Press Releases

Press Releases

9/95 Film Rolls Growing Larger: Plastics Technology

4/95 Danafilms Produces Wider, Larger, Rolls On New BGE Blown Film Line: The High Liner, Volume 9, Number 1

1/95 Expansion Pays Off At Danafilms: Enercon Industries Corporation

3/01 Battenfeld-Gloucester Newsletter

Danafilms extends its reach with new Battenfeld Gloucester lines

For over 30 years, Massachusetts-based Danafilms, Inc. has been producing polyethylene films for a remarkable array of customer applications from adhesives to electrostatic device packaging. The common thread among the markets Danafilms serves is a demand for quality. Customers trust Danafilms for films that process well and can withstand the rigors of high-speed printing, laminating, coating and bag machines. The company's reputation has led to significant growth, which is one reason it recently built an impressive new manufacturing facility in southern Kentucky - equipped entirely with blown film technology from Battenfeld Gloucester.

A new plant for demanding markets

Danafilms' customers are primarily converters in specialized markets such as laminated films for circuit board and electronics packaging, food packaging, and specialty adhesives. Everything from the brightly colored tapes that surround construction sites to metallic trick-or-treat bags to household duct tape starts with Danafilms products.

In 2000, Danafilms opened a state-of-the-art, 47,000 square-foot manufacturing location in Franklin, Kentucky, to increase production capacity and provide broader geographic coverage for regional customers. When it came time to equip the new facility, Danafilms wanted the best. "The lines in our original facility represented a number of manufacturers, including Battenfeld Gloucester. We were very satisfied with the Gloucester equipment and liked the results we were getting," said Robert P. Simoncini, vice president of sales at Danafilms. "We would also be producing films in the new plant for a customer we were already serving from our existing Gloucester lines, so we had to be certain the new lines would deliver the quality they were used to." All those factors led Danafilms to install two lines equipped entirely with Battenfeld Gloucester technology in the Franklin facility.

Top-of-the-line configurations

Danafilms' two Franklin lines started up in September and October of 2000. The lines are similarly configured except for die size, and they run a variety of low-density homopolymers, metallocene-catalyzed resins, LLDPE and EVAs. "We wanted a state-of-the art system to provide the best film flatness possible," said Simoncini. "Roll flatness is critical to our customers, especially in the adhesives market."

Another important consideration for Danafilms was the ability to produce large-diameter rolls - up to 42" for some customers. For converters running printed, laminated, or cut applications, larger rolls allow for longer runs without downtime for a roll change. But manufacturing large rolls presents additional challenges for a film producer. The larger the roll, the more difficult it can be to control the gauge consistency and roll uniformity required for smooth downstream processing.

Danafilms met those challenges by configuring its new Battenfeld systems with features that support outstanding consistency and gauge control at every step.

Designed for flatness, from bubble to roll

"We wanted the system to be as automated as possible and easy to use for our staff," said Simoncini. "We also wanted to get the best possible consistency across runs, and Extro® gives us excellent control over that. "Extro technology is Battenfeld Gloucester's integrated process control system. It automates and centralizes control over all extrusion processes from feeding and blending through hauloff and winding.

Danafilms' Extro implementation includes an Autoprofile™ control system, which directs temperature-adjusted air to precise areas of the bubble wall to ensure the best gauge control possible. Sensing devices monitor the thickness of the bubble wall, and Extro technology integrates this information to regulate air temperature and reduce gauge variation. The Autoprofile system is unique in that it involves no thermal or mechanical action on the die.

Both of Danafilms' Franklin lines are also equipped with Internal Bubble Cooling (IBC) technology. This patented ultrasonic sensor system accurately controls bubble diameter to maintain a cool, stable bubble and smooth operation. Air flows from an internal air ring to stabilize the polymer stalk, cooling it from the inside and improving layflat control. IBC has also been shown to boost line throughput by as much as 35 percent.

The Danafilms system includes a Composite Idler Roller Collapser, a low-friction system that minimizes scratches and wrinkles to the film during bubble collapse. Danafilms also takes advantage of an oscillating nip for gauge randomization, improving roll geometry and flatness even on the largest rolls. Danafilms selected a horizontal nip configuration; Battenfeld offers nip technology in both vertical and horizontal configurations to meet customer needs and preferences.

When film is ready to be unloaded, the extra weight of a large-diameter roll presents yet another challenge. Larger rolls require heavy support shafts, which can be difficult for an operator to manage. That's why Danafilms and Battenfeld Gloucester worked together to customize a unique swing-out shaft design that simplifies roll removal. The shaft pivots so the operator can easily and safely remove the roll.

Future growth

Danafilms' Battenfeld Gloucester lines occupy two of eight available bays in the new Kentucky facility. Today, the facility produces about 25 million pounds of product per year. Danafilms hopes to deploy one new line per year until the plant reaches capacity, which will give it ability to run approximately 150-200 million pounds per year to meet the needs of even more customers in the region.

9/95 Film Rolls Growing Larger: Plastics Technology

Danafilms Inc. in Westborough, Mass., a supplier of custom blown films, expects larger rolls to assume a bigger role in converting markets. Sales manager Steve Crimmin says more customers want "longer runs with fewer changeovers." That demand comes principally from adhesive coaters, laminators, and metalizers. Bag makers and form-fill-sealers are also interested in large-diameter rolls. "Because we're making larger rolls we are getting larger accounts," Crimmin says.

Bigger is Better

Until now, converters have commonly purchased film rolls with 24-in. OD and standard layflats up to approx. 60 in., Crimmin says. However, requests are rising for rolls with 36-in. OD and layflats of 70 in. or more. Crimmin says the larger rolls may help a customer reduce downtime for roll changes by two-thirds. For example, he says a roll of 2-mil film with a 24-in. OD would hold 17,000 linear feet, while a roll of similar gauge film with 36-in. OD would yield approx. 40,500 ft -- a 138% increase.

But larger rolls necessitate some adjustment in roll handling for Danafilms and its customers. "Some equipment can't handle these large rolls," Crimmin notes. Consequently, Danafilms has purchased a custom-built forklift that has a fixed metal bed covered with carpet.

Winders for Big Rolls

To meet the growing interest, Danafilms bought a new blown film line from Battenfeld Gloucester Engineering Co., Inc., Gloucester, Mass. The line has two 1009-S shaft-type, single-turret winders for large-diameter winding. Danafilms v.p. Of sales Robert Simoncini says finished roll quality was the leading criterion in selecting the new extrusion line, which is the company's fifteenth but its first from Battenfeld Gloucester. Simoncini says the horizontal movement of the winder assembly ensures positive web contact and control throughout the winding sequence, reducing the risk of a slack web during the indexing and cutover cycle. And since roll flatness is critical for larger rolls, Danafilms purchased the line with Gloucester's Traversanip oscillating haul-off to minimize potential gauge bands.

The winder allows Danafilms to make 36-in. rolls with a max. layflat of 70 in. The Gloucester 1009-S winder has a max. winding speed of 400 fpm, but Danafilms typically runs it at 200-350 fpm. (CIRCLE 112)

Danafilms also has a Harpoon winder from Black Clawson Sano Inc., Amelia, Ohio, which can handle 36-in. OD and layflats to 80 in. It typically runs at 200-350 fpm. (CIRCLE 113)

4/95 Danafilms Produces Wider, Larger, Rolls On New BGE Blown Film Line : The High Liner, Volume 9, Number 1

Key to Danafilms Recent Growth

Danafilms, Inc. of Westborough, Massachusetts recently commissioned a Battenfeld Gloucester blown film line feed by a 4.5-inch extruder. Robert Simoncini, VP Sales of Danafilms, explains that one of the primary reasons they choose Gloucester equipment was because of the quality of the finished roll. The goal for this line was to continue Danafilms' policy of producing flat, perfectly uniform ultra-smooth rolls... but wider with larger diameters. "This is a trend thatÕs been developing for a while," says Mr. Simoncini. "Our customers want to change rolls less frequently to avoid the downtime that comes with a roll change. So, wider, larger diameter rolls give them more throughput in a shift."

Danafilms prides itself on being a custom supplier, fully recognizing the degree of production flexibility that the term 'custom' entails. Most of the company's production is polyethylene, and most of that is low density. There are also many linear low blends, homopolymers, EVA copolymers, rubber modified high density PE and more. Physically the products range from one inch tubular to 80 inch wide sheet.

Roll diameters for most of Danafilms' products, according to Mr. Simoncini, were around 24 inches. Now the converters are frequently requesting rolls up to 36 inches, with the trend moving toward even larger diameter and wider rolls. "As long as the quality is there," adds Mr. Simoncini, "to permit high-speed bag-making and other converting." The winder is especially important to the quality of the finished roll. Gloucester's Model 1009-S, one of BGE's most advanced design, was well chosen. It is a shaft-type, single-turret center winder with an extremely operator friendly Touch Screen Control system.

The horizontal movement of this winder's layon assembly (versus the pivoting type used by most competitive winders) was significant to Danafilms. This feature assures positive full web contact and control throughout the winding sequence. Further, it reduces the risk of slack web during the index and cutover cycle. which is common to most winders with auto cutoff.

Gloucester's Traversanip oscillating hauloff, which oscillates 720 degrees at the top of the tower to minimize and randomize potential gauge bands, was also a principal consideration in the decision to acquire the line.

Danafilms' personnel were able to "test drive" the entire system, including the winder, in Battenfeld Gloucester's Polymer Process Center before deciding to purchase the system.

"We have a lot of experience that tells us the critical things to look for," Mr. Simoncini said. Danafilms wanted a high level of overall expertise since they were purchasing a complete line. Though the winder was important, everything had to fit, including the Gloucester people. Gloucester met those criteria, particularly in the area of good communications, and meeting schedules and commitments.

The new line, which will run 1,200 to 1,300 pounds per hour, raised Danafilms capacity from approximately 30 to 40 million pounds annually which supports the company's continuing growth.

Expansion Pays Off At Danafilms: Enercon Industries Corporation

In the wooded rolling hills 25 miles west of historic Boston lies Westborough, Massachusetts, home of Danafilms. "Founded in 1970, Danafilms produces extruded blown films for a diverse range of applications, including packaging, tape, laminates, adhesives, food service and the medical industry," says Mr. Gerry Gustafson, Production Manager for Danafilms.

Four years ago, with the market somewhat soft, Danafilms decided that long term growth possibilities required the company to position itself for the turnaround by expanding its capacity. Potential growth through a diverse client base, required both flexibility and quality in its film production. Danafilms wanted to expand its capacity to supply treated films from 0.0007" to 0.010" (10mil) for clients customarily requesting dyne levels ranging from 38 to the high 40's. To meet their clients' needs, Danafilms recently installed two state-of-the-art blown film lines, one built by Black Clawson-Sano and the other by Gloucester Engineering. Both lines utilize corona treaters and power supplies from Enercon Industries which is headquartered in Menomonee Falls, Wisconsin. The two lines have doubled Danafilms' products output capability from 20 million pounds to 40 million pounds over the past two years.

Danafilms' first new line, a 6" Sano extrusion unit, went on-line in 1993. The line includes two 36" maximum roll diameter, 80" wide back-to-back winders that provide significantly larger rolls to their customers. These processors realize substantial savings from lower machine down-time for roll changeover. A bubble enclosure that rises above the frost line assures more consistent film gauge and quality by reducing the effects of air movement in the plant. The line also features two 7.5kW, 9000 series Compak power supplies with built-in watt-density controllers and an adjustable web width, stainless steel electrode and ceramic roll treater which has the capability to treat film at a maximum width of 82 inches.

Danafilms' newest blown film line, the Gloucester line, was installed in September of 1994. The line is fed by a 4.5" extruder and produces 1000 to 1100 pounds per hour. It includes a Gloucester model 1009-S winder which was chosen in part for its shaft-type, single-turret center winder with the operator friendly Touch Screen Control system. This system produces a high quality, large diameter (38") finished roll which is important to Danafilms. The horizontal movement of the winder's layon assembly assures positive, full web contact and control throughout the winding sequence. It also reduces the risk of a slack web during the index and cutover cycle which can occur on winders with auto cutoff.

Enercon equipment was chosen for the Gloucester line because of the Sano line success and Danafilms' growing positive relationship with Enercon Industries. "Enercon wanted to work with Danafilms," says Gustafson. "The fact that they got me to switch to Enercon from a long-standing supplier is a testament to their design team. They researched our needs, made proper design decisions, and came up with a treater solution that will grow with us into the next decade."

The Gloucester line features two Enercon 2.0kW Compak 2000 power supplies, each with an automatic watt-density controller. The Enercon treater on the Gloucester line features a Hypalon covered metal ground roll and an adjustable width stainless steel electrode, the same type used on the Sano line, and has a maximum treat width of 72 inches.

The 35 foot tall Sano and Gloucester towers are installed side-by-side with a convenient walkway between the two at the 10 foot level. The positioning of the walkway assures Danafilms technicians easy access to both units. During design/development meeting with Enercon, Gustafson requested the power supplies and watt-density controllers be mounted at the treater station level. "We want the technician to observe the treat, and if necessary, be able to make any adjustments immediately," explains Gustafson.

Both the Sano and Gloucester lines have two treater rolls, each with its own power supply. These supplies are wired such that in the event of a power supply malfunction on one roll, the supply from the healthy roll could effectively provide power to the failed roll in order to maintain production schedules. Danafilms runs 24 hours a day, 363 days a year. The efficient design of the power supply system helps them achieve such an intense production schedule with minimal disruption.

Danafilms had several options when choosing a vendor for corona treating and power supply technology. Enercon Industries' unique corporate structure is what set them apart from the rest of the field and made them the choice of Danafilms. "I am uncomfortable with change, but our usual vendor was less open about information access," says Gustafson. Sales engineers from Enercon researched Danafilms, asked the right questions and formed a strong line of communication between Danafilms and the Enercon design/engineering team.

When Danafilms began researching the Sano line, one of the design parameters they requested was the installation of 1/2 inch segments for the web-width adjustment feature. Danafilms believed that the 1/2 inch segments would provide a more critical treatment. However, Enercon explained the benefits of 1 inch stainless steel segments including lower costs and greater durability which result from having half the number of segments covering an 82 inch treat width. Danafilms changes web widths frequently and because of the fewer number of segments, the changes take only minutes. Technicians simply turn the segments and adjust the kW level of the power supply. The tolerances are acceptably close and the treatment is smooth across the web width. The watt-density control feature on these lines will be an asset to Danafilms in future runs by extending the flexibility of the lines for a variety of applications.

With its two new blown film lines, and its new supplier of corona treating technology, Danafilms has experienced rapid growth in the past two years. Danafilms will continue to utilize the open lines of communication with Enercon to update its technology and to continue producing the highest quality products for its customers. This progressive philosophy is helping Danafilms meet the challenges of innovative treating requirements and is carrying them into the 21st century.