Key Factors in Selecting a Suitable Web Cleaning System Presented By: Matt Fyffe Product shown in this document may be covered by one or more patents, patents applied for and/or registered designs and/or trade marks. For further information please refer to our Head Office or visit www.meech.com. Meech international UK: +44 1993 706 700 USA: +1 330 564 2000 Belgium: +32 8067 0204 email: sales@meech.com Hungary: +36 27 535 075 China: +86 21 6119 6725 web: www.meech.com Meech Static Eliminators Ltd 2010
Web Cleaning Systems Web cleaning systems provide effective solutions to problems such as: Dirty webs causing loss of profit and customer dissatisfaction Excessive downtime on printing presses Frequent blanket washing High reject rates in laminating or coating processes Unacceptable quality in pharmaceutical or food packaging Poor print quality
Critical Requirements for Successful Cleaning Effective static elimination of the web and contamination Break the boundary layer of air on the web surface Disturb and remove the surface contamination Successfully isolate and trap all of the disturbed contamination
Web Cleaning Systems Tacky Roll Cleaner Contact Web Cleaner Non Contact Web Cleaner (Vacuum Blow Vacuum) Non Contact Web Cleaner (Rotary)
Tacky Roll Contact Web Cleaners How it works Elastomer cleaning rollers contact the full width of the web with even pressure. Dry, unbonded contamination is lifted from the web surface. A Pneumatically actuated adhesive roller is in contact with the elastomer roller. Contamination is transferred from the surface of the elastomer roller to the adhesive roller where it is trapped. Any static charge present on the web is neutralised on exit from the web cleaner; minimising the risk of statically attracted recontamination.
Vacuum Based Contact Web Cleaners How it works Static Neutralization Breaks the bond between dust particles and web, leaving the web neutral after cleaning. Breaking boundary layer Brushes destroy boundary layer on fast moving webs and dislodge any physically attached particles. Powerful Vacuum Extremely high speed airflow through faceplate is very turbulent. The turbulence allows removal of very small particles.
Non-Contact Web Cleaners How it works The web passes through a cloud of ionization on entry to the cleaning, which neutralizes any static charges. The web is then subject to a force of turbulent air created by the blowing and vacuum airflows within the head unit. High frequency micro-movements of the web are created by the turbulent air. The combination of the high frequency micro-movements and turbulent air shatters the web boundary air layer, releasing the contamination into the vacuum airflows. As the web exits the head, it passes through a second cloud of ionization to prevent re-contamination of the web.
Rotary Non-contact Cleaning Method How it works High speed rollers rotate at speeds of up to 6000rpm in the opposite direction to the web but without physically touching the substrate surface. ShearClean uses air turbulence to destroy the surface boundary layer on the web. 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.
Extraction and Filtration
Tacky Roller Vacuum Vacuum Blow Vacuum Rotatory Printing Labelling Laminating Coating Slitting & winding Corrugating Food and medical packaging Paper making and converting Wood/furniture and flooring Automotive Narrow Web Specialty Films Pharmaceutical LCD Screens Solar Panels Filter Material
Narrow Web Tacky Roller Installations
Mid Web Vacuum Installations
Vacuum Blow Vacuum Installations
Rotatory Non-contact Installations
Tacky Roller - Pros & Cons Pros Cons Low initial cost Restricted to lower web speeds (up to 250 m/min) Excellent cleaning performance, proven to 0.5 micron Not suited to highly contaminated applications Compact size Ongoing adhesive material requirement Ease of installation Suitable for sensitive materials
Vacuum Systems - Pros & Cons Pros Cons Excellent for high contamination applications Not suitable for sensitive materials Suited to high speed applications Requires installation space at the machine and adjacent to it Particularly suited to paper and board Larger systems require a 3 phase electricity supply Relative ease of installation Excellent cleaning performance, proven to 5 micron Suitable for wide web applications
Vacuum Blow Vacuum System - Pros & Cons Pros Cons Suitable for all materials Restricted to a maximum web width of 3m Excellent cleaning performance, proven to 0.5 micron Only available for double sided cleaning Very compact size Ease to install Suitable for low and high speed applications Suitable for web widths up to 3m
Rotary Non-contact - Pros & Cons Pros Cons Suited to all material types; particularly very sensitive materials Initial higher investment level Excellent cleaning performance, proven to 0.3 micron Requires full line integration Suitable for low and high speed applications
Web Cleaning types and technologies Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary
Key factors affecting selection of suitable web cleaner: 1. Contamination size: Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary >0.5 micron >5 micron >0.5 micron >0.3 micron
Key factors affecting selection of suitable web cleaner: 2. Contamination level: Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary >0.5 micron >5 micron >0.5 micron >0.3 micron low very high high high
Contaminated Adhesive Reel Surface
Inline Test Filter of a Vacuum System
HEPA Filter Contamination and Discolouration
Dust and Component Contamination from a Rotary Non-Contact System
Key factors affecting selection of suitable web cleaner: 3. Type of material: Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary >0.5 micron >5 micron >0.5 micron >0.3 micron medium very high high medium paper, film >10 micron any, >50micron any any
Key factors affecting selection of suitable web cleaner: 4. Web speeds: Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary >0.5 micron >5 micron >0.5 micron >0.3 micron medium very high high medium paper, film >10 micron any, >50micron any any 250m/min 1600m/min 800m/min 600m/min
Key factors affecting selection of suitable web cleaner: 5. Web width: Contact Web Cleaning Non Contact web Cleaning Tacky Roller Vacuum Vacuum Blow Vacuum Rotary >0.5 micron >5 micron >0.5 micron >0.3 micron medium very high high medium paper, film >10 micron any, >50micron any any 250m/min 1600m/min 800m/min 600m/min 2.0m 8.0m 2.6m 2.1m
Other factors affecting selection of suitable web cleaner: Web tension Installation environment (cleanroom) Noise levels Single sided or double sided cleaning Ease to install Accessibility to the web cleaner Size of web cleaner
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