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Shear Clean OV

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					            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.

				
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posted:5/27/2010
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Description: Static solutions