www.bobst.com
Bobst Manchester Ltd.Pennine Business Park, Pilsworth Road,Heywood, Lancashire, OL10 2TL, UKTel: +44 1706 622442 Fax: +44 1706 622772 [email protected]@bobst.com
BOBST General K4000COMPLETE FLEXIBILITY
K4000/02/2013
TECHNICALMax web width (mm) 1250 1650Min web width (mm) 425 625Max roll diameter (mm) 1000 1000Max line speed (m/min) 840 840Average power consumption (kW) 147 204Average water consumption (m3/hr) 23 27Overall length (mm) 10352 11352Overall width (mm) 5670 5670Overall height above floor (mm) 3105 3105Estimated annual output (tonnes) 2300 3100
HIGH PERFORMANCEVACUUM METALLIZING
SPECIFICATIONS
PERFORMANCE20 µmOPPOxygen transmission rate (cm3/m2/ day) < 40Water vapor transmission (g/m2 / day) < 1OD uniformity (%) < ± 5%12 µmPETOxygen transmission rate (cm3/m2/ day) < 1Water vapor transmission (g/m2 / day) < 1OD uniformity (%) < ± 5%25 µmCPPOxygen transmission rate (cm3/m2/ day) < 40OD uniformity (%) < ± 5%
*coating thickness 2.3 OD; barrier data depending on actual substrate type; throughput depends on customer’s production parameters.
TECHNICALMax web width (mm) 2050 2450Min web width (mm) 825 1025Max roll diameter (mm) 1000 1000Max line speed (m/min) 840 840Average power consumption (kW) 224 253Average water consumption (m3/hr) 32 38Overall length (mm) 15195 15995Overall width (mm) 5670 5670Overall height above floor (mm) 3105 3105Estimated annual output (tonnes) 3800 4500
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K4000
Superior technology helps improveconverters’ profitability by theproduction of high quality webs atexcellent productivity levels. TheK4000 metallizer is a good exampleof such technology. The machinecan be used to produce metallizedor optionally aluminium oxidecoated films, with quickchangeover at the touch of abutton, for various film types,including PET, BOPP, CPP, OPA,LDPE, HDPE and PS. It can also beused to produce metallized paperas long as the base paper issuitable. The use of metallizedplastic webs for the production offlexible packaging high barriermaterial is also possible on theK4000 machine, by using pre-treatment or post-treatment
plasma modules. Additionally theK4000’s superior evaporationsource control system results infewer defects and out ofspecification coating levels whichcan be monitored by our uniqueBOBST General Hawkeye Pinholedetection system.
The K4000 has an extremelyflexible winding system that canhandle even the most scratchsensitive of webs, like metallizedstamping foil, without problems.
The user interface is simple andlogical and helps the productionteam keep consistent high qualityoutput by using the comprehensiverecipe system.
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COATING QUALITYThe plasma treatment system canbe used before coating to achieveimprovement in metal adhesion,water vapour and oxygen barrierand dyne level retention. It canalso be positioned after the coatingzone for further improvement offilm barrier and other properties.
The K4000 can be fitted with aselective metallizing system up to1650mm that allows the productionof in-line de-metallized film. Thisfilm can be further processed toproduce sophisticated packagingand technical products thatincorporate clear windows or anyother design of the customer’schoosing.
PRODUCTIVITY AND ENERGYSAVINGSBOBST’s design engineers andtechnicians have also concentratedon developing a machine thatreduces the cost of production.The K4000 has been developedusing the latest technologicalinnovations to reduce energyconsumption. The canned motortechnology on the vacuum pumpsallow the use of “vacuum seal free”running, which reduces energycosts whilst at the same timeincreasing reliability. Its footprintmeans that it is the smallestmachine on the market per unitproduction, so it is relatively easyto fit into existing production halls.
PLASMA PRE-TREATMENTAND POST-TREATMENT
FEATURES
The preparation of the film surface for metallization or clear coating(aluminium oxide) is a critical step in constructing the desired properties ofthe finished structure, for both adhesion and barrier properties. The BOBSTtechnology is based on medium frequency (40KHz) powered plasma units,from pre-treatment through to full plasma coating (PECVD – plasmaenhanced chemical vapour deposition).
PLANAR PLASMA PRE-TREATMENTUNITStandard pre treater unit availableup to 3650mm (wider available onrequest) and typically utilising 10-20Kw power supplies. The BOBSTunit gives high treatment levels atlow power densities.
ROTATABLE PLASMA POST-TREATMENT UNITStandard post treater unit availableup to 2450mm and using 10Kwpower supply. The cathodes in thisunit are rotating, allowing selfcleaning performance at high oxygenconcentrations.
NARROW WEB PLASMA UNITFor development and pilot scaleproduction, BOBST manufacture arange of narrow web, fixed cathodeunits up to 500mm wide and 5Kwoperating power. These units areused for web designing and surfacepreparation.
Example of % improvement of oxygentransmission on OPP with plasma
Example of % improvement of watertransmission on OPP with plasma
VERSATILITYThe K4000 metallizer is an exceptionally versatile machine that can vacuumcoat a wide variety of materials. It can coat using a number of techniques,each of which adds significant value for the customer.
The aluminium evaporation source can be adjusted to the optimum distancefrom the coating drum to ensure the correct coating weight versus speedcharacteristic is achieved. It also allows niche products, for example windowfilm, to be produced at higher quality and higher production speeds.
No Plasma Plasma
No Plasma Plasma
←←
65%
79%
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BOBST GENERAL REGISTRONHAWKEYE
An OD beam measuring up to 4.5 ODat 25mm pitch with maximum webwidth of 4m, the design is modular,robust and easy to calibrate witheasily replaceable probes. With asimple user interface, the unit canbe standalone or integrated into themetallizer control system and givesthe choice of which functionality isrequired.
Developed by BOBST's renownedoptical group in Lausanne, Hawkeyeis designed and built to the higheststandards. When a defect isdetected, the operator is alerted andthe type of defect is logged.
Hawkeye counts and classifies holesin 3 sizes, the minimum size ofdetectable holes is between 0.1mmand 0.2mm and the unit can countup to 255 max holes for eachcategory at each sensor, with asampling rate of 500ms or larger.Any holes detected which are largerthan 2mm will be classified as ascratch. The production speed iscurrently 1000m/min.
Hawkeye also provides easycleaning, modules that can easily beadded or removed as necessary,100% functionality from 10°C to45°C and a design that is so stable, itcan go for 1 month withoutcalibration and of course, vacuumcompatibility. This new product canalso be used during the AlOx processto allow greater precision controland quality assurance.
CLEAR & OPAQUE BARRIERCOATINGS FROM ONE MACHINE
With many types of packaged foods,consumers prefer to see thecontents of the package they arebuying. This has to be balancedagainst the requirements of thepackaging. The packaging mustprotect the product, beenvironmentally friendly and costeffective, whilst also being attractiveto consumers.
BOBST has launched into the marketa vacuum coated clear barriercoating which is a potentialreplacement for existing metallizedstructures and polymer clearcoatings and combines the benefitsof a clear barrier coating applied inatmosphere, with the additionaladvantages of a vacuum coatedbarrier layer. A distinctive propertyof vacuum coating is that it requiresonly a small fraction of the thickness
of the equivalent atmosphericcoating with the barrier properties ofthe two being similar. This results ina coating which has a lower cost ofproduction.
BOBST uses a standard aluminiummetallizing machine as a foundationfor this process which results inversatility as one machine can beused for two processes withoutcomprimise. BOBST technologyuses the controlled injection ofoxygen into the aluminium vapourstream causing a reaction betweenthe two elements to producealuminium oxide (AlOx). Thiscompound can be transparent if theprocess conditions are correctlycontrolled.
*OTR cm3/(m2 d) Film Plain AlOx BIF PET 12µm ≈100 <1 >50 BOPP 20µm ≈2400 <100 >24 CPP 25µm ≈2000 <100 >20 PLA 20µm ≈850 15-30 28-57
*WVTR g/(m2 d)Film Plain AlOx BIFPET 12µm ≈45 <1 >45BOPP 20µm ≈6 <6 >1CPP 25µm ≈7.5 <7.5 >1PLA 20µm ≈300 5-15 20-60
AlOx BARRIER PERFORMANCE ONVARIOUS SUBSTRATES
*WVTR 37.8 oC, 90 %RH
BIF = Barrier Improvement Factor
*OTR 23 oC, 50 %RH
