Post on 04-Apr-2018
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Brückner ServtecCompany Profile
© Brückner
About Us
Established in 2003 as individual legal entity within the Brückner Group
Today 50 employees with many years of experience in biax business
Solid back-up by our sister company Brückner Maschinenbau
Supported by a number of service locations around the world
We provide service for …... any Brückner line, regardless whether it is 3 or 30 years old!... all lines built by Cellier, Proctor & Schwartz and Barmag extruders.... a growing number of lines supplied by Brückner competitors.
© Brückner
Complete Service Offered Out of One Hand
Production optimization
Line upgrading & conversion
Process optimization
Spare parts
Service contractsPersonnel service
Line inspection
Mediation of used equipment
Clip & chain refurbishment Condition monitoring
Measuring service
Line relocation
Teleservice24-h hotline
Consultancy
TrainingRepair
© Brückner
Upgrade Your Line and Stay Competitive
From resin to mill roll, from hardware to software: get the latest and proven technology for your existing line!
Improvements, which pay back in short time
Solutions provided by people, who understand your business:
● Punctual shipment
● Precise installation schedule
● Short interruption of your production
● Fast start-up
● One face to the customer
© Brückner
Upgrading TopicsTruck and big bag feeding Gravimetric Dosing
Multilayer film extrusion
High speed pinning system
MDO roll direct drives
MDO stretching unit with automatic roll bend protection
High efficiency film heating
Minimized lubricant consumptionHeat recovery
Integrated process control (IPC)
Programmable resin supply
Closed loop die bolt control Chill roll direct drive
High efficiency water removal Digital drives
High speed chain track system
Surface treatment
Thickness control integrated tension controlActive damping via linear motor technology
Roll handing system
Cut optimization (CUT)
© Brückner
Highlights in Upgrading I
Speed upgrade: the world‘s fastest BOPP line - 525 m/min
7-Layer film production with high barrier EVOH capability
Upgrades of non-Brückner lines, e.g. 5-layer special film production with thickness control
Line conversion to shrink film production (OPS or OPVC)
Electrical and automation upgrades
© Brückner
Highlights in Upgrading II
Special MDO for optical film, 100% direct drive controlled and with automatic roller cleaning
TDO heat recovery and condensate absorption system
Thickness measurement by controlled infrared heaters in TDO
Fully integrated web scan systems for maximum quality control
Winder contact roll system upgrade (LIWIND), ultra-fast response and highest accuracy
© Brückner
Service Highlights: Professional Line Inspection
Unscheduled line stops or process problems caused by:
Failures
Unavailable spare parts
Misalignment and maladjustment
can be avoided with regular line inspections by our service specialists
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Service Highlights: Mobile Service Assistant
Expert support available within minutes
Saving of travel expenses and travel time
Problems can be discussed directly on site
Suitable for any mechanical, electrical or process issue
Training
Easy troubleshooting, maintenance and increased uptime
© Brückner
Service Highlights: On-Site Roller Surface Repair
Damage: Step 1:
Step 2: Finished!
© Brückner
Service Highlights: CLIPFITClip & Chain Refurbishment
Not new –but perfectly overhauled
by Brückner Servtec!
Unprofessionalcleaning, no
quality inspection!
© Brückner
Service Highlights: Energy Audit
Experienced auditors Assessment for the complete plant● Material supply ● Stretching line● Electrical system● Utilities and surroundings, e.g. energy supply,
air conditioning, production hall illuminationReport with customised energy saving solutions
More efficient use of energy
© Brückner
Condition Monitoring and Measuring SystemsKeep your fingers on the pulse of your machine!
IR-Camera inspection:Electrical equipment, cast film, insulations and mechanical parts
Online and offline Machine Condition Monitoring (MCM):Gearboxes, bearings and other rotating components with alert function and statistical evaluation
© Brückner
Condition Monitoring and Measuring SystemsKeep your fingers on the pulse of your machine!
Oil Inspections:Verification of oil condition, evaluation of condition of the concerning machine part
Measuring services:Speed synchronization, TDO air distribution, check of the wear condition
© Brückner
Mediation of Used Equipment
Finding potential buyers foryour used equipment
We take care of a safe transfer of payments and goods
Valuation of your equipment
Finding economical spare parts solutions for older lines
On demand: professional overhaul
© Brückner
Training & Seminars: The Brückner Academy
Sharing knowledge and experience
Increase your profitability
Qualification and motivation of your staff
Increase safety level
© Brückner
Upgrading the Process Control System
Good Reasons for Investing in a …… New Process Control System:
Avoid spare-part problemsIncrease reliabilityIncrease productivityIncrease and ensure product qualityTransparent production
© Brückner
IPC, Overview
S7-416
I / O Drives
Ethernet TCP/IP Profibus
MS - Windows Workstations
Fiel
d-Le
vel
Linux Server
• Central data- & event handling• Open architecture (expandable)• Reliable: RAID, UPS, Redundant Power...• Thickness control, roll- and process-data
Brückner Integrated Process Control System - powered by PVSS-II
Supe
rvis
ory-
Leve
l
DieboltControl
Options: - Integrated Thickness Control- Integrated Web-Inspection
Internet
Upgrading the Process Control System
DSL-Router
• Online-support• Trouble-shooting
© Brückner
MMSManufacturing
ManagementSystem
Information Flow
© Brückner
MMS – Efficiency Boost for Old and New Lines
Brückner´s MMS is the solution to control film production processes right from the start to the very end.
© Brückner
MMS – What You Get
You Save ● Set-up time● Waste (e.g. CUT 0,5% - 4%)● Inventory
You Improve● Product to market time
You Gain● Increased market share
Fast Return on Investment (ROI)
© Brückner
Heat Recovery System for TDOIncluding Condensate Absorption
Easy upgrade with short delivery time● Max. 10 weeks
Short installation period● Max. 1 week
Easy and cheap maintenance of the system● Max. 2 times per year
Higher quality of the filmHigh profitability
Average amortization within less than 1,5 years !
© Brückner
Heat Recovery System for TDO – Advantages
Reduced energy consumption by returning existing heat energy● Up to 270 kW per hour
Improvement of film quality by preheated fresh air● Less temperature differences● Less pressure differences
Higher air conformity in the TDO oven
© Brückner
Condensate Absorption – Advantages
Less maintenance in the TDO● By controlled absorption of condensate ● By easy collecting ● By easy removing
Less emission to the environmentLess condensate at slots, holes and cold bridges by● Reduced flow of cold air● Controlled overpressure in the oven
Improvement of film quality
Condensate hose
Condensate tray
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Linear Motor Winding System (LIWIND®)Mechatronic Damping System for the Contact Roll at the Winder
© Brückner
LIWIND® – Perfect Mill Rolls for All Film Types
© Brückner
Web Inspection – Basic Principle
High speed cameras
Embedded PCs with low heat processors
High power fluorescent lighting
100 MB Ethernet data transfer
Evaluation software
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4
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Web Inspection – Detectable Defects
SpotsContaminations (dust)Cracks and holesCoating defectsOil and condensate dropsFluff balls
Die linesBurned granulesScratchesInsects and/or gel inclusions and similar appearancesFlow marks
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Web Inspection – Advantages
Comprehensive quality inspection records
Avoidance of unnecessary and expensive complaints
Optimization of the production by online detection and correlation to the process
Improved sales argument by optimized and recorded quality
Possibility of partitioning for each roll in different quality segments
Waste reduction by automatic online alarm
Quicker set-up of new products by online quality observing
© Brückner
7 Layer Upgrade
Output increaseNewest products with the latest developed resinsAbility to produce highest grade films with special recipes Be prepared for future marketsReturn to competitiveness
Skin layer (Co- or Terpolymer)Core layer (Homopolymer)Tie layer (Adhesive layer)EVOH (Barrier layer)Tie layer (Adhesive layer)Core layer (Homopolymer)Skin layer (Co- or Terpolymer)
7 Layer high barrier film
© Brückner
Upgrade TDO Chain TrackFOK 4.4.2 to FOK 4.7 System
Speed up of the chain system up to 300 m/min
The existing chain track will be reused
No more exchange of sliding bars after modification
Less maintenance cost by special plastic runners
Save more than 50% of lubrication on the sliding parts
Reduced down time due to minimized maintenance stops
One of our standard upgrades – done already several
times!
© Brückner
Upgrade TDO Chain TrackFOK 4.4.4 speed up to 400 m/min
High-speed sliding chain
Excellent sliding properties
Precision cast clips
Magnetic clip closer and opener
Speed up to 400 m/min
© Brückner
Upgrade TDO Chain TrackFOK 5.1 to FOK 5.3 System
Speed up to 250 m/min
Lubricant free chain
Much less oil on mono rail
6 roller bearing system for smoother running
Magnetic clip closing
Special bearings for increased lifetime, grease filled, sealed for lifetime
Overhaul at Brückner Servtec facility
Easy & economic maintenance
© Brückner
Upgrade TDO Chain TrackCellier to FOK 5.3 System
Speed up to 250 m/min
Lower oil consumption
Lubrication free
Less wear due to better sealing
Pneumatical clip pre-opening at film break
Magnetic clip closing
We also do upgradings of non-Brückner lines!
UpgradingLatest References
© Brückner
Upgrading – Latest References ICountry Customer Project Upgrading
Year of Installation
Japan 1201 TOC IPC / PVSS upgrading
2008
Japan 1250 LOC Modification MDO
Spain 3341 NAV Various upgradings of a relocated line
Finland 272 AHL Cross cutter, safety upgrading contact roll
Italy 248 ISEA Replacement of TDO electrical heatingto oil heating
Republic of Korea 1092 ROK New electrical system with new cabinets PLC and
process control system including thickness TCE
Czech Republic
0268 TECH Web inspection system
2007
Czech Republic
0268 TECH Dedusting system
Czech Republic
0268 TECH
Complete revamp to 3 layer line with twin screws, direct drives, new TDO chain, new winder, IPC with
PVSS II / S7
Turkey 3343 ISA 5-layer and thickness gauge modification
© Brückner
Upgrading – Latest References IICountry Customer Project Upgrading
Year of Installation
Canada 231 BORD Raw material supply
2007
Netherlands 1255 KEY Modification of extruder
Chile 1227 SIG Magnetic clip opener system for FOK 4.7 -300m/min
Chile 1227 SIG Die bolt temperature control system, network upgrade
Republic of Korea Ja Kang Industrial Co.Ltd. 1111 LAD Corona generators and new electrodes
Greece 1278 HEL Version update integrated process control system, new die bolt temperature control system
Greece 1270 EKO Version update integrated process control system, new die bolt temperature control system
Greece 1278 HEL Magnetic clip opener and closer system for FOK 4.4.4. - 360m/min
Greece 1270 EKO Magnetic clip opener and closer system for FOK 4.4.4. - 360m/min
Italy Axial s.r.l. 3342 AXI TDO for shrink film
© Brückner
Upgrading – Latest References IIICountry Customer Project Upgrading
Year of Installation
Germany 1072 EFO Long term roll based data archiving analysis and reporting – RDH extended
2007
USA Confidential 1289 OTA Electrical control system for KARO IV
USA Confidential 1242 HUT Line relocation
USA Confidential 1241 TAPInterchangeable configuration plates for adapter
block to achieve different layer configurations with the same adapter block
Confidential Confidential Confidential IPC upgrading PVSS II/S7, new DC drives, change distribution I/O’s from ET100 to ET200
Belgium Treofan Group 1165 NIE Gravimetric dosing
Malaysia Confidential Confidential Modification of extrusion system / adding screen changer unit
Belgium Treofan Group 1165 NIE Digital drive system
Malaysia Stenta Films 1168 MASIntegrated process control with PVSSII/S7 and
distributed I/0’s, digital drives and winder modification
Malaysia Stenta Films 1205 SAM Modification die bolt control system
www.brueckner.com // servtec@brueckner.com // tel. +49 8662 63 0 // fax +49 8662 63 9370
Brückner Servtec GmbHThank you very much for your attention.