Teknek Contact Cleaning and... · Removal down to 1 micron Analysis of Contamination Adapts to Web...
Transcript of Teknek Contact Cleaning and... · Removal down to 1 micron Analysis of Contamination Adapts to Web...
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Teknek Contact Cleaning
Presented to Hi Q Surf meeting
Inchinnan
8th January 2008
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The Contamination
• Human Hair
• Clothing Fibre
• Packaging Fibre’s
• Slitting Dust
• Machinery debris, Bearings, Paint Chips
• Ink from printed Stock
• Debris from metallizing
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Wiping
Wiping with Tack Rags
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Brush System
STATIC BRUSH
Space due
to wearing
ROTARY BRUSH
Space due to wearing
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Air System
Vacuum SystemSurrounding dirty air pulled in
Blowing System
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Ultrasonic System
Direction
of Web
Compressed Air and Vacuum System
Vacuum
Ultra Sonic Generators
Idle roller
Surrounding dirty air pulled in
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Bemoulli Effect
Daniel Bernoulli-18th century scientist who discovered :-
“as the velocity (speed)of a fluid increases its pressure
decreases”
100 micron
Boundary Layer
Area of low pressureArea of low pressure
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The Boundary Layer
Air speed
Velocity
d
0
d
No slip area
Solid Boundary
Air flow50/150mm
Free Air Stream
Boundary Layer
Blue roller penetrates
Boundary Layer
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Teknek Transfer Technology
Direction of Web
Double Sided Cleaning
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
++++++++++++++++++++++++++++++++++
Static
elimination
Adhesive
roll
Cleaning
roller
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Summary - Cleaning TechnologyCleaning Method
Penetrate
Boundary Layer
Removal down to
1 micron
Analysis of
Contamination
Adapts to
Web Movement
Noisy
Large
Footprint
Ducting,
Filters
Simple
Installation
High
Maintenance Cost
Brush Ultra Sonic RollerVacuumAir Blower
NO NO NONO YES
YES
YES
YES
YES
YESYESYESYES
YES
YESYESYESYES
YESYESYESYES
YESYESYES
NO NO NONO
NO NO NONO
NO NO NONO
NO
NO
NO
NO NO NONO
NO
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Cleaning Efficiency’s
100 75 50 30 25 10 5 1 0.5 0.2
Air Knife
Brush & Vac
High Velocity Vacuum
UltrasonicContact Clean Machine
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Particle Size, Microns
Efficiency of Cleaning Methods
$
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Unique Capabilities
• Highly Integrated
– Only contact cleaning to produce own rubber and adhesive
rollers
– Only contact cleaning company to design and manufacture own
machines.
• Engineering Resource
– More employees in engineering than some contact cleaning
companies in total
• Lean thinking
– Teknek is one of the most forward thinking companies in the
contact cleaning world
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The Contamination Problem
• Machine Downtime
• Scrap Material
• Re-Work
• Poor Yields
• Lost Revenue
• Poor Quality
• Late Deliveries
• Lost Customers
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• The People (Hair, Clothing, Movement)
• The Material (Particles Carried in to the Process)
• The Machine (Paint Chips, Wearing Parts)
• The Atmosphere (Airborne Particles)
The Contamination Carrier
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Eliminate
defects from the
printing process
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Contamination from - board packaging
Plastic outer +
Individual paper
Boards are insulators ~ typically shrink wrapped in plastic film or
individually wrapped in tissue paper > on unpacking, static is
generated, making the board a magnet for attracting contaminants
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Teknek Manufactured Elastomer Rollers
• High Precision Solid Stainless Steel Shaft
• Elastomer is Moulded and Extruded for perfect straightness to ensure
total contact with substrate
• Two post-cure stages to guarantee no free-chemistry
• Autoclaving to 220 degrees to guarantee sterility
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Types of Elastomer Roller
Film (F)
F3
Substrate
Panel (P)
Cleaning roller
Cleaning profile
Substrate
Soft (S)
Cleaning roller
Cleaning profile
ESD
Teknek Manufactured Elastomer Rollers
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Teknek Own-Manufactured Roller Types
• “P” - for standard panels
• “F” - for films
• “F3” - for thin films
• ESD – Uniquely designed for static sensitive applications
• Sizes - 1” (25mm) to 156” (4m)
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Teknek Engineered Adhesive RollPRE-CUT SHEET
BATCH LABELOVERLAP OF
PRE-CUT SHEETS
HIGHIMPACT
POLYSTYRENE
CORE
60 LAYERS
(20M ADHESIVE PAPER)
ADHESIVE COATING
BASE PAPER
RELEASE COATING
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Plastic Core
Base paper
Adhesive coating
60 pre-cut sheets to
guarantee 100% usage
of product
Release coating
Batch Label
Teknek Engineered Adhesive Roll
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Teknek Engineered Adhesive Rolls
• Excellent Wind Quality - Any unevenness in the wind of the adhesive
roll can prevent full contact with the cleaning elastomer rollers, thus
contamination remains on the elastomer rollers and subsequently on
the product being cleaned.
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Teknek Engineered Adhesive Rolls
• The Core - made from high impact polystyrene,
it will not bend ensuring straightness and mechanical rigidity
• The Paper - The thickness and density are specified to ensure wind
quality remains constant. Moisture stabilised.
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Teknek Engineered Adhesive Rolls
• Packaging – Adhesive rolls are protected by film, wrapped
individually in a cardboard tube and shrink wrapped in packs of 4
providing tamper proof protection.
• Identification – The Teknek logo is printed on the paper and a unique
batch number is located on the inside of each roll and end cap label
for traceability.
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Teknek Engineered Adhesive Rolls
• Release Coating - designed to ensure roll is not too difficult to
unwind. Coating never leaves paper therefore no cross
contamination.
• Adhesive Coating - twice thickness of some other brands. Does not
attack chemistry of cleaning roller. Teknek rollers can be used up to
double the time compared with copy rolls.
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NWCM
Retro-fit to Arsoma
EM-280 Press
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NWCM
Fitted with Idle Rollers
on Kopak Press
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WGCM
Adhesive Roll Pull
Out on WGCM
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XCH
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EPC
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“Building on Experience”
• Over 20 years manufacturing experience
• Highest Price:Performance Ratio in the Industry
• Utilising Advanced Technology
• Accelerated Life Testing for 10year life
• Robust and reliable
• 24 / 7 duty cycle
• Complete EMC compatibility
• Extremely low audible noise
• Patents applied for worldwide