Remaining at the cutting edge of technology is the basis of success for any manufacturing business. However, during difficult economic times investment is kept to a minimum, and the replacement of existing lines and machines is postponed.
In this respect there are good reasons for remaining on the ball in technological terms:
Improvement of the profitability of a line
Improved productivity
Cost reduction through product change
Competitive advantages through improved quality
Reduction or elimination of emissions
Reduced energy consumption
Achieving this does not necessarily mean making a new or re-investment. Specifically, Kroenert lines, with their modular design, can be upgraded or converted with relatively little expense and effort. Noticeable technical improvements can be achieved with low investment.
1. Expanding of lines
A duplex laminating line applying solvent-based, water-based and solvent-free adhesives for flexible packaging (Illustration, Fig. 1) has been designed so that it can easily be converted to a triplex laminating line. This extension of the product range and doubling of available capacity can be achieved without major renovations or long shutdowns.
Fig.1: Extension of a duplex laminating line to a triplex line
In exactly the same uncomplicated way, for example, a single-purpose line for solvent-based siliconizing (Fig. 2) can be converted to an in-line machine for siliconizing and hotmelt or UV-cured acrylic adhesives for the production of self-adhesive labels.
2. Upgrading of lines
Upgrading using additional components is a way of adapting an existing line to suit individual needs. Is your existing line not suited to high solids and environmentally-friendly systems? Using a Trolley based coating station, the change can be completed within 15 minutes (Fig. 3).
Fig.3: Coating head with pressure-filled chamber doctor blade (MPG 600 CI) as a fixed component (right) and as a trolley-based roll-away component (left)
In doing so, the line can be used for coating with solvent-free UV-cured lacquers or adhesives and the application of solvent-based hotmelts with a solid content of up to 65% and viscosity of 60s, Ford Cup 4. In addition, the quality of the application is improved through lower tolerances and a better appearance. The replacement of the drive and control systems can also be a sensible option. Older systems are often prone to breakdown, and lead to line shutdown. Replacement with modern Siemens or Rockwell hardware increases system availability significantly (Fig. 4).
Connecting a process-management system is also possible for older systems through an online connection through Teleline. The Teleline connection enables a rapid diagnosis and error response during a shutdown.
A further option is equipping a line with non-stop turrets retrospectively. As opposed to single unwinding and rewinding, this winder conducts semi or fully-automatic roll changes at production speed (Fig. 5).
Fig.5: Single unwinding (left) and non-stop turret (right)
To increase the lines speed, the dryer can be extended. Extensions of two to three meters have a noticeable effect and are easily implemented by adding sections to the existing dryer (Fig. 6).
Fig.6: Extension of a dryer (here with coating head)
3. Product optimization
To lower production costs the application of finer substrates, lower coating weights and lower coating weight accuracies are targeted. Often, however, the existing line is just not suited to this.
To deal with this situation, Kroenert in Hamburg has its own technical development line in place. New materials can be tested under production conditions on this widest and fastest line in the world (Fig. 7).
Fig.7: Layout of the RECO 800 A technical line
Subsequently, the Kroenert service team works out proposals and guidelines for processing these materials with the existing lines.
Raw materials, formulas and products are changing and environmental and security regulations are becoming stricter. However, with upgrades and conversions, it is still possible to remain competitive with an older Kroenert line.
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