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www.convertingtoday.co.uk August 2006
today
FLEXO ADVANCE
Sun Chemical, Comexi and
ESI team up for new process
WINNERS ALL
Quality comes top in the
ExxonMobil OPPack awards
WASTE AWAY
Kongskilde system takes care
of trim removal at PSG
CT Polyester p26_27 Aug 06 8/3/06 2:54 PM Page 26
COVER STORY psg
Partners in
PROGRESS
Converter PSG and suppliers Kongskilde and
TS Converting Equipment co-operate closely
London based PSG Group, whose new Below: trim pipe on Deacro
cleanroom facility was featured in our C24 in cleanroom. Right:
November, 2004, issue, has continued to tailormade trim pipes lead
improve its operational efficiency by installing an to chopper motors on old
advanced Kongskilde waste removal system Harnden slitters. Opposite,
serving all of its converting machines. In top: Multicutter in-line on
addition to the tangible benefits this has C24. Below: Multiairs, rotary
achieved, the installation is representative of the separator, Venturi system
close level of collaboration that exists between and air return. Far right: Air
PSG and its suppliers. This is typified both by the separators above waste
work with Kongskilde UK - and by the trimstorage
converting company's long standing partnership
with slitting machinery supplier TS Converting
Equipment.
The new bespoke waste handling system was
commissioned last month. It removes continuous
edge trim from the various machines in the
factory (including the Deacro slitter in the
cleanroom), chops it into small pieces for used to convey the chopped edge trim waste
compaction, and conveys these through air from the various slitter positions within the
ducts to a central collection point. factory to a collection area outside. The two
Kongskilde UK sales manager John Kightley KU4000 air separators have been positioned
reflects: “Considering the layout, the number of within the roof structure of a small extension to
different machines involved, and the types of the building which is close to the road, enabling
material thicknesses, it is one of the most easy access for collection of the waste
diverse systems we have installed. We have used containers.
several different items of equipment from our A 'through fan' system was selected to
range within the installation.” convey the material from the existing and
The initial waste removal system supplied for proposed Deacro slitters in the cleanroom
the cleanroom slitter two years ago was because of the long conveying distance
designed by Kongskilde to extract two-edge trim required. It also generates the largest volume of
up to a maximum width of 40mm, 250 micron waste material, due to the fast operating
thick, at a rate of 500m/min. It comprised two speeds. A Multiair 1075S with an RVS rotary
60mm diameter flexible pick-ups feeding separator operates in conjunction with single
through an in-line twin blade Multicutter cutters on two of the machines handling the
running at 2,800rev/min. A Multiair 215TR quiet lighter gauge materials to convey the waste.
pressure fan provided the air for an ITF100 Kongskilde was able to use the initial Multiair
Venturi to create the suction required to convey it had supplied for the first system at PSG in
the chopped material into a roll-top container conjunction with an FVO Venturi and air return
positioned under an air separator some 30m to extract the waste from the slitter dealing with
away. removal system for each one,” reveals John the heavier gauge materials. Here it was
Now there are edge trim removal systems for Kightley. This was achieved using a computer considered prudent to use a cutter for each of
all four of PSG's slitting machines, with provision programme designed by Kongskilde that the trims in this application to ensure longer
to connect to a second Deacro slitter planned calculates the required air speed and back blade life.
for eventual installation in the cleanroom. pressure of each system, and confirms the most Particular attention was paid to operational
“We considered the various material economic and power efficient method for each noise levels for the three systems. In-line
parameters and line speeds for each of the one. silencers are positioned either side of the
machines and designed a specific edge trim Three different methods of extraction are cutters, and at various points in the system to
www.convertingtoday.co.uk CONVERTING TODAY AUGUST 2006
CT Polyester p26_27 Aug 06 8/3/06 2:54 PM Page 27
the investment. “Technology has improved dramatically over
“It's brought us a the years,” observes Tim Self, director of TS
huge saving,” enthuses Converting, “but the fundamental principles of
managing director slitting and rewinding are still very similar.
Lawrence Gardezi. Technology, however, has improved the
“Now we have a system controllability and consistency of machines, and
for all our machines, it the transfer of that technology on to the older
has saved a lot of space equipment often gives them a new lease of
in our factory. The total life.”
volume of waste Available on all Elite Cameron and Deacro
material has been products, the Response service contract is said
halved through being to provide an affordable means for maintaining
handled much more the machines, maximizing productivity,
efficiently. Overall noise minimizing downtime and maintaining
levels are also much consistently high levels of quality. It includes:
lower than before, and regular servicing and safety inspections;
we have improved continuous updating of technical and
cleanliness and safety. production files; maintaining machine
reduce noise both within the production area We have decreased waste costs, increased calibration; and discounted spare parts.
and outside at the waste discharge point. productivity, reduced the workforce (we used to Telephone and on-line support systems often
The system was designed into three separate employ a full-time cleaner to clean up around enable customers to make their own repairs or
functions so that, in the event of a motor the machines), and ensured health and safety adjustments immediately.
failure, only 30 per of the production would be compliance.” PSG and Kongskilde have both had close ties
lost, unlike a centralized system where all He is happy for the waste handling system to with TS Converting/Elite Cameron for many
production would stop. Kongskilde also serve as a demonstration facility for Kongskilde - years. Deacro only uses Kongskilde systems on
provided PSG with detailed three dimensional “because it is unique. It serves a range of its machines in the USA. “We have just supplied
CAD layout drawings for the three systems that machines, from elderly slitters that are still doing TS with a system for a bespoke slitting machine
enabled them to be installed by the company's a valuable job to the latest Deacro, and for another customer, to remove 14 individual
own engineer - saving on the mechanical everything in between. Not only the machines, trims,” reveals John Kightley.
installation costs. but the types of material they handle are so Lawrence Gardezi concludes: “All three
Since the installation, labour costs associated varied. John has been involved from the companies co-operate closely. We all have the
with waste removal from the factory have been beginning and continues to work closely with same philosophy of doing whatever is required,
reduced considerably. The introduction of the in- us. He's always up to the challenge of adapting for whoever, and whenever. Kongskilde gave us
line Multicutters within the trim extraction pipe systems to meet different applications.” a system that could cope with this - and the
lines has dramatically reduced the volume of In addition to these latest improvements, service from TS supports our machinery. Thanks
material entering the waste containers. Initial PSG has long benefited on the machinery front to our competitive capabilities, we have doubled
calculations indicate this to be a fifth of the from the TS Converting Equipment service our international business in the last year.” ■
volume compared with continuous edge trim package, which has enabled it to keep
systems conveyed to PE bags adjacent to the equipment both old and new in good running CONTACTS
slitting machines. This will produce the greatest order. TS provides service and support for all the
cost saving, as all waste collected from the company's machines, from its 20-year old PSG Group:
factory is charged by volume. Cameron winder to the latest Deacro model. Tel: +44 (0)20 7740 9740
At around £50,000, the new system was a “We have benefited immensely over the www.polyesterconverters.com
considerable investment for PSG, but the years using the Response after sales service,” Kongskilde UK:
improved working conditions will result in confirms Lawrence Gardezi. Support was one of Tel: +44 (0)1869 253058 www.kongskilde.com
increased production with reduced labour costs the main factors when we chose the Deacro TS Converting Equipment:
which, together with an 80 per cent reduction slitter. They cover everything, from knives to Tel: +44 (0)1823 283411 www.tsconverting.com
in waste disposal charges, should soon amortize software - even for machines that aren't theirs.”
AUGUST 2006 CONVERTING TODAY www.convertingtoday.co.uk
