Plast-Control UK Ltd

The Profile Measurement Online Systems for Blown Film applications that we offer at Plast-Control UK present a graphical image of your film with variations in thickness that are contrary to your original design highlighted. The Profile Measurement software uses sensor technology to determine the variations in film thickness in either percentage terms or measured in microns.

The sensors that send the data for the online profile of the blown film are based on a C-Head unit on an automatic adjusting arm that regulates the level of contact with the film. The arm of the C-Head can either be mounted or on a scanner track. We offer C-Heads that can measure various thicknesses and low slip films if required.

For more details of the Profile Measurement Online Software for Blown Films applications, please contact us.

At Plast-Control UK we offer the most advanced Profile Measurement online software for monitoring the quality and thickness of flat film during the production process. The sensors we use in our measurement systems are durable and long-lasting, and require no specialist safety equipment to handle. The Profile Measurement online system provides a high-resolution image of the film detailing any issues relating to the thickness of the flat film.

The C-Head unit contains a load cell so that it maintains the optimum distance from the film to provide a consistent reading. Our Type Air C-Scan unit is mounted within a flat-bed scanner, and can be used for flat-bed die applications.

If you require more details of the Profile Measurement Online for Flat Film Production, please feel free to contact us.

All of our automation principles over the last 35 years have been based on gravimetric extrusion control.

The “loss in weight” principle guarantees precise measurement of throughput and control designed for all types of extrusion processes. Extrusion control has proven to be an essential first step for establishing a stable extrusion process.

Fully modular construction allows up to 6 dosing units plus main material to be fitted to each extruder (including co-extruders). Precise dosing of costly additives and master batches takes place directly above the extruder throat.

All dosing units outputs are synchronized with the main hopper output to guarantee an accurate product recipe. The latest generation of dosing unit now incorporates a high torque motor delivering a wide speed range.

The PRO-JET Profile Control is achieved with a segmented plate that is mounted underneath an existing air ring. Adjustable air valves, located below the air ring, controls the volume of airflow in each segment. Suitable for stationary and moving dies with diameters from 100 mm - 2500 mm (4”-100”).

The PRO-LAB II has a touching sensor for the absolute, real thickness measurement of film profiles according to the norms DIN 533370 / ISO 4593 / ASTM-D 6988-08.

In addition to the touching sensor, the system is available with a capacitive sensor for a continuous measurement mode or with a combination of both sensors.

To analyze the thickness Distribution, a film strip is put into the holding device of the
PRO-LAB II system. The measuring value is registered with the mechanical detection head at selectable distances or continuous with the capacitive sensor. The maintenance free stepper motor moves the film strip step by step to the mechanical detection sensor.

The PRO-LAB II basic system is equipped with a serial interface, so that the system can be connected to a customer PC. The software package is Windows based and has a user friendly environment allowing a professional profile analysis. Based on meaningful profile graphics, average values, min. and max. values, the tolerance of the pre-selected set points will be easily detected. With the help of Windows, these measuring results can be documented with product or order numbers, archived or recorded.

The PLAST-CONTROL Central PCC plant-wide connection of your extrusion lines provides a powerful and convenient tool for accessing and storing all production data – in real time.

All production data is displayed centrally and optionally on Personal Computers integrated into your plant-wide network. Optionally, production specific data from your system network can be sent to the PCC.
Precise material balance sheets, quality control, central data saving and production supervising are possible without the need of large Information Technology budgets.
The basic software package includes a number of sophisticated data logging and order database applications. Custom screens can be implemented for a specific customer request. A good example is the implementation of an OEE – Software. This tool enables the user to localize problems in the production and stop them from reoccurring.

The IBC-control system PRO-SONIC can be integrated into all PLAST-CONTROL systems or can be supplied as a stand-alone system.

For accurate control of the bubble diameter, speed is everything. PRO-SONIC incorporates non-contact high quality ultrasonic sensors processed by ultra-fast signal processing hardware and software. Bubble diameter is calculated within 100 ms per update.

Stepper motor driven air Throttle Valve (STV) supplies instantaneous response to the control required by the system. Layflat width variations are reduced to a minimum. Start up requires minimal operator interaction.

Edge trim and start up waste can be reduced and nominal thickness is maintained.

Ultra-Sonic Sensors
We have achieved width tolerances of less than +/- 2 mm on existing lines using the latest generation of Ultra Sonic sensors combined with the newly developed air control valve.

Vacuum pumps and dust contamination filtration

Dust and contamination of the virgin material often creates problems in the extrusion process. Long transport distances and many elbows between the silos and the machines produce dust and angel hair. These contaminates must be removed before entering the extruder by use of filtration devices.

More and more extrusion companies are changing to a centralized vacuum supply. Advantages like energy efficiency, noise reduction at the work station and a significant higher output at lower costs are only a few reasons. The uptime is increased while the maintenance effort is decreased.

PLAST-CONTROL provides software and hardware to deliver plastic pellets within a plant.

PLAST-CONTROL engineers can design plant-wide layouts or individual system configurations. A properly designed system eliminates dust and angel hair. Minimizing conveying distances and maximizing throughput rates while reducing energy needs - these have been our key-expectations while developing PRO-VIDER.

If your requirements are to convey small amounts of a single material over a short distance, or a production hall central vacuum system with several tons per hour demand - we have the technical solution and the appropriate equipment

The most suitable solution to control the final film width is by using our absolute width infrared sensor measuring system. Mounted after the collapsing Frame, these sensors will report the physical width of the layflat. Width adjustments are made by automatically opening or closing the calibration cage on IBC systems or with a digital air valve on non-IBC lines.

For gusseted films we offer the option of installing Ultra Sonic sensors above the calibration cage which measure the bubble diameter; the PRO-SONIC controls the opening and closing of the cage.
The NANO width measurement is a technically revised version of our width scanning system, with simplified electronics and lower cost. Actual width is measured just before the winder and thus corresponds exactly to the true width of the film roll, with any shrinkage already taking place prior to the measuring point.