PT Kencar Grows Southeast Asia Business with Davis-Standard Cast Film Technology

 

Indonesian film producer PT Kencar Sukses Investama is expanding its presence in the Southeast Asian film market by adding two more Davis-Standard cast film machines to their facility in Sidoarjo, Indonesia. This brings their total to four Davis-Standard machines in just over five years. Kencar has introduced several innovative food-packaging films to the region, accounting for a rapid growth rate and strong customer base. Kencar was the first company in Southeast Asia to introduce five-layer CPP films, and with the additional Davis-Standard machines, will become the first with six-layer capabilities. This will enable Kencar to support markets for high barrier CPP as well as CPE films that offer better thickness uniformity and clarity than comparable blown films.

According to Kencar president Eddy Soelayman, “The Southeast Asia flexible packaging market is growing at more than eight percent per year and Kencar has outpaced that growth by more than 50 percent. We see a transition in the CPP market from commodity to high-performance films that have superior barrier, metal adhesion, gloss and heat seal properties.” He added, “We are currently producing five-layer CPP films with heat seal properties like CPE with excellent gloss and metal adhesion. With the new machines we can take that a step further by producing CPP films with unique barrier properties that allow converters to down gauge and reduce conversion steps to save cost.”

The Davis-Standard cast film machines, slated for installation in January 2017 will be higher speed versions of the original two. Both machines will feature next-generation DSBÒ barrier screws to handle Kencar’s diverse range of materials and film applications. Feedblock and die technology will accommodate up to seven distinct layers in a structure. The “ironing” roll will be included on the winder for consistent roll conformity. Kencar appreciates Davis-Standard’s proven technology, which produces films with higher surface treatment retention, better metal adhesion and improved oxygen and water vapor barrier properties, all critical in flexible packaging.

“Davis-Standard has been excellent in providing creative solutions for the unique films we continue to introduce to the market,” added Soeleyman. “They have a good understanding of polymer processing and know how to transform our vision into final products.”

For more information, about Kencar, visit www.ptkencar.com. For more information about Davis-Standard’s cast film technology, contact Steve Post at spost@davis-standard.com.

Congressman Joe Courtney Visits Davis-Standard’s Pawcatuck Facility

 

Davis-Standard welcomed Joe Courtney, U.S. Congressman for Connecticut’s Second District, on Friday, August 19, at its headquarters in Pawcatuck. Congressman Courtney and Congressional staff member Taijah Anderson visited the site to learn more about Davis-Standard’s technology, economic impact on the region, and the upcoming expansion of the Pawcatuck facility. Davis-Standard’s president and CEO, Jim Murphy and other Davis-Standard leadership provided an overview and tour of Davis-Standard, offering insight into the company’s impressive global growth, plant specifics and diverse equipment portfolio.

“Davis-Standard has an impressive operation and it was an honor to tour the facility in Pawcatuck,” said Congressman Courtney. “The cleanliness of the machining floor, advanced manufacturing practices and employee engagement is really something to behold.” He continued, “We’re very proud of Davis-Standard and the strong economic boost they continue to provide to southeastern Connecticut.”

Murphy added, “We enjoyed Congressman Courtney’s visit and appreciate his support of the manufacturing industry. Last year, Congress enacted an R&D tax credit this has been beneficial in helping us further our technological advancements. We also appreciate the Congressman’s support of the Pawcatuck expansion, which will house manufacturing capabilities for our growing blown film business.”

Davis-Standard is adding 15,000 square feet of manufacturing space and over 30 jobs in the next two years to its Pawcatuck headquarters, which currently employs over 400 people. The addition, slated for completion later this fall, will house the manufacturing and precision machining of advanced multi-layer blown film dies. It also enables Davis-Standard to move all blown film manufacturing for its Gloucester Engineering product line from Gloucester, Massachusetts, to Pawcatuck.

Davis-Standard has operated in Southeast Connecticut since 1848 and is one of the oldest and largest employers in the Southeast Connecticut/Southwest Rhode Island region. The expansion of the Pawcatuck site reinforces the company’s commitment to the local region. Through its long-standing position as a market leader, it is considered the “Center for Excellence” for Connecticut’s extrusion technology sector. In addition to the Pawcatuck facility, Davis-Standard has manufacturing facilities and subsidiaries in the U.S., Europe and Asia.

For more information about the expansion, contact Carli Guigli at (860) 599-1010.

Davis-Standard to Host Seminar on Basics of Plastics Extrusion

 

2016, September 1

Davis-Standard, LLC will host its popular workshop on “The Basics of Plastics Extrusion,” October 4th & 5th, 2016 at its headquarters in Pawcatuck, Conn. The comprehensive two-day class will cover the fundamentals of plastics extrusion, as well as the composition and properties of various polymers and the mechanics of essential downstream processes. Seminar topics include extruder components, temperature control, maintenance and screw design.

In addition to instruction, course participants will tour Davis-Standard’s Technology Center and manufacturing facilities, and will have access to polymer process engineers and technical specialists. The fee is $750 per person with a 10 percent discount given for groups of three or more. Course books and materials are included and class size is limited to promote student/teacher interaction.

For enrollment or more information about Davis-Standard’s seminar, contact Debbie Crowley at dcrowley@davis-standard.com.

Davis-Standard’s High-Speed Foil and Film Unwind at K 2016

 

Davis-Standard will exhibit a high-speed unwind during K 2016 that is engineered for splice speeds up to 800 meters per minute (2,600 fpm) for sensitive, thin webs. This unwind features pneumatic splice-unit control for improved processing and functionality. It is uniquely engineered for extrusion coating applications involving aluminum foil and PE films.

 

 

 

The two-position, shaftless, phantom-axis turret design offers several advantages:

  • Driven idler rolls on the turret
  • Direct spindle drive using a timing belt without backlash
  • Cross-cut knives on the turret between two driven idler rolls
  • Lightweight carbon fiber knife holder
  • Inverter controlled turret drive
  • Precision turret control with an absolute encoder
  • Continual gap mode between the bumper roller and reel during the unwinding process
  • Automatic air inflation for pneumatic chucks with pressure control
  • Tension control via a long-stroke dancer roll
  • Ultrasonic sensor measurement for the incoming roll diameter
  • Automatic edge guide control

The unwind is capable of roll diameters from 300 to 1000mm (11 to 40 inches) with a maximum diameter of 800mm (31 inches) for aluminum foil, and a maximum roll weight of 1800 kilograms (4,000 pounds). It is ideal for aluminum foil webs ranging from 6 to 20 µm and PE films from 30 to 100 µm.

The unwind is typically used as an auxiliary unwind for aseptic packaging lines to maintain consistent high- speed operation. However, it can also be used as the primary unwind for flexible packaging lines that process a wide range of substrates, including paper up to 150 gsm.

For more information about Davis-Standard’s unwind technology prior to K, visit www.davis-standard.com.

 

Davis-Standard to Market Benefits of High-Speed Extrusion During K Show

 

The efficiency and throughput capabilities of Davis-Standard’s high-speed extrusion technology will be promoted during K 2016 in Hall 16, Booth A43. Davis-Standard is one of only a few manufacturers worldwide to offer a high-speed extruder for demanding processes where rates and energy savings significantly impact profitability. Advantages such as better product quality, less machine volume for reduced changeover time, and a wider processing window are just a few reasons high-speed extrusion is a cost-effective option.
“We’ve supplied high-speed technology for awhile, but there is still a lot of opportunity for those who seek new ways to boost throughput and performance,” said Steve DeAngelis, Davis-Standard Vice-President of Sheet and Foam. “The potential for improved processing is especially evident for high-speed sheet, fiber and extrusion coating processes. Our design has demonstrated excellent thermal stability and melt quality at throughput rates up to 1,500 kilograms per hour (3,300 pounds per hour). It has also shown increased performance density for PP and PS extrusion. We look forward to discussing these benefits with customers during the show.”
Davis-Standard’s 75mm, 40:1 extruder offers processing versatility due to a favorable surface to volume ratio when compared to conventional extruders. The extruder can be supplied with a direct drive AC motor or permanent magnet synchronous motor configuration. Davis-Standard’s high-speed model offers energy savings of 10 to 15 percent when compared to traditional systems. Additionally, the screw speed and drive unit can be adjusted to accommodate different processing conditions. Davis-Standard has done extensive work on screw designs to further support performance.
For more information about Davis-Standard’s high-speed extrusion technology prior to K, visit www.davis-standard.com.

Davis-Standard to Promote dsX™ Product Line at K 2016

 

Davis-Standard’s popular dsX™ systems for converting applications will be promoted during K 2016 in Hall 16, Booth A43. There has been a positive industry response to these adaptable machines for extrusion coating, cast film and blown film processes due to a competitive advantage in price, performance and delivery. Following is a brief summary of each.

The dsX flex-pack™ (extrusion coating) provides converters and package printers with a high-value, competitively priced system. An adaptable machine configuration gives processors the flexibility to compete in a variety of emerging application markets including salted snack and noodle bags, toothpaste tubes, personal care products, condiment packs and stand-up pouches. Production benefits include product consistency, excellent bonding strength, greater uptime and productivity, and reduced waste and production costs. The economical benefit of these 450 meter-per-minute (1,500 fpm) machines is allowing many regional converters to separate themselves from the competition.

The dsX s-tretch™ (cast film) is the first all-in-one system of its kind for in-line, pre-stretch cast film processing. Integrated technology eliminates the need for traditional pre-stretching methods, resulting in thinner films, faster line speeds and improved film strength. Films as thin as 6μ at speeds from 550 to 1000 meters per minute (1,800 to 3,200 fpm) can be run in three-, five- and seven-layer configurations. As an added benefit, the dsX s-tretchÔ has a narrow footprint for installation in tight spaces maximizing production area while still allowing operator accessibility. It is also available with coreless winding to reduce waste.

The dsX flex-film™ (blown film) is built to support the industry’s core blown film market, including providers, distributors and manufacturers. Target applications include films for laminating and converting, bag making shrink film, hood shrink film, collation film, multi-unit packaging films, roll stock and surface print films. This line merges U.S. and European components to support robust and reliable performance on a user-friendly platform. Unlike similar systems, processors can take advantage of upgrades that balance productivity against capitol investment. This includes multiple extruder packages and options for greater efficiency.

For more information about dsX™ technology prior to K, visit www.davis-standard.com.

Davis-Standard to Promote Global Advantage™ at K 2016

 

Davis-Standard, LLC will exhibit the depth of its Global Advantage™ in extrusion and converting technology during K 2016 in Düsseldorf in Hall 16, Booth A43. Technology being shown includes examples of extruder, feedscrew, die, unwind, and control system advancements as well as the company’s innovative dsX™ technology and extensive aftermarket capabilities. As an added benefit, Davis-Standard’s team will host visitors at ER-WE-PA’s Erkrath facility for equipment demonstrations. Following are highlights from Davis-Standard’s K display:

Extruder with QSE Adapter – This 3.5-inch (90mm) extruder has preferred features such as computer-designed feedscrews, electrical barrel heating with air-cooling for each zone, and simplified electrical installation. Mounted on the extruder will be a QSE (Quick Screw Exchange) adapter for fast screw changes without disturbing the downstream melt path.

High Speed Film & Foil Unwind – Designed for thin substrates, this two-position turret unwind is designed for an 800 meter-per-minute splice speed for sensitive webs such as aluminum foil at 6 µm. Unique splice unit controls and safety standards create excellent reliability for high-speed splicing of complex webs.

Feedscrew and Die Displays – Davis-Standard is a global leader in feedscrews and die designs for improved processing efficiency. Multiple feedscrew designs and finishes will be shown in the booth at the K Show, as well as a seven-layer die stand from Davis-Standard’s Gloucester Engineering product line. Also being promoted will be the new die rebuild services offered by Davis-Standard Limited in the United Kingdom.

dsX™ Technology – This popular line of extrusion coating, cast film and blown film equipment offers processors advantages in price, performance and delivery. Each system is engineered for greater up-time, increased productivity and reduced waste, and backed by Davis-Standard’s 24/7 global support network.

Aftermarket Capabilities – Davis-Standard’s ability to service equipment for nearly every extrusion and converting application, including non Davis-Standard brands, is one of the company’s greatest advantages. This includes an extensive spare parts inventory, timely 24/7-customer service, global technical capabilities rebuild and retrofit services.

For customers interested in visiting Erkrath, Davis-Standard will offer transportation to and from the Düsseldorf Fairgrounds. The transportation schedule will be available at the show. ER-WE-PA will demonstrate new horizontal winding technology and discuss extrusion equipment for a variety of applications. Customers will also learn more about Davis-Standard’s regional service team for the European market, which provides customers with a quick response by service technicians and a large stock of available spare parts. Service and support for Davis-Standard’s line of control systems enables customers to upgrade PLC, drive and mechanical systems on thousands of existing installations, including non Davis-Standard brands.

For more information prior to K, visit www.davis-standard.com.

Davis-Standard Turret Unwind Upgrades Boost Productivity

 

Davis-Standard’s aftermarket group offers turret unwind upgrades that significantly improve productivity and minimize downtime. An upgrade for Green Bay Packaging Inc. involved the modification of two turret unwinds on a 1200 feet-per-minute (365 mpm) pressure-sensitive adhesives (PSA) coating line. Davis-Standard changed the turret unwind operation from air brakes with a speeder motor to a fully regenerative operation, which significantly improved both efficiency and performance.

“Upgrades are an excellent way to extend the longevity of turret unwinds that are still operational,” explained Andre Icso, Vice President Global Aftermarket Sales. “It also allows them to run lighter products with significantly better tension control, less scrap, and increased energy savings. For this upgrade, the modification and re-commissioning took only two weeks enabling us to get the customer back up and running quickly.”

Icso said there are several different upgrades available, but the one for Green Bay was very straightforward. Davis-Standard’s team removed the brakes and speeder belt and installed new turret motors and mechanical power transmission to the unwinding spindles. New slip rings, spindle glue line sensors and turret position encoders were also included as well as the installation and integration of four new unwinding spindle drives.

Davis-Standard’s aftermarket group is able to upgrade PLC, drive and mechanical systems on thousands of existing installations, including non Davis-Standard brands. For more information about Davis-Standard’s aftermarket capabilities related to this article, contact Andre Icso at aicso@davis-standard.com.

Davis-Standard Limited Announces Die Rebuild and Cleaning Services

 

Davis-Standard Limited is pleased to announce the addition of blown film die rebuild and cleaning services at its facility in Brierley Hill, United Kingdom. The new services, commencing August 1, 2016, will apply to all blown film dies from Davis-Standard product lines and heritage brands, including Gloucester Engineering. Non Davis-Standard brands will be considered on a case by case basis. This regional capability further supports Davis-Standard’s large installed base of blown film equipment throughout Europe, the Middle East and Africa.

“Our service team is highly knowledgeable in the cleaning of blown film dies as well as the disassembly and assembly of various key components,” said Mark Woodgate, Managing Director of Davis-Standard Limited. “Our vigorous component inspection program ensures customers are immediately aware of any parts that may require refinishing or replacement. This can often result in great cost savings when compared to purchasing a new die. Having a die professionally rebuilt by the original equipment manufacturer using certified replacement parts also brings a level of assurance that others cannot provide.”

The rebuild services will be located within a dedicated area of the Davis-Standard Limited facility, and staffed by technicians with decades of experience in extrusion and blown film processes. Support is available both on- and off-site to ensure customer needs are addressed in a timely manner. Davis-Standard’s aftermarket team in the United Kingdom is part of a global aftermarket team that offers a full range of services including parts replacement and support, complete rebuilds for gearboxes and extruders, as well as control upgrades, drive conversions and more.

For more information about the aftermarket services at Davis-Standard Limited, contact Mark Woodgate at mwoodgate@davis-standard.com or visit www.davis-standard.com.

Davis-Standard Ships First Large-Scale Accumulator Head Machine From Fulton Facility

 

Davis-Standard is pleased to announce the shipment of its first 75-pound accumulator head machine from its new blow molding facility in Fulton, N.Y. This is the largest blow molding machine Davis-Standard has built at this facility, which opened in October of last year. Overall dimensions of the machine are 26 feet wide by 43 feet long and 28 feet tall (8 by 13 by 8.5 meters) to accommodate production of large flat panels, drums and outdoor recreational equipment. Due to the size of the applications, the machine is equipped with a press that has a clear paten area of 60 inches wide by 96 inches tall (1,500 by 2,400mm) and 250 tons of clamping force.

“We have built machines larger than this one before, but this is the first of its size to come out of Fulton,” explained Mark Panaro, Davis-Standard Product Manager, Blow Molding. “The transition to Fulton has been seamless as we continue to offer customers the full range of blow molding machine sizes and head requirements. It was exciting to get this big one out the door.”

As with all Davis-Standard accumulator head machines, this machine was wet tested prior to shipment to simplify installation. The head is equipped with a spiral diverter for efficient wall distribution and color changeovers, and features a clamp with a rollout function to facilitate mold installation and changes. A convenient remote access feature on the machine controller enables viewing of operations via an Internet connection. The total project took nine months from order placement to completion, an excellent timeframe for a machine of this size.

Davis-Standard’s versatile accumulator head systems are available for multiple applications including automotive parts, packaging and consumer products. Machinery advantages include shot-to-shot consistency, cycle-to-cycle precision, and highly accurate parison control for both polyolefins and engineered thermoplastics. Davis-Standard’s Extrusion Technical Service Group can upgrade and refurbish all makes and models of single screw continuous blow molding extruders. This includes replacement screws, process improvements, mechanical and electrical upgrades.

For more information about Davis-Standard’s blow molding capabilities or the new facility in Fulton, contact Mark Panaro at mpanaro@davis-standard.com.