Maintaining Air Ring and IBC Openings
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Questions and Answers

What is the primary reason for operators not to have music in their ears when running a blown film extrusion machine?

  • To make the work environment more enjoyable
  • To improve the quality of the extruded film
  • To prevent potential damage to the production or equipment from sudden acceleration or deceleration (correct)
  • To enhance the speed of the extrusion process
  • What is the fastest way to stop a line in a safety condition?

  • Activate the emergency stop (correct)
  • Shut off all power to the machine
  • Inform the operators to stop the line manually
  • Slow down the extrusion rate gradually
  • Why should the emergency stop not be used as the standard method for stopping the line?

  • It can cause unnecessary wear and tear on the equipment (correct)
  • It is not a reliable method of stopping
  • It may lead to damage to the produced film
  • It takes longer to activate than slowing down the extrusion rate
  • Who is responsible for slowing down the downstream equipment in a manually controlled system when stopping the line?

    <p>The operators</p> Signup and view all the answers

    What is the recommended approach for stopping the extruders under non-emergency conditions?

    <p>Slow them down to zero over a minute or two</p> Signup and view all the answers

    Why is it important to clear any unwanted film or excess polymer from the outside of the machine before restarting?

    <p>To prevent contamination of the new film being produced</p> Signup and view all the answers

    In a fully automated system, what happens when the extrusion rate is slowed down to zero?

    <p>Downstream equipment slows down as well</p> Signup and view all the answers

    What should operators do if they need to stop a line under non-emergency conditions?

    <p>Slow down all components gradually until stopped</p> Signup and view all the answers

    What is one potential consequence of using an emergency stop as a standard method for stopping the line?

    <p>Increased wear and tear on equipment</p> Signup and view all the answers

    What should be done after slowing down all components of a blown film extrusion machine?

    <p>Clear any debris before restarting</p> Signup and view all the answers

    Study Notes

    Pre-Startup Preparations

    • Avoid overheating the material inside the extruders or die, which can cause partial decomposition and produce carbons that can take a long time to clear.
    • Warm up the gearbox oil by slowly running the nip rollers, winders, and oscillating nips for 30 minutes before starting production.
    • Use this time to test the open/close functions of the primary and secondary nips, and ensure the web handling motors are warm.

    Equipment Preparation

    • Ensure cooling systems are up and running, with water temperature between 40 and 50°F (4-10°C).
    • Check that blenders are ready to operate, with all electro-mechanical devices functioning properly.
    • Prepare the air ring by allowing time for the heating die to soften any solid material, then clean the air ring and IBC cooling openings of leftover resin and silicone grease.

    Startup Procedures

    • Don't start the oscillating die until the line is running stable, which can take 30-60 minutes after startup.
    • Listen to the line and pay attention to the sounds of the motors, as sudden changes can indicate potential problems.
    • Avoid using music with earbuds while running the line, and instead use hearing protection to allow for awareness of changes in the machine's sound.

    Stopping the Line

    • Use the emergency stop only in safety-critical conditions, and instead slow down the extrusion rate to zero over a minute or two under normal conditions.
    • Slow down the downstream equipment, including the nips, winders, air ring, and IBC, before stopping the line.
    • Clear any unwanted film or excess polymer from the outside of the machine before restarting.

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    Description

    Learn about the importance of cleaning air ring and IBC cooling openings from left-over resin and silicone grease. Understand the significance of proper positioning and adjustment of air ring and IBC for production efficiency.

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