatic screenchanger option is available.

Following operations are possible:• Extruder with constant rotation – gear pumps

with constant rotation:Pressure monitoring before the sieve package

• Extruder with constant pressure – gear pumpswith constant rotation:Continuous monitoring and full automatic measurement to determine the Filter PressureVolume (FPV)

• The gear pump can be operated with constantpressure both, before and after the pump (itself)

T h i c k n e s s , G l o s s ,

Haze difference 40%

Illuminationparallel light

Sample

Sonde

Flap

Integrating sphere

Entrance Exit

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Hazemeter Gamma12 according to ASTM 1003

The functional principle of Gamma12 complies withthe standard ASTM 1003. The film sample which hasto be measured is passed across the opening in anintegrating sphere so that parallel light can passthrough the sample into the sphere. The intensity ofthe dispersed light can be measured using a high-pre-cision sensor by means of the dispersion of the trans-mitted light beam. Light beams with dispersion anglesexceeding a standardised value cannot leave the spherethrough the exit and are reflected by the sphere sur-face. The intensity of the scattered light is measuredafter multiple reflections within the integrating sphere.

The intensity of the total light transmitted can bedetermined by measuring with the sphere exit closed.The haze value is calculated from the ratio of thescattered light and the total transmitted light.

H a z e a n d C o l o u r M e a s u r e m e n tGlossmeter GM according to ASTM D 523/DIN 67530

The Glossmeter serves the determination of the glosscharacteristics of the manufactured film. The measure-ment is effected by analysis of the reflected lightduring the running process. The Ethernet Interfacepermits the evaluation and documentation of themeasuring results. The data exchange is realised byModbus/TCP protocol or optional OPC server.

Thickness Measurement TM9

The stand-alone measuring device TM9 is used for thecontinuous measurement of the film thickness with theaid of measuring rolls. The integration of TM9 into theCR9 system is a perfect solution for the cast / blownfilm thickness control. The data recording is carriedout by a digital calliper. The measurement data andthe various functions of the film thickness control aredisplayed on the CR9 touch panel. The electronic con-trol and data output can be realised by a serial inter-face with a modbus protocol (RS232/RS485) or alter-natively by an interface 4-20 mA/0-10V.

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FSP600

FSP600 is a modular surface inspection system foruse in production. The production quality of thematerial to be inspected is assessed opto-electronically.The measurement data are stored in an inspectionreport so that later analysis (e.g. monthly statistics) ispossible at any time.

The modular concept permits the use of severalcameras working in parallel so that optimum adapta-tion can be achieved for every problem. The system isdimensioned as a function of the production speed,the inspection width and the inspection accuracy(resolution) so that complete inspection of the entireweb width is ensured.

In addition to the mere recognition and classificationof defects, the system can also be used for analysis,recording, archiving and documentation purposes.Every defect detected is transferred with the defectimage to the measurement protocol together with itsfeature vector (position, size, shape ...).The system can be modified exactly to suit the res-pective requirements using the comprehensive soft-ware packages.

W i d e W e b I n s p e c t i o n

TRIOPLAST

NORDENIA

BISCHOF & KLEIN

KWH PLAST

KLÖCKNER PENTAPLAST

RKW

WINDMÖLLER & HÖLSCHER

BREYER

BRÜCKNER

ALCAN PACKAGING

EDV COEX

WIPAK

SICHT-PACK HAGNER

SÜDPACK

AEP

ORBITA

SEALED AIR VITEMBAL

RENOLIT

ETIMEX PRIMARY PACKAGING

SILVALAC

BONSET AMERICA

AVERY DENNISON

VALERON STRENGTH FILMS

AMCOR FLEXIBLES

DANNEMANN GLOBAL EXTRUSION

LOHMANN TAPES

The Pellet Transport System PTS is a continuous andautomatic transportation of pellets between the pro-duction lines and measuring systems.Samples of pellets from the production line are affectedby means of pneumatic sample takers. Samples aresent through aluminium or stainless steel pipes (shotpeened option). The PTS consists of hopper loaders(Cyclone) with shutter valves for extruder with lowand high level sensors for sampling.Furthermore a stand by tank for purge and calibrationmaterial and a 3-way switch for a starvation systemis available.

The PTS is controlled with a PLC which is driven witha TFT touch panel for visualisation and control of thesampling system.The system is equipped with a digital I/O interface tothe DCS for transferring status and alarms. All pipesand bends (elbows) are specified to avoid dust, angelhairs and streamers. Totally gap-free flange connections (recommended: Slip-on collars and looseflanges with projection and recess). A de-dustingdevice for removing dust and streamers etc. is anoption.

P e l l e t T r a n s p o r t S y s t e m P T S

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Turnkey laboratory services

OCS-lab provides total turnkey laboratory packagesand utilities for the plastic industry for any licence,fully adapted to the demands of our customers.

Many aspects are involved in planning a total turn-key package. For any plastic laboratory project OCS-lab is compiling a tailored package in compliancewith client. After several iterations with subject mat-ter experts of our clients a proposition is made. Afterthe announcement of the tender by the customer,OCS-lab prepares the related documentation and calculates a total price for a bid to the customer.

During the planning process, it is very convenient touse the visualisation tools allowing both parties tosimulate how the final configuration looks. OCS-labhas experts in the team who can work with state ofthe art software packages for this purpose.

C o m p l e t eL a b o r a t o r y

Benefits

• One contact – One line of communication• One company is liable • Efficient and fast • Cost-effective and high quality• A contractor with experienced people who knows

the plastic industry• A partner at any time and any place• A global player with a global network

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Optical Control Systems

®

Optical Control Systems GmbHWullener Feld 2458454 Witten, GermanyTel: +49 (0) 2302 9 56 22-0Fax: +49 (0) 2302 9 56 22-33e-mail: info@ocsgmbh.comhttp://www.ocsgmbh.com

Turnkey Solutions for the Polymer Industry

Laboratory• Measuring Extruder• Pellet & Powder Analyser• Melt & Liquid Analyser• Chill Roll & Winding Unit • Blown Film & Cast Film Lines• Film Quality Testing Systems• FTIR-Spectroscopy• Gloss, Colour, Haze & Thickness Measurement• Pellet Transport Systems• Online Rheometer

Production• Online analyser house• Extruder for small-batch production• Wide Web Inspection