NEWARK, N.Y., September 21, 2022 – Addex Inc. will introduce its integrated blown film Cooling and Stabilization System (CSS) for extrusion lines at the upcoming K 2022 exhibition (Hall 17/C41), which runs Oct. 19-26 in Düsseldorf, Germany. The digital, automatic bubble cage (Dcage) features Addex’s “Operator-Assist” (Å) technology which controls the entire cooling process on one screen.
Addex has partnered with Pearl Technologies, Savannah, N.Y., a leading supplier of quality web guiding and handling equipment, to create a robust, “smart” bubble cage featuring Addex’s proprietary 100% pure digital automatic controls. The Addex + Pearl Digital Bubble Cage provides smooth, consistent bubble diameter control and features Pearl’s unique patented cage arm technology. Each cage arm is fabricated from a lightweight custom aluminum extrusion with a smooth, fully radiused active surface that always faces the bubble. Surface-modified with Pearl’s SM24 “Extreme-Slip” ultra-low coefficient of friction (COF) hard-coat material, the resulting design offers long wear life and superior quality film without blemishes, tracks, or chatter marks.
Addex has engineered control over stepper motors to perform precise repeatable axis adjustment for vertical positioning of the cage, as well as the horizontal adjustment for bubble diameter integrated with their all-digital IBC Control System (DIBC).
Addex’s bubble cage system represents a breakthrough in the blown film industry. The company’s depth of process knowledge coupled with a strong desire to make operator-friendly equipment was the impetus behind the “smart” Bubble Cage + DIBC and the resulting Å – Operator Assist technology. Additionally, all the system components are service friendly, allowing remote maintenance-friendly diagnoses/troubleshooting, thus avoiding delayed and costly in-person technical service calls.
The Bubble Cage and DIBC system are “smart” because they enable a processor to “set it and forget it,” according to Bob Cree, President of Addex Inc. Upon startup, the operator loads a previously memorized setpoint and the Dcage + DIBC automatically adjust themselves, making for faster, greener changeovers, freeing the operator to focus attention elsewhere. Setups are saved in the system, and once selected, DIBC sensors are linked with the digital cage positioning. If the system sees the bubble coming too close, it won’t allow the cage to come in too tight. It digests all inputs before operation, ensuring success for every operator regardless of experience.
Addex’s Digital IBC Control (DIBC) uses patented, split, fully-digital ultrasonic sensors that eliminate errors caused by interference common to other systems and enable the air flow intake and exhaust to react to the slightest change in bubble size. This occurs while retaining high precision and accuracy over the resulting bubble size. Additionally, a digital stepper motor valve control retains this high degree of precision to ensure tighter control over the entire process, as well as repeatability.
Also new to the Addex lineup and displayed as part of the Digital Bubble Control System is Short Stack Intensive Cooling, the latest iteration of Addex’s patented Intensive Cooling technology. Short Stack is an enclosed two-level, stacked Intensive Cooling system that guarantees 15% to 20% output gains with low-melt strength materials that typically are impossible to run on other raised-up cooling systems. Short Stack also provides up to 50% output gains with easier to run, high-melt strength materials. The Short Stack stabilization and bubble cooling immediately upon exit of the die is the key to impressive output gains while maintaining film quality through enhanced bubble stability. Short Stack Intensive Cooling also features digital control over that portion of the cooling process, including Å-Operator Assist technology and remote maintenance capability.
Addex’s CSS system also includes quality-enhancing gauge control, provided by the Addex EGC (External Gauge Control) Intensive Cooling auto-profile air ring, which sits atop the Short Stack and controls 100% of the airflow to the air ring. Fully digital, very high resolution of the control is assured by a multitude of control zones that can be moved to any “in” or “out” position within each channel. Addex’s proprietary mapping software processes the raw profile input from several profiler options, including the Kundig K-500 Rotamat KT thickness measuring system (showing at K 2022), plus all other Kundig and NDC profiling options. The mapper combines profiler signals with feedback from reversing haul-off position and nip roll speeds to achieve 1-degree film profile mapping, producing best-in-industry twist and turn compensation due to Addex’s sophisticated mapping.
Kundig rotomat mounting points are included standard, providing excellent stability support for the bubble which stays on center for better quality profiles and enhanced film quality. “By stabilizing the bubble near the sensors’ profiler, everything gets better because the bubble is not moving around,” says Cree. “This eliminates the spikes, dips, and high points that aren’t real, but a consequence of bubble motion; this smart bubble cage stabilizes the bubble and makes the profile quality better to begin with.”
The Addex Cooling and Stabilization System comes ready-to-install, using just two connection types – power and ethernet – which interconnect the system in a simple way. A mini-control panel can control just the cage or optionally be expanded to integrate the DIBC, EGC, and Short Stack together. Addex’s pre-engineered solution for installation minimizes downtime, requiring only a four-point mount to install. The company reports that retrofits with the Digital Bubble Control System, including operator training, can be accomplished in as little as two days if mounting points are pre-installed. This automation of a blown film line can be retrofitted to older lines, giving customers the best value for their investment – with standard delivery times running 14 to 16 weeks.
“The biggest advantage of this fully-integrated system approach to bubble control is the support it provides operators, especially those less experienced, thereby ensuring experienced results,” said Cree.
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Press Contact:
Joseph Grande
J. Grande Communications Inc.
413.684.2463
joe@jgrandecommunications.com