Converting-Machinery Subsystems Applications Watch

The installation of a Davis-Standard (www.davis-standard.com) Integrator™ C control system economically improves film processing for Irvine, CA-based B. Braun's Plastics Business Unit. B. Braun (www.bbraunusa.com), a global supplier of healthcare products, installed the Integrator on a 25-year-old film line to replace an aging CMR control unit. Davis-Standard was proactive in implementing the program for B. Braun with an engineered solution and complete installation responsibilities. Since the July 2008 installation, B. Braun has reportedly seen greater efficiencies through the Integrator's digital format, improved line performance and reduced downtime. The collaborative effort between Davis-Standard and B. Braun also helped limit the excessive costs and risks associated with a major upgrade.

"The film line receiving the Integrator runs 80 percent of our internal needs," says John Taylor, manufacturing manager for B. Braun Plastics Business Unit. "We knew it needed upgrades; at one time we thought we might have to replace the entire line. It was a high-risk project that could have cost hundreds of thousands of dollars for each day we were down. With the Integrator, we solved performance issues while saving time and money. We kept our downtime to a minimum, and we were able to boost the line's performance for the price of a control unit. Davis-Standard is currently working with us on a die upgrade, which will be integrated into the system very soon."

The Integrator replaced B. Braun's existing CMR supervisory control unit, which is no longer available. Davis-Standard reportedly offers several options to accommodate system requirements and budget parameters for these older supervisory systems. The new single-point Integrator provides the functionality of the CMR with additional features including recipe management, historical data trending and alarms. The Integrator also employs a new PLC-drive interface, improved temperature controls and enhanced gauge control based on the age of the existing gauge system.

B. Braun project engineer Mark Tanouye, who was responsible for this project, has been very impressed by the Integrator's performance.

"The Integrator C has very intuitive screens, it is easy to understand and aids in troubleshooting," says Tanouye. "Davis-Standard's personnel were very responsive during the entire process. Initially, we thought it would be a three-week installation, and we were able to get it done in two. They have an outstanding knowledge base, so there was no need to explain; they just automatically knew the issues we needed to solve."

Stow, OH-based, pressure-sensitive paper manufacturer MACtac North America (www.mactac.com) recently collaborated with Rollguard® (www.rollguard.com), a Great Northern Corp., to implement a new way to deliver materials and improve worker safety, while also achieving sustainability. MACtac, a Bemis Co., employs Rollguard's recycled-fiber full-roll cradles to overcome hurdles associated with ergonomics and safety, lean throughput and sustainability.

"I thought this was obviously an opportunity for us to gain internal and external savings for our customers, and not just monetary savings," says Dave DeSimio, supply chain director for MACtac North America. Rollguard's fiber roll cradles come in a variety of configurations, all of which are reportedly made from recycled corrugated molded pulp and are 100-percent recyclable. The full-roll cradles are said to provide support along the entire length of cylindrically-shaped products and are ideal for heavy rolls with diameters from 9 to 40 in. The standard cradles are 37 in. wide by 47 in. long with a deep well created by a 5.5-in. wall height.

MACtac produces p-s adhesive rolls and ships them to its finishing centers located throughout the country. The finishing centers slit the product down to widths between 2 and 20-plus in. and rewwinds them into lengths of 3,000 to 20,000 ft. Eventually, the rolls are shipped to MACtac customers who further convert them into products, typically labels.

Improved ergonomics during this process has resulted from having fewer packaging components. "Our finishing centers previously utilized a multi-part package with a total of eight discrete components," says DeSimio. "With Rollguard, we've been able to reduce that to five. By only having to put down one item on the skid before the product is placed versus putting down two or three items, we've reduced the number of hazardous body positions [ergonomically] per skid."

The reduction in components also provides leaner throughput. "We simply place the roll cradle down, place the product on the cradle, finish our packaging and the load is ready for shipment, explains DeSimio.

Sustainability improvements were achieved by eliminating petroleum-based products. "Getting [greener] came from getting rid of the foam sheet, expanded-polystyrene wedges and significantly reducing the stretch wrap, DeSimio adds. "Those are all removed or significantly reduced and replaced by a single recycled and recyclable product."