Together with industrial partners and the Technical University of St. Petersburg, we develop solutions that can be used directly in film production.
New project · Process technology
VR headset for calender technology
A model developed over ten years of research with the Technical University of St. Petersburg calculates the flow processes in the roll nips of calender lines. From boundary conditions, slip properties of the rolls, rheology of the polymer compound and heat transfer, the film properties that are decisive for the operator are calculated in advance.
Usable directly on a laptop or via VR headset with images of your own calender line – as if standing in the production process. Partner: Technical University of St. Petersburg.
Video (3 min, English/Russian): virtual trainer for the calender line – data entry in the VR headset and output of the calendering result.
Thickness variations in the machine direction are hard to detect, but they reveal bearing damage and run-out errors. Thickness measurement over the film length with Fourier analysis to assign the variation to rotational speed and roll diameter – the basis for preventive maintenance.
Stabilization against thermal degradation: up to five samples simultaneously with uniform insertion into a heating cabinet, evaluation of the degradation via color camera analysis. Optimizes the stabilizer content for further stresses such as thermoforming.
Unusual surface properties for films: antimicrobial, conductive, scratch-resistant or selectively printable. Implemented via sol-gel technology and spray application with IR drying.
Tool for predicting plant failures and identifying possible causes: three alarm levels, WLAN communication between the devices, data view online and from the archive – on any device with a web browser.
Models for the cooling process, film shrinkage and thickness distribution as well as 3D simulation of the line. Basis: mass balance, momentum equation, heat balance and rheological equation of state – for process optimization and operator training.
Anti-counterfeiting system as well as measurement methods for shrinkage and shrink force, scratch resistance and dimensional measurement of formats – developed for use in the laboratory and on the line.
Digital tools from our process development – to try out and to use on your line.
Calender thickness calculation
Web app for calculating the thickness distribution across the roll width: enter roll geometry, roll crown, roll bending and roll crossing and see the profile and 3D analysis immediately. Runs directly in the browser – no download or installation.
Flow, pressure and heat calculation in the roll nip: mean thickness, calendered width, throughput, shrinkage and optimum roll settings – on a laptop or in the VR headset with images of your line.
Planning engine with sequence-dependent setup times (color, width, thickness), campaign building and capacity constraints across multiple plants – available as a demonstrator, adaptable to your ERP data.
Whether process analysis, selection of measurement technology or a digitalization project – we will get back to you promptly and discuss how we can specifically support you.
