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أخواني في الله أحضرت لكم كتاب Manufacturing Flexible Packaging - Materials, Machinery, and Techniques Thomas Dunn
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Table of contents Introduction Background Reference 1. Basics of Web Processes Web Tension Web Winding Cross-Web Variation Web Dimensional Analysis 2. Rotogravure Printing Gravure Process Gravure Cylinders Halftone Image Reproduction Ink Metering Gravure Process Innovation Cylinder Cost and Cycle Time Reference 3. Flexographic Printing The Flexo Process Reference 4. Adhesive Lamination Adhesive Laminating Process Adhesive Lamination Strength Other Coating Processes Adhesive Laminating Innovation Reference 5. Extrusion Lamination and Coating Extrusion Laminating Process Extrusion Coating Process Extrusion Laminating Innovation References 6. Finishing and Slitting Communicating Slit Roll Requirements Slitting Options Rewind Options References 7. In-Line Processes Equipment Requirements Operational Considerations Success Criteria 8. OEE Effectiveness Overall Equipment Effectiveness Availability Performance Quality OEE Calculation References 9. Efficiency and Cost Accounting Efficiency Cost Accounting References 10. Basics of Control Systems Distributed Control Systems Data Inputs Process Feedback References 11. Rotogravure Presses Press Components 12. Flexographic Presses Press Components Reference 13. Adhesive Laminators Dry Bond Laminators Solventless Laminators Online Coating Measurement 14. Flexible Packaging Extrusion Coating/Laminating Line Line Configuration Gauge Measurement and Control 15. Slitters 16. Preventative Maintenance versus Available Production Time Availability Preventative Maintenance Calibration Actual Operating Time 17. Setup/Cleanup versus Scheduled Production Time Performance Setup and Cleanup Decreased Speeds and Minor Stoppages Increased Speeds 18. Saleable Product versus Product Produced Quality Reference 19. Paper Paper Dimensioning Paper Grades Paper Coatings Paper for Flexible Packaging References 20. Foil Production Converting Commercial Trends References 21. Unoriented Plastic Films Flexible Films General Film Property Effects References 22. Oriented Plastic Films Film Orientation Oriented Film Applications Special Oriented Film Effects References 23. Bulk Polyolefin Resins Polymer Structure Functional Description Value Provided Forms Used Reference 24. Specialty Sealant and Adhesive Resins and Additives Polymer Structure Additives Functional Advantages 25. Barrier Resins Barrier Kinetics Polyvinylidene Chloride Ethylene Vinyl Alcohol Nylon Coextrusion References 26. Inks Ink Vehicles Ink Pigments Ink Curing Ink Selection References 27. Overprint Varnishes and Coatings Overprint Varnish Coating Integrity Vacuum Deposition Reference 28. Adhesives Polyurethane Adhesives Acrylic-Based Adhesives Energy-Cured Adhesives References 29. Primers Polyethylene Imide Primers Ethylene Acrylic Acid Copolymer Primers Other Primers Primer Selection Reference 30. Conditioning Standard Conditioning Special Conditioning References 31. Intrinsic Material Properties Standards Intrinsic Property Influences Case Study: Intrinsic Property Influences 32. Secondary Quality Characteristics Containment Integrity Characteristics Protection/Preservation Characteristics Transportation Integrity Characteristics Communication Integrity Characteristics Flexible Packaging Material Specifications References Index Table of contents Introduction Background Reference 1. Basics of Web Processes Web Tension Web Winding Cross-Web Variation Web Dimensional Analysis 2. Rotogravure Printing Gravure Process Gravure Cylinders Halftone Image Reproduction Ink Metering Gravure Process Innovation Cylinder Cost and Cycle Time Reference 3. Flexographic Printing The Flexo Process Reference 4. Adhesive Lamination Adhesive Laminating Process Adhesive Lamination Strength Other Coating Processes Adhesive Laminating Innovation Reference 5. Extrusion Lamination and Coating Extrusion Laminating Process Extrusion Coating Process Extrusion Laminating Innovation References 6. Finishing and Slitting Communicating Slit Roll Requirements Slitting Options Rewind Options References 7. In-Line Processes Equipment Requirements Operational Considerations Success Criteria 8. OEE Effectiveness Overall Equipment Effectiveness Availability Performance Quality OEE Calculation References 9. Efficiency and Cost Accounting Efficiency Cost Accounting References 10. Basics of Control Systems Distributed Control Systems Data Inputs Process Feedback References 11. Rotogravure Presses Press Components 12. Flexographic Presses Press Components Reference 13. Adhesive Laminators Dry Bond Laminators Solventless Laminators Online Coating Measurement 14. Flexible Packaging Extrusion Coating/Laminating Line Line Configuration Gauge Measurement and Control 15. Slitters 16. Preventative Maintenance versus Available Production Time Availability Preventative Maintenance Calibration Actual Operating Time 17. Setup/Cleanup versus Scheduled Production Time Performance Setup and Cleanup Decreased Speeds and Minor Stoppages Increased Speeds 18. Saleable Product versus Product Produced Quality Reference 19. Paper Paper Dimensioning Paper Grades Paper Coatings Paper for Flexible Packaging References 20. Foil Production Converting Commercial Trends References 21. Unoriented Plastic Films Flexible Films General Film Property Effects References 22. Oriented Plastic Films Film Orientation Oriented Film Applications Special Oriented Film Effects References 23. Bulk Polyolefin Resins Polymer Structure Functional Description Value Provided Forms Used Reference 24. Specialty Sealant and Adhesive Resins and Additives Polymer Structure Additives Functional Advantages 25. Barrier Resins Barrier Kinetics Polyvinylidene Chloride Ethylene Vinyl Alcohol Nylon Coextrusion References 26. Inks Ink Vehicles Ink Pigments Ink Curing Ink Selection References 27. Overprint Varnishes and Coatings Overprint Varnish Coating Integrity Vacuum Deposition Reference 28. Adhesives Polyurethane Adhesives Acrylic-Based Adhesives Energy-Cured Adhesives References 29. Primers Polyethylene Imide Primers Ethylene Acrylic Acid Copolymer Primers Other Primers Primer Selection Reference 30. Conditioning Standard Conditioning Special Conditioning References 31. Intrinsic Material Properties Standards Intrinsic Property Influences Case Study: Intrinsic Property Influences 32. Secondary Quality Characteristics Containment Integrity Characteristics Protection/Preservation Characteristics Transportation Integrity Characteristics Communication Integrity Characteristics Flexible Packaging Material Specifications References Index Index Note: Page numbers followed by “f” and “t” refer to figures and tables, respectively. A Acid copolymers, 203 Acrylates. See Acrylic esters Acrylic chemistry, 237 Acrylic esters, 236 Acrylic polymer, 237 Acrylic-based adhesives, 236237 Actual operating time, 140141 Adaptor technology, 169170 Additives, 200201, 219 chill-roll-release, 169 Adhesion primer, 239 Adhesive(s), 4041 acrylic-based, 236237 energy-cured, 237238 failure, 4344, 233, 264265 lamination, 39 coating processes, 44 innovation, 4547 process, 4142 strength, 4344 laminators, 123 dry bond laminators, 123124 online coating measurement, 125126 solventless laminators, 125 polyurethane, 234236 Air gap, 5253 Alkanes, 187 Alkene, 187188, 199f Alpha olefins, 199, 199f Alpha-olefin comonomers, 199200 Alpha-olefin copolymers, 204205 Aluminum alloys, 161 Aluminum foil, 161, 267268 Amphiphiles, 200201 Anchor coat, 239 Anilox cylinder, 3435 Annealing, 162, 163f ASTM F99 Specification Guide for Flexible Barrier Material, 263t, 276 Attributes, 153 Automatic die bolt adjustment, 131 Automatic ink cleaning systems, 3536 Automatic roll indexing, 145146 Availability, 7374, 81, 137138 B Barrier kinetics, 207214 Barrier layer, 39 Barrier resins, 207 barrier kinetics, 207214 coextruded flexible films, 216217 277Barrier resins (Continued) ethylene vinyl alcohol, 215216 nylon, 216 OTR performance for, 208f polyvinylidene chloride (PVDC), 214 WVTR performance for, 208f Basis weight, 911, 10t, 155156 Benefits of manufacturing flexible packaging, 87 Beta gauge, 130 Beta systems, 131 Beta transmission, 126 Beta-ray, 130 Between-color (BC) dryers, 117, 121 Bleeding edge, 6162 Blow up ratio (BUR), 170 Blown film, 167, 171f, 173175 Bond strength, 266 Bulk polyolefin resins density ranges of, 193f forms used, 195196 functional description, 189194 intrinsic material characteristics, 190194 polymer structure, 187189 value provided, 194195 Burst strength, 273 Business plans, 8788 n-butene, 199 C Calibration, 139140 Cast (tenter), 180182 Cast films, 169170, 172173, 174t Catalysts, 187188 Cellophane, 159, 177 Centersurface winding, 4, 66 Center winding, 4, 65 Central impression (CI) flexo press, 71, 117 Chemical Abstracts System (CAS), 221 “Chemical etching” process, 1415 Chemical vapor deposition (CVD), 231232 Chill drum, 129 “CIE 1976 color space”, 2930 Clamshell dryer, 111, 129 Clay-coated paper, 158 Cleanup time, 9495, 98 “Closed-loop” control system, 106108 Coated paper, 158159 Coating integrity, 228229 Coating processes, 44 Coating weight, 42, 5051 Coefficient of friction, 149, 264 Coextruded film, 171172, 179180 Coextruded flexible films, 216217 Coextrusion, 4950, 216217 Cohesive failure, 4344, 264265 Collapsing frame, 170171 Color register, 25 Communication integrity characteristics, 274 scuff resistance, 274 whiteness, 274 Comonomers, 188, 198, 198f Conditioning, 245 antifog, 248 278 INDEXelectrostatic charge, 248 humidity sensitivity, 246247 measurement, 245, 248 sample, 245 special conditioning, 247248 standard conditioning, 246247 temperature sensitivity, 246247 Contact angle, 234f Containment integrity characteristics, 264266 bond strength, 266 coefficient of friction, 264 hot tack strength, 265266 seal initiation temperature, 266 seal strength, 264265 tear strength, 266 thickness, 266 Continuous tone images, 19 Contract converting, 88 Control systems, 82, 103 data inputs, 105106 distributed control systems (DCSs), 103105 process feedback, 106110 closed-loop control system, 107108 open-loop control system, 106107 PID controls, 108110 shop-floor, 140141 Converting operation, scheduled production time in, 9394 running time, 94 setup and cleanup time, 9495 Copolymers, 54, 197, 201202 acid, 203 α-olefin, 204205 Cost accounting, 93101 direct and indirect costs, 9596 local facility and general company costs, 95 minimum order size, 98101 Covalent bonding, 52 Covalent bonds, 52 Cross-direction, 1, 156157 Cross-web variation, 58 Crystalline structures, 172173 Curing, 4041, 233 ink, 222223 D Dedicated slitter capability, 135 Depreciation schedules, 9697 Designed experiment, 151 Die gap adjustment, 131 Diffusion coefficient, 210211 Digital devices, 115 Diisocyanate, 234, 235t Direct costs, 9697 Distributed control systems (DCSs), 103106 Distributed Control Systems, 127 Doctor blade, 21f, 22 Double bonds, 187188 Down web variation, 78 Draw down ratio (DDR), 51, 173175 Dry bond laminating, 4041 Dry bond laminators, 123124 Drying technology, 121122 E Effective feet per minute (efm), 9495, 94f, 145 Effectiveness, defined, 80 Efficiency, 8893 defined, 80 INDEX 279Efficiency (Continued) material waste, 9092 time waste, 9293 Elastic plastic materials, 254255 Electron beam, 237 Electron beam energy, 223 Electronic drives, 74, 115 Electrostatic assist (ESA), 114 Emerson, Harrington, 7778, 78t Energy-cured adhesives, 237238 Energy-cured inks, 223 Enterprise resource planning (ERP), 7778, 103104 Equipment automation, 144 Ethylene acrylic acid (EAA), 198199, 203, 241242 copolymer primers, 241242 Ethylene methyl acrylate, 202203 Ethylenepropylene copolymers, 197 Ethylene vinyl acetate (EVA), 202, 215 Ethylene vinyl alcohol (EVOH), 200201, 207 Extended gamut, 36 Extrusion coating, 5556 laminating process, 4955 innovation, 5759 promoting adhesion melt curtain, 5254 substrate, 5455 Extrusion coating/laminating line, 127 equipment components, 128t gauge measurement and control, 129131 line configuration, 129 Extrusion laminating, 4955 Extrusion primers, 242t F Falling body technique, 113 Feedstocks, 187188, 220 Fibers, 155156, 184185 Fick’s first law, 210211 Film orientation, 178180 Financial accounting, 9597 Finishing and slitting equipment components, 135t Fit-for-use product design, 243 Fit-for-use products, 127129 Flagging rolls, 115116 Flex crack resistance, 267 Flexible films, 167172 Flexible packaging layers, 50t package functions distributed into, 40t Flexible packaging material specifications, 274276 Flexo ink metering, 3233 Flexo process, 2837 innovation, 3537 Flexographic presses, 117 finger printing process, 121 press components, 117122 drying technology, 121122 plate cylinder pressure, 118119 plates, mounting tape, and plate sleeves, 120121 Flexographic printing, 27 halftone printing, 3335 ink metering, 3233 numerical color space, 2831 process, 2837 process innovation, 3537 280 INDEXFlotation dryers, 121122 Foil, 161, 273 annealing process, 162 “A-wettable” foil, 162 commercial trends, 164165 converting, 163 production, 161162 rolling process, 161 Form-fill-seal packaging, 177178, 182 Fourdrinier-paper machine, 156 Fracture plastic materials, 254255 Free radicals, 237 Frozen storage, 272 Functional coating, 158159, 227 Functions of packaging, 40t G Gamma backscatter, 126 Gauge bands, 129130 Gauge measurement and control, 129131 Generally Accepted Accounting Principles (GAAP), 95 Glass transition temperature, 178 Glassine, 157 Gloss coating, 228 “Good roll formation”, 4 Gravure press. See Rotogravure, presses Gravure. See Rotogravure, printing H Halftone image reproduction, 1620 Hazardous air pollutants, 114 Heat seal coating, 158159, 177178, 227229 n-hexene, 199 High-density polyethylene, 199 Homopolymers, 197199 Hot tack strength, 265266 Humanmachine interface (HMI), 103104 Hydrogen bonds, 52, 215, 240 Hydrogen chloride gas, 214 I Image monitoring, 114116 Image screening, 1618 Impression cutoff, 6162 Indirect costs, 9596 Infrared preheating, 121 Inks, 219 curing, 222223 metering, 2022, 3233 pigments, 221222 selection, 223225 vehicles, 219220 viscosity, 113114 In-line processes equipment requirements, 7173 operational considerations, 7374 availability, 7374 performance, 74 quality, 74 success criteria, 7475 In-line quality assessment, 150 Inside diameter (ID), 63 Integrated form-fill-seal packaging, 177178 Intrinsic material properties, 190194, 251 intrinsic property influences, 253255 case study, 255258 INDEX 281Intrinsic material properties (Continued) materials, mechanical properties of, 256t standards, 253 Ionic bonding, 52 Ionomer, 203204 ISO 291: 2008, 246 J Job cost estimate/calculation, buildup of, 96f K Kraft process, 156 L Lamination strength, 4344 Light barrier, 270271 Linear low-density polyethylenes, 199 Linear polymers, 173175 Linear/slot extrusion die, 167 LLDPE, 204205 Low-density polyethylene (LDPE), 199, 251 M “Machine direction”, 1 Machine hour rate, 9697 “Make-ready” stock, 91 “Make-to-order” business, 137 “Makeup” solvent, 113114 Manual devices, 115 Master web, 61 Material traceability, 116 Material waste, 9092 Materials engineering, 251 Matte finish, 56, 184185 Mean time to failure, 140 Measuring/controlling gauge, 130 Mechanical linkages, 71 Melt flow index (MFI), 191 Melt flow rate (MFR), 191, 192t Melt index (MI), 191 Melt point, 198199 Metallized films, 164165, 231 Metallocene catalyst, 200, 204205 Meter mixer, 125 MFI resins, 172 Migratory additives, 200201, 201t Minimum order size, 98101 Minor stoppages, decreased speeds and, 145146 MLLDPE, 204205 Moisture barrier, 270 Moisture-cured urethane reaction, 258f “Moisture-proof”, 177 Monomers, 187188 N Nakajima, Seiichi, 78, 81 Newton’s laws of motion, 12 Nip pressure, 34, 78, 118119 Nitrocellulose (NC) bases, 219220 Nonmigratory additives, 200201, 201t Numerical color space, of flexographic printing, 2831 Nylon, 178, 207, 216, 246247 Nylon 6, 246247, 247t O Olefins, 187188 chemical structure of, 188f Online coating measurement, 125126 282 INDEXOnline databases, 252 “Open-loop” control system, 106107 Operations waste, 9091 OPP films, 179 Oriented films, 172173, 178180 Oriented nylon, 164165, 180 Oriented plastic films, 177 applications, 180182 cast (tenter), 180182 crystalline, 179 double bubble process, 183f film orientation, 178180 special oriented film effects, 183185 tubular (bubble), 182 Outside diameter (OD), 9, 63, 103, 107 Overall Equipment Efficiency (OEE), 77, 7980, 135 availability, 81 calculation, 8384 effectiveness, 138t, 144t, 150t origins of OEE methods, 78t performance, 8182 quality, 83 Overhead dryer, 72, 121122 Overprint varnish, 227228 Oxygen barrier, 216217, 267 of polymers and films, 208f Oxygen permeation dynamics of, 268f permeation cell for, 269f Oxygen transmission rate (OTR), 207 P Paper, 177, 246 coatings, 158159 dimensioning, 155156 for flexible packaging, 159160 grades, 156158 paper/plastic lamination, 160f “Pattern coating” process, 44 Pattern cohesive coatings, 72 Performance rate, 8182 Performance rate metric, 143 Permeability, 207209, 213214, 269270 Permeant, 210211 Permeation coefficient, 211, 213 Photoinitiator, 237 Photopolymer plates, 120 Physical vapor deposition (PVD), 231232 Pigment, 20, 219, 221, 221t chemistry, 221222 constitution number, 221 generic name, 221 Pinholes, 161, 231 Plasma-enhanced chemical vapor deposition (PECVD), 231232 Plastic, 254255 additives, 200 extruder, 4950 films, 200, 227, 258, 267 lamination, 160f “Plate cylinder”, 28, 32, 117 pressure, 118120 Plate mounting tape, 121 Plate sleeves, 120121 Polyamides, 178, 216 Poly-chloro-tri-fluoro-ethylene (PCTFE) film, 207 Polyethylene imide (PEI) primers, 239241 INDEX 283Polyethylenes, 11, 3940, 55, 168169, 178, 187, 198199 Polymer chains, 173175, 183184, 198, 212213, 234 Polyolefin resins, 187 chemical structure of, 188f Polyolefins, 207, 246 Polypropylene, 5253, 174t, 187, 195, 216217 Polyurethane adhesives, 234236 diisocyanate, influence of, 235t polyol, influence of, 235t solvent-based urethanes, 236t solvent-free urethanes, 236t Polyvinyl alcohol (PVA), 215 Polyvinylidene chloride (PVDC), 207, 214 Pounds per linear inch (PLI), 2, 69 Pounds per ream (ppr), 42, 155156 Predictive maintenance, 8182 Prepolymer, 234, 237 Prepress, 2324, 3334, 36, 120 Press fingerprinting, 3133 Preventative maintenance, 81, 138139 versus available production time, 137 actual operating time, 140141 availability, 137138 calibration, 139140 Primary additive colors, 1819, 18t Primary adhesive failure, 4344 Primed foil, 239 Primers, 239, 242 ethylene acrylic acid copolymer primers, 241242 hydrogen bonding, 240241, 243 ionic bonding, 241, 243 polyethylene imide primers, 239241 primary nitrogen sites, 240 selection, 242243 Priming, 5455 unit, 129 Print trolley, 111113 Process, 44 of adhesive lamination, 4142 feedback, 106110 of extrusion coating, 5556 of extrusion lamination, 4955 of flexographic printing, 2837 innovation of flexographic printing, 3537 of rotogravure printing, 22 printing, 3335 of rotogravure printing, 14 Process printing, 3335 Product shelf life, 238, 271 Production logs, 140 Productivity, defined, 80 Programmable logic controllers (PLCs), 103104 Programmed waste, 90 Proportional-integral-derivative (PID) controls, 108110 Protection/preservation characteristics, 266272 flex crack resistance, 267 284 INDEXlight barrier, 270271 moisture barrier, 270 oxygen barrier, 267 product shelf life, 271 Pulp, 156 Puncture resistance, 273 Q Quality, 27, 83, 115, 149154 secondary characteristics, 259 Quality control, 30, 84t Quality management, 74 system (ISO 9000), 7778, 84t variability concerns in, 84t Quality rate, 83 Quick changeover, 9293, 111 technique, 144145 R Raw materials, 911, 44, 7778, 8990, 98, 150152 and market prices, 8889 Razor blade (or burst) slitting, 65 Razor slitting, 65, 66t Ream, 10t, 42, 155156 Relative humidity (RH), 177, 207, 246247, 270, 272 Renewable resources, 160 Resin blends, 198199, 264265 Reverse printing, 3536 Rewind, 1, 6569, 111, 134135 chart, 63f designation, 12 options, 6569 Rework methods, 150 Roll doffs, 133134 Roll length estimation, 11 Roll quality, 135 Roll rewind designation, 12 Roll telescoping, 6465 Rolling oil, 162 Roll-to-roll quality assessment, 16, 150 Rotogravure presses, 111 electrostatic assist, 114 image monitoring, 114116 ink viscosity, 113114 press components, 111116 printing, 13 cylinder cost and cycle time, 2325 cylinders, 1415 halftone image reproduction, 1620 ink metering, 2022 process, 14 process innovation, 22 work practices, 2425 Running time, 94 S Saleable product versus product produced, 149 overall equipment effectiveness, 150t quality, 149154 Scan-a-webs, 115 Score (or crush) cut slitting, 65 Scuff resistance, 227, 274 Seal initiation temperature, 204205, 266 Seal strength, 55, 264266 Sealant layer, 39, 72 Secondary adhesive failure, 4344 INDEX 285Secondary colors, 1819, 18t Secondary quality characteristics, 259 communication integrity characteristics, 274 containment integrity characteristics, 264266 flexible packaging material specifications, 274276 performance considerations of, 263t protection/preservation characteristics, 266272 to product consumption, 262t test methods for, 263t transportation integrity characteristics, 272274 properties, 149, 252 Sensor calibration, 139 Setup reduction, 9293 Setup/cleanup, 143145 overall equipment effectiveness, 144t versus scheduled production time, 143 decreased speeds and minor stoppages, 145146 increased speeds, 146147 performance, 143 Shear slitting, 65 Shop-floor control systems, 140141 Shrinks films, 178 Side-chain branching, 172, 188, 192194 Single bonds, 187 Single extrusion laminator, 129f Slit roll inside diameter (ID), 63 outside diameter (OD), 63 requirements, 6165 Slitters, 133 Slot die extrusion, 182 Slow solvents, 146147 100% solids laminating, 4041, 4950 Solubility coefficient, 211 Solute, 210211 Solvent-based adhesives, 123 Solventless laminators, 125 Spare parts inventory, 140 Special conditioning, 247248 Special oriented film effects, 183185 Specialty sealant and adhesive resins, 197 and additives, 200201 functional advantages, 201205 alpha-olefin copolymers (LLDPE and mLLDPE), 204205 ethylene acrylic acid, 203 ethylene methyl acrylate, 202203 ethylene vinyl acetate, 202 ionomer, 203204 neutralization, 203 polymer structure, 197200 alpha-olefin comonomers, 199200 Standard conditioning, 246247 Standard industry rewind chart, 63f Standard operating procedures, 9193, 110, 143, 152153 Statistical process control (SPC), 84t, 150151, 153154 feedback system, 151f 286 INDEXto manufacture product, 151152 value of, 153154 to web processes, 153, 153t Statistical product control, 84t Sticky back, 28, 121 Strength, of adhesive lamination, 4344 Subtractive colors, 1819, 18t Supercalendering, 157 Supply chain integration, 8788 Surface printing, 3536 Surface treatment, 54, 181 Surface wet-out, 53, 233 Surface winding, 4, 66 T “Tag” or “Bag” sheet, 156 Tandem laminators, 72 Taper tension, 67, 106 TAPPI conditions, 247 TAPPI standard, 246 Taylor, Frederick W., 7778 Tear strength, 266 Tensile properties, 195, 254255 Tension transducer, 105f Tenter frame, 180182 Test methods, 253, 273 Thermoplastic properties, 189190 Thickness, 266 Time in air gap (TIAG), 53 “Time to first quality product”, 144 Time waste, 9293 Torque units of measure, 34 “Total Productive Maintenance” methodology, 78, 81 Total quality management, 83, 84t TPM tenkai, 78 Traction, 45 Transfer rollers, 125 Transient defects, 149150 Transportation integrity characteristics, 272274 burst strength, 273 puncture resistance, 273 Tubular biaxially oriented films, 182 Tubular film manufacturing, 170 Twin-foil rolling process, 162 U Ultraviolet light, 222, 237 Unoriented plastic films, 167 cast, 169170 chill-roll-release, 169 extrusion, 167 flexible films, 167172 frost line, 170171 general film property effects, 172175 internal bubble cooling, 171f modulus, 168169 sheeting, 167168 surface treatment, 169 tubular, 170172 Unplanned maintenance, 140 Unwind stand, 117, 133 Urethane formulation, 242 V Vacuum deposition, 229232 Vacuum-deposited coatings, 231 Value-add rate (VAR), 9899 calculation, 99101, 100t Van der Waals force, 213, 222 Variables, 127, 153 Vendor managed inventory (VMI), 140141 INDEX 287Vinyl acetate (VA), 202, 215 Viscose, 177 Viscosity, 190 Vision systems, 115116 Voided films, 184 Volatile Organic Compounds (VOCs), 45 Voluntary consensus standards, 253 Vulcanized rubber plates, 120 W Waste in converting, 90 Water vapor transmission rates (WVTRs), 207 Water-based adhesives, 4546, 123 “Waterleaf”, 157158 Water-quenched film, 167, 172 Web dimensional analysis, 912 industry units of measure, 911 Web length estimation, 11 Web materials, 1, 6465 Web processes cross-web variation, 58 roll rewind designation, 12 web dimensional analysis, 912 industry units of measure, 911 web length estimation, 11 web tension, 23 web winding, 35 Web width, 64 Web winding, 35 Web-converting processes, 103 Wet bond laminating, 4041 Whiteness, 274 Winding processes, comparison of, 5t Wire-wound (Mayer) rod, 123 X X-ray transmission, 126 Y “Yield” measure, 911, 10t Z Zahn cups, 11
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