ShearClean™ Non Contact Web Cleaning System Overview 1. System Introduction 2. How ShearClean works 3. Prototype, Current and Planned Installations 4. Testing Results 5. General Assembly Drawing 6. Vacuum Extraction Systems Meech International www.meech.com Offices in: © Meech Static Eliminators Ltd 2009 UK USA Belgium Hungary China 1. System Introduction The Meech ShearClean™ web cleaning system is a state-of-the-art design based on patented technology that utilises well established aerodynamic and fluid dynamic technologies to achieve the very highest levels of cleaning efficiency without the need for physical contact. The Meech ShearClean system comprises two major components - a cleaning head and a vacuum extraction system. The cleaning head incorporates proprietary “non contact” cleaning rollers and ionising bars for control of static charges. Connection to a Meech Compact Extraction System or vacuum unit allows easy removal and collection of contaminants. The proprietary cleaning rollers operate at a high rotational velocity close to the surface of the web. The roller design has been optimised to generate a high speed boundary layer of air. The greater energy of this layer destroys the boundary layer associated with the incoming web, exposing even the smallest particles resting on it to the powerful cleaning force. The low pressure, high velocity region created by the roller lifts and removes the particles from the web and carries them to the vacuum extraction chamber. Ionising bars ensure neutralisation of static charges on the web and easy breakdown of the bonds holding contaminants to the web surface. The risk of re-attraction of contaminants to the cleaned web surfaces is also minimised. Feature Benefit Non contact cleaning Eliminates risk of surface marking and damage. No interference with web tension or web tracking. Suitable for both single and double sided cleaning. Integrated static control Neutralises static charges to optimise cleaning performance and prevent re-contamination. Hinged, clam shell design Allows unit to open for easy threading of the web. No consumable items No requirement for expensive replacement sticky tapes. Minimum maintenance and low running costs. Compact design Flexible positioning & easy installation. Digital control & graphic Easy to set up and adjust extraction system. display Quiet operation. Can be installed in enclosed work areas. No H&S issues due to noise. 2. How ShearClean works High speed rollers rotate at speeds of up to 6000rpm in the opposite direction to the web but with out physically touching the substrate surface. The minimum roller speed required is 4000rpm. The boundary layer produced on the roller is greater than the boundary layer on the web. ShearClean uses this air turbulence to destroy the surface boundary layer on the web that holds the contaminants against the web surface. A crucial low-pressure zone is also created at the web surface. This low-pressure zone dislodges the contaminants. Now airborne, the contaminants are swept into the ShearClean vacuum chamber. An integrated aerodynamically designed ‘Shear Bar’ keeps the rotor clean and prevents re-contamination of the web. Model 914 ionising bars with 905 power units provide effective static control to optimise the cleaning performance and prevent re-contamination of the web. 3. Prototype, Current and Planned Installations Prototype Development of ShearClean was primarily undertaken on: Edale Gamma Press Timsons T Flex Press Timsons T Flex Timsons T Flex Current Installations The ShearClean is currently installed on the following line: Machine: Cerutti 10 Colour Gravure Press Line Speed: Up to 300mtrs/min (material dependant) Materials: Various plastics Material Width: Various up to 1,000mm Installation Position: Prior to the Corona Treater Cerutti Installation A ShearClean unit complete with path rollers and gas struts for ease of opening/closing is installed interlocked with the Cerutti for auto start/stop. ShearClean at Ground Level There are 3 components to the system that are sited at ground level; A. Control panel B. 5 micron collection bag housed in a cabinet C. 2.2KW fan unit A B C ShearClean on the Press The ShearClean is mounted on a custom made bracket. Contaminated air is extracted from both sides of the unit via a combination of 6” (150mm) diameter flexible and rigid ducting. The contaminated airflow passes through item B above before entering the fan unit and being exhausted to atmosphere. The following 2 photos show the ShearClean at various stages of installation. Photo 1: ShearClean hinged open to show the cotton rollers prior to the ducting being connected. Photo 2: ShearClean with ducting connected. Planned Installations Planned installations include the following lines: Gallus EM280 Nilpeter Label Press 4. Testing Results External Testing It has been confirmed that the ShearClean has provided the following improvements: Reduced impression roller cleaning Reduced print defects Reduced carry through of splice shards Internal Testing Several internal tests have been completed, the latest on a metalised film, width 300mm. Additional contamination was added to the metalised film before running through the ShearClean. The following results were collected using a microscope on 60x magnification. 0.06mm 0.08mm 0.20mm Image 1 - Showing the heavily contaminated film Image 2 - Showing the film after passing through the ShearClean once. 5. General Assembly Drawing All dimensions in mm. 6. Vacuum Extraction Systems The ShearClean system incorporates either a Compact Extraction Unit or Vacuum unit as follows: ShearClean Length Extraction System 200 - 600mm Compact Extraction Unit 600 - 2000mm Vacuum Unit Compact Extraction Unit Feature Benefit 74dBA noise level Can be installed in close proximity to line operatives, as it is substantially lower than current legislative guidelines 240V electrical requirement Does not require a costly 3-phase supply 2.4KW electrical consumption for up Cheaper to run than other vacuum based contact cleaning to 1200mm of web width (single sided systems A cleaning) Variable vacuum control (manual) It can be set to perform optimally for each individual application at time of installation Automatic vacuum control Once set, it will automatically adjust to maintain the pre-set level of vacuum, removing the need for constant operator adjustment to maintain optimum performance Labyrinth filter technology – 1 micron Allows the unit to be positioned next to the machine without concerns of re-contamination, as the exhausted air is filtered to an extremely high level Compact design incorporating the fan Casters make the single unit easy to move into the required and labyrinth filter location without lifting equipment Stainless steel design Looks stylish whilst being able to withstand ‘normal’ production environments Filter condition lamp Allows the operator to see the condition of the filter at a glance Remote on/off Allows switching with production line state A Typical vacuum based cleaning systems would have an electrical consumption in the region of 4KWs for a 1200mm single sided web width Vacuum Unit Feature Benefit Gate Valve Allows manual control of the vacuum level so that it can be set for optimum application performance. Anti vibration mounts Reduces the vibration noise level of the fan unit so that it can be installed on mezzanine levels 5 micron filtration The unit can be positioned next to the machine without concerns of re-contamination Silencing options Gives flexibility of the installation locations, allowing the fan unit to be installed near operators. The noise level can be as low as 70dBA (1 meter, free field) Inline filtration option The contaminated airflow is filtered prior to passing through the fan unit, removing concerns of blockages for certain materials. EX approval options: The airflow from an EX rated zone can pass through the fan Anti spark unit. Zone 1 & anti spark The fan unit can be installed in a Zone 1 area and the airflow from the area can pass through the fan.