PCT Engineered Converting Projects User Manual

Converting Projects
Project Objective: Plant Wide Process Assessment & Automation Plan
Customer: Specialty Converter, Eastern U.S.
PCT provided:
On site evaluation of all major process equipment and material handling systems
Interviews with production, maintenance, engineering, and management staff
Development of a plant wide automation plan
Recommendations for equipment and process modifications
Estimated costs and schedules to complete modifications
Project Objective: Improve the Performance on Several Slitters
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
On site evaluation of the slitters in order to take measurements, observe machine operation, and gather drawings and program files
This evaluation considered input from engineering, maintenance and operations
Modifications to the slitter speed and tension control logic as required
Added taper tension control to improve finished roll quality
Minimized lay on bounce
Optimized slitter for lock core winding
Retrofit existing controls and drive to
modern equipment
On site commissioning support for starting up and tuning the new control program
On site support for initial production at which time PCT continued to refine the system tuning
© 2007 PCT Engineered Systems LLC. All Rights Reserved
Project Objective: Upgrade Single-Layer Extruder to 7-Layer Extruder
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
Integrated system for control of the blending system, vacuum pump, and extruder
(7) multi-bay control enclosures including PLC, drives, SSR’s and power distribution
New operator stations
Programming for the PLC, HMI, and drives
Onsite commissioning and support
Project Objective: Supply of a Complete Electron Beam Process Line
Customer: South American Location of a Major Film Producer
PCT provided:
Final design, fabrication, assembly and testing of turret unwind, splicing station, chill roll stand and turret rewind
Refurbishment, modification, assembly and testing of a BroadBeam electron beam processor
Integrated line control system including PLC’s, drives and operator stations
Shop testing of the entire line including training of operators from the plant
On site installation and commissioning support
Project Objective: Modify Slitter Mechanics to Improve Reliability
Customer: Midwest Location of Major Blown Film Producer
PCT provided:
Engineering study to recommend mechanical changes
Created a pass line drawing from customer drawings
Simplified the pass line by removing several rolls and developed alternate thread paths for the system
Replaced 4 rolls in the unwind section based on engineering discoveries
Replaced 3, high inertia, “billy rolls” with a single, low inertia roll
Modified upper fold board roll for load cell mounts to provide appropriate tension feedback
Replaced the nip roll mechanisms with driven S­wrap rolls
© 2007 PCT Engineered Systems LLC. All Rights Reserved
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