Combating the invisible problem

Vaassen Flexible Packaging (VFP), based in The Netherlands and part of the Clondalkin Group, is a specialist supplier to the tobacco and dairy industries. It is a leading European manufacturer of inner liners for the tobacco processing industry.

VFP’s comprehensive product range, which includes printed and unprinted aluminium foil/paper, metallised paper, mentholated foils and lacquers, enables it to satisfy the industry’s demand for 400 billion cigarettes every year. Its customers are mainly located in markets across Europe.

All VFP products are said to be suitable for use in the ultra high-speed packaging machines used by leading cigarette manufacturers. Supplying such a demanding industry means that the company’s R&D department is continually testing new production methods and techniques.

Always striving to enhance the manufacturing process, VFP staff identified two areas with room for improvement. During the pre-lacquering process, they found there was a build-up of static after the paper had passed through the rubber cylinders. Typically, VFP used a piece of copper positioned across the machine to provide a connection to earth. However, this was not completely satisfactory for safety reasons as there was the potential for severe shock to operators as the static discharged.

Secondly, it was observed that during coating, the paper dust contaminated the pressure roller on the web, resulting in poor print quality, caused by missing dots. This led to costly downtime and a loss of production as the line was stopped for cleaning.

To resolve the problem of static build-up in the pre-lacquering process, the company decided to invest in a Meech 915 AC ionising bar, which is said to be designed to provide ‘powerful and intense’ ion production. The ionising bar’s fast decay times makes it effective, even at faster web speeds. It can be installed at lengths of up to 150 mm and features an easy-wipe casing to provide sustained performance and minimised downtime, as well as ease of maintenance.

To tackle the problem of the dust contamination, VFP again turned to Meech. They installed the Series 1000 web cleaner, which is said to provide effective web cleaning, improving quality and productivity.

The Series 1000 SCT system incorporates static eliminators, brushes and a high power vacuum dust collection system. This not only eliminates dust contamination but also minimises the risk of attracting further dust. Meech static eliminator bars break down the electrostatic bond holding dust particles to the web, and the brushes destroy the boundary layer on the moving web, allowing efficient removal of contaminants via a vacuum control plate that completely covers the material’s surface. Flexible ducting then carries the contaminants to the collection system, where they are deposited in a filter bag.

Dust control may be an issue in the packaging and printing industries, but VFP seem to have overcome the problem effectively. “Web cleaning systems such as the Meech Series 1000 provide effective control of dust contamination and impart significant production benefits,” says VFP.