Paper, Film and Foil Converter magazine recently interviewed Mark Rainville, Product Manager for NDC Technologies' Film Extrusion and Converting businesses, on the topic of testing, inspection and quality. Mark provides his insight into the challenges faced by customers and how selecting the right company and gauging solution can help drive numerous manufacturing efficiencies.
In the converting industry, what is your area of expertise in testing, measurement & quality control?
NDC Technologies is a leading global provider of intelligent, connected measurement and control solutions. We offer a wide range of non-contact gauging and process analysis technologies that accurately and reliably measure the basis weight, thickness, coating weight, moisture and length and speed. Our products address a broad scope of applications in industries such as Paper, Film and Foil; Labels and Tape; Coating and Laminating; and Protective and Flexible Packaging. Our measurement technologies include infrared, optical, beta/gamma, laser, terahertz, haze and x-ray. As a measurement and controls solutions provider, we work closely with converters to understand their unique quality, cost and gauging objectives to deliver the best application-specific solution. Every measurement system is individually optimized for each project. Our goal is to help customers improve product quality, increase productivity, boost process efficiencies and reduce manufacturing costs.
What are some challenges your customers face and how do your products & services solve these problems?
There are a number of them, and it depends on the application. For example, as you know, the Paper, Film and Foil industry covers a broad range of coating processes and end-user products. The manufacturing processes are often complex, requiring specialized measurements and web gauging applications expertise. Frequently, the coating combination represents the greatest value-added component of converted paper, film and foil products. As such, it’s vitally important that the right coat weight measurement technique is employed. NDC has the widest range of non-contact gauges dedicated to coat weight measurement, combined with in-depth applications knowledge. NDC’s applications expertise extends across a broad range of coating techniques to provide the most effective measurement solution. These solutions provide accurate coat weight measurement and controls that are independent of the substrate’s characteristics.
In label and tape applications, successful label stock manufacture depends on the accurate measurement of four key properties: moisture content of facing and backing paper, adhesive coat weight, silicone release coat weight and optical quality. NDC’s non-contact gauges are designed to directly measure adhesive coat weights for tapes, plus measure label stock moisture and silicon release coat weight using a single gauge and scanner configuration. This provides a cost-effective, low-maintenance solution. For applications where a single gauge is not suitable, NDC typically provides either direct or differential measurements using gauges before and after the coating station. These may be either infrared, terahertz or beta/gamma gauges or x-ray gauges using same-spot measurement techniques to provide accurate coat weight measurement and control. In addition, we offer other product control strategies to flatten the coat profile and optimize coat weight and material usage.
How can improvement in testing, inspection & quality control improve the overall converting process?
Employing the right non-contact measurement and control system in the converting process enables converters to meet their customers’ expectations while optimizing their own manufacturing operations and delivering long-term value, such as:
- Improved product quality
- Reduced start-up times
- Raw material savings
- Higher yields
- Increased productivity
- Better process efficiency
- Flat coat weight profiles
- Optimized coat weight
- Improved materials usage
- Reduced scrap/waste
- Greater profitability
Understanding the process is key to ensuring measurement success. NDC has a long history of helping customers with their specific measurement needs and optimizing processes and product quality.
What new technologies and products have you incorporated into your product portfolio? How do they benefit converters?
There are a few notable new products to mention. The first one is our HazePro sensor. It’s designed to measure the optical quality (haze) of film during the process. We released this product over a year ago. We found out that in this circular economy countries want to reduce their plastic scrap. Many of our customers are moving from films that are hard to recycle to films that are easy to recycle -- especially films with barrier properties. New single polymer films are being worked on, and the haze in a film can indicate the barrier property. A low haze indicates a better barrier property. A high haze indicates a deteriorating barrier property.
Another new product that we came out with is the Series 9 sensor. This next-generation infrared sensor directly measures the moisture and coat weight in converted products. This new sensor really expands the range of coating and converting applications, and we incorporated added capabilities for increased reliability and advanced diagnostics for peace-of-mind operation.
Our new Terahertz sensor offers highly accurate measurements for multiple layer film and sheet applications, which in the past would require multiple sensors and scanners. This new product makes all the film or sheet thickness measurements simultaneously using a single sensor. For example, our Terahertz sensor can measure the thickness of each individual layer, the combined thickness of layers and even the density of a particular layer – to improve the overall quality of products.
In addition to these new products, we also recently released our SlimTrak II scanner with compact footprint for narrow web processes. This single-beam scanner is uniquely designed to fit into the tightest machine spaces and is built for reliable, long-lasting, trouble-free operation.
What are key factors converters should pay attention to when choosing the right testing & quality control products and services for their needs?
As a solutions provider, we’ve seen more and more companies relying on measurement technology to automate the quality control of their products. With the promise of cutting costs, streamlining production and improving product quality, many companies are looking for a measurement system solution that can deliver a substantial return on investment (ROI) – and continue to deliver value for the long term. Important factors to consider include:
- Experience. Be sure the company you’re evaluating has the depth of experience and applications expertise to understand your process and measurement challenges and will be able to offer a specific gauging solution to meet your unique needs. NDC has been delivering measurement and control solutions for over 50 years and we have over 100,000 measurement systems in service around the globe that have amassed over 1 billion operating hours. We know how to solve the toughest measurement and control challenges.
- Peace of mind. Be sure to look at the best measurement and control strategy for your process operation and how you’ll plan to evaluate the system’s performance. The adoption of an in-process measurement system is not merely a technology investment; it’s a business investment. So, it’s prudent to prepare a business case to evaluate the ROI, long-term value and peace of mind you’d like to realize. NDC’s measurement and control systems help converters to transform acquired process data into knowledge and knowledge into intelligence. Intelligence that enables them to enhance production processes, increase productivity, boost process efficiencies and deliver the highest quality products.
- Service and Support. Be sure to evaluate the company’s after-the-sale service and support programs. Ask about the ease of product servicing, regional and international service and support locations, training programs, available maintenance contracts, and on-line service and support capabilities, to name a few. NDC has a globally connected team in over 60 countries to assist customers through the service lifecycle. And we’ve digitized the customer support experience, so our valued customers get immediate care via our 24-7 service cloud – myNDC.com.
For more information on NDC's gauging solutions for the converting industry, please visit our information portal -- rich with measurement, applications and product content.