CEMA Fundamentals Seminars Agenda

In this presentation, a variety of methods to deliver coating fluid from a storage tank to an application point are presented. Pump systems, pressure systems, and gravity systems are described. The importance of elimination of bubbles and controlling temperature is emphasized. Process steps of filtration, flow measurement, and in-line mixing also are presented. Additional topics include handling of flammable fluids, materials of construction, and clean-up methods.

SPEAKER BIO
Ken McCarthy has over 35 years of experience, primarily related to coating, at Polaroid and most recently at Multilayer Coating Technologies LLC until it closed in November, 2007. Since then, he has formed a consulting service, Clean Room Coating Solutions. His areas of expertise include coating fluid mix preparation and delivery, coating operations, clean room operations, coating applicator design, environmental management, and new product development. In addition, he has extensive experience in new product translation, from laboratory through scale-up into full-scale manufacturing.

In this presentation, a variety of base cleaning methods are discussed. The importance of starting with base that has been well prepared is emphasized, along with the importance of controlling static charge. Methods of cleaning presented include air knife, vacuum systems, ultrasonic systems and contact systems. The relative cleaning efficiencies of these systems also is outlined.

SPEAKER BIO
Ken McCarthy has over 35 years of experience, primarily related to coating, at Polaroid and most recently at Multilayer Coating Technologies LLC until it closed in November, 2007. Since then, he has formed a consulting service, Clean Room Coating Solutions. His areas of expertise include coating fluid mix preparation and delivery, coating operations, clean room operations, coating applicator design, environmental management, and new product development. In addition, he has extensive experience in new product translation, from laboratory through scale-up into full-scale manufacturing.

The flexible packaging industry, despite the still-ebbing economy, continues to experience a technological revolution aimed at value-adding graphics, increasing consumer motivation, and delivering sustainable solutions for a host of challenges throughout the manufacturing and distribution chain. High performance package configurations and new printing technologies (notably flexo) continue to drive packaging into existing as well as completely new markets. Statistically, the U.S. flexible packaging industry is expected to experience annual sales revenue growth of 8.1 percent in 2011 according to the Flexible Packaging Association. The Freedonia Group forecasts revenues for the US commercial printing industry will reach $82 billion in 2011 and that US demand for printing inks will grow 1.8% annually to reach $4.8 billion by 2013. And although the global packaging industry is valued at a burgeoning $450 billion, the emerging markets of China and India for example convert only about 7% of all their packaging by the flexographic process. The market growth opportunities for flexographically-printed flexible packaging are therefore vast. As new state-of-the-art package printing technology is installed in these markets and with processing costs under pressure to enable these processes to ramp-up in 2011, surface pre-treatment technologies must become a key enabler relative to higher processing speed, wider widths, and requirements on inks and coatings to transfer and adhere to substrates at these speeds and widths. This paper presents evidence of new flexible packaging print performance opportunities using new atmospheric plasma treatment (APT) technology.

SPEAKER BIO
Douglas DeLong is the owner of DOCTORUV.COM / DDU Enterprises, Inc. in Redondo Beach California. He joined the Converting industry in early 1987 as VP of Lesco UV. Doug started DOCTORUV.COM / DDU Enterprises, Inc. in 1991. He has been Enercon's West Coast representative since 1998. Doug has a strong knowledge of Enercon's Surface treatment using corona and atmospheric plasma. He attended Palomar College, San Marcos CA.

This presentation will give an overview of the web coating process. It will discuss the following topics:
- Basic hardware elements that comprise a coating line
- Coating methods and principles of operation
- Characterizing the coating process
- The four basic classes of coating methods and specific uses: Self-Metered, Doctored, Pre-metered, Hybrid
- Selecting the best coating method
- Coating technology Information sources

SPEAKER BIO
Dr. Cohen is a technical consultant in all aspects of the web coating process. His expertise is in the coating and drying of thin films, coating process development and scale-up, polyester base development, film defect mechanisms, defect characterization techniques, litigation support and professional development activities for scientists.

Dr. Cohen has over 45 years experience in coating research and manufacturing technology with the DuPont Company, retired as a DuPont Fellow, and as a consultant. He has extensive publications in the field and has published several books and articles for industry publications. Currently he is Technical Consultant for AIMCAL. He was founding president of the International Society of Coating Science and Technology. He has a Bachelor of Science in Chemical Engineering from Tufts University and a Ph.D. in Physical Chemistry from the University of Delaware. His honors are the John Tallmadge Award for Contributions to Coating technology and the AIMCAL President’s award.

After first being used in Germany in the 1880’s Wire Wound Coating Rods were popularized by Charles Mayer. Mayer’s rods were first used for the manufacture of carbon paper and spread from there. This paper will answer the question: “Why use a 100 + year old coating Process”? The simple answer is that it delivers an accurate, smooth, repeatable coating and using it is relatively inexpensive.

This paper will discuss:
- How the rod works.
- Basic components and why they are chosen.
- Different rod configurations and when they are used.
- Various application configurations
- Wrap angle over the rod.
- Web tension
- Range of Coatings.
- Coating Head Configuration
- Rod holders and Drives
- Operating parameters
- Surface finishes available
- Rod life
- The four most important factors in Mayer Rod Coating

SPEAKER BIO
Doug Krasucki has been president of R.D. Specialties, a family business, since 1976 and holds a BS in Business from Fairleigh Dickinson University. His company has made Mayer Rods since 1936. Doug is the past president of the Webster Chamber of Commerce in Webster, NY, has been a member of TAPPI since 1974 and a member of AIMCAL since 2002.

This presentation will address the mechanical and web handling aspect of lamination and laminator design, including the key factors to minimize problems in tensioning, wrinkling,
nipping, driving, and handling. The presentation will also include of where and why lamination is integrated with your process and review the cause and remedies of the most common web handling related laminate defects.

SPEAKER BIO
Timothy J. Walker is a web handling, winding, laminating, and slitting specialist with 25 years experience in the converting industry. His company, TJWalker+Associates Inc, provides engineering support to client companies through training, development, and problem-solving. Tim has avidly taught web handling and winding best practices and estimates total students at over 4000 since 1989.

Tim’s resume includes: a BSME in Mech. Engrg. (Univ. of Iowa) and Master’s in Mgmt of Technology (U. Minnesota), 17 years at 3M Company (including ten years in their corporate web handling group), and found TJWalker+Associates, Inc in 1999. Tim is on the Board of Trustees for CEMA and AIMCAL’s Technical Panel. He writes a monthly column for PFFConverter magazine, Web Lines.

This presentation will cover the various technologies that are available to
produce laboratory and pilot coatings. Specific topics to be covered are:
-Traditional laboratory hand coaters
- Recent pilot coating technology advances: Automated Bench-top sheet coater dryers; Laboratory continuous coaters; Modular pilot coaters
- Improvements in cost quality and reproducibility

SPEAKER BIO
Dr. Cohen is a technical consultant in all aspects of the web coating process. His expertise is in the coating and drying of thin films, coating process development and scale-up, polyester base development, film defect mechanisms, defect characterization techniques, litigation support and professional development activities for scientists.

Dr. Cohen has over 45 years experience in coating research and manufacturing technology with the DuPont Company, retired as a DuPont Fellow, and as a consultant. He has extensive publications in the field and has published several books and articles for industry publications. Currently he is Technical Consultant for AIMCAL. He was founding president of the International Society of Coating Science and Technology. He has a Bachelor of Science in Chemical Engineering from Tufts University and a Ph.D. in Physical Chemistry from the University of Delaware. His honors are the John Tallmadge Award for Contributions to Coating technology and the AIMCAL President’s award.

This is a short course in conventional drying methods including heat transfer, efficiency considerations and the pros and cons of common drying techniques. Understanding the process impact on drying is discussed along with design and features to consider for ease of operation. Convection drying, Infrared heating, and combination systems are covered.

Are your coating and laminating dryers limiting production throughput? Are process energy costs eating away at your profitability? Does your drying process create product defects that result in waste or unhappy customers? If you answered yes to any of these questions, this presentation will be of interest to you.

Learn how to optimize your existing drying equipment so as to eliminate costly product defects, reduce energy costs and increase production throughput. The presentation will review current best operating practices and equipment upgrade opportunities as they relate to forced convection air drying technology. Topics will include; exhaust air recirculation loops, energy recovery equipment, efficiency gains through process automation, and other helpful tips to improve the operation and reliability of your existing drying systems.

SPEAKER BIO
Dan Bemi joined MEGTEC in 1999 and is a Regional Sales Manager. Prior to MEGTEC, Dan held several sales and marketing management positions with the Wolverine Massachusetts Corporation and Applied Web Systems. Dan attended Knox College in Galesburg, IL where he studied creative writing.

Dan is an active member of several industry associations including AIMCAL, CEMA, A&WMA and FFTA. He currently serves as Chair for the AIMCAL Environmental Committee and also serves on the Environmental Committee of the Flexographic Technical Association. Dan is one of the 2004 recipients of the John Matteucci Technical Excellence Award.

UV systems possess heat management controls that fine tune the exothermic and delivered heat in the UV curing process. This presentation will explore the various methodologies and controls that allow UV processors to cure UV adhesives, UV inks, and UV coatings when applied to heat sensitive substrates.

The presentation will illustrate the effects of the above stated heat management methods on the UV dosage (J/cm2), peak UV intensity (mW/cm2), average and maximum temperature rise (ATR & TR). Review the capital equipment, operational and maintenance costs related to each heat management method.

SPEAKER BIO
Juliet Midlik, Vice President of Sales, Prime UV Systems, has spent over fifteen years in technical sales and marketing to the converting, coating and printing industries. Upon graduation from the University of Massachusetts, Amherst, she joined Prime UV as Marketing Specialist, and was subsequently promoted to Director of Customer Support and Regional Sales Director for the company. Juliet is an Ultraviolet equipment specialist and has conducted seminars and authored articles on the technical applications of UV systems for the converting industry, and the development of high-speed UV curing systems. CEMA, the Converting Equipment Manufacturers Association, has elected Juliet Midlik President for a two year term - 2008/2009. Juliet is an active member of AIMCAL and the FTA, Flexographic Technical Association.

The demand for increased functionality and higher quality in multi-layer films and coated web products is rising, resulting in more complex and costly structures. Layers and coatings are getting thinner, production runs are shorter and line speeds are increasing. To meet this demand and remain competitive requires an efficient process able to run quality product, within specification, from the start to finish of a run. This can not be accomplished with periodic lab sampling, since a defect caught in the lab may be hours old! Add requirements for proof of compliance, the ability to conduct effective product development, and real time process troubleshooting and an on-line gauging system becomes a tool in this effort.

The purpose of this session is to discuss the applicable on-line gauging sensor technologies and coating measurement techniques.

SPEAKER BIO
Ted Schnackertz has over 25 years experience in process control utilizing on-line gauging systems. He has worked as a field engineer, systems engineer, project manager, applications engineer and currently as Strategic Accounts Manager at NDC Infrared Engineering. Ted studied electronics at CCNY (New York, NY) and electrical engineering at Lowell Institute of Technology (Lowell, MA) Ted is a TAPPI member and has instructed at TAPPI Short Courses and presented papers at Aimcal, CEMA and TAPPI PLACE conferences

This presentation will review the four different types of web guide control systems, how to properly select the right guide for your application and will cover the many options that are available. We will also cover the ten rules of web guiding and how to avoid common pitfalls and mistakes people can make when selecting, applying and operating a web guiding system.

Web tension control is often misunderstood and the many options can be confusing. This presentation takes the mystery out of tension control and explains the basic theories and best practices. Specifically it discusses unwinds, rewinds and point to point applications. The presentation also covers manual, open loop and closed loop control schemes and the advantages and disadvantages of each.

SPEAKER BIO
Chris Harper is the Global Product Manager for MAGPOWR tension controls.
Chris has 20 years of experience with the MAGPOWR tension control line. He has worked with increasing responsibilities within MAGPOWR including field service, inside sales and 8 years as an outside salesman for Maxcess which includes MAGPOWR, Fife and Tidland.

Industrial precision rolls: Types; Hard chromium plating; Precision grinding; Finishes; Tolerances; Polishing. Processing a new roll, refinishing a used roll - the steps; Knowing your precision rolls - characteristics, specifications; Knowing what your roll provider should ask, what you should ask; Saving time and money.

SPEAKER BIO
David Johnston has been in the industrial roll grinding and plating business, with Roll Technology for 3 years. He has been involved with sales and marketing for 20 years. Before that he was in the acting profession in Los Angeles, CA for 10 years.

David received his BA at Lynchburg College in Lynchburg, VA and now lives in Greenville, SC where Roll Technology is located.

The right core shaft in your application can make the difference between profitable rolls and high scrap and rework. This presentation addresses five key performance factors to insure you match the right shaft to your winding or unwinding application. Ergonomics means fitting the task to the worker. This presentation reviews potential hazards in converting operations and provides practical solutions to reduce workers' compensation claims and improve the overall efficiency and job satisfaction of your operators.

SPEAKER BIO
For over 20 years, Sean Craig has designed and applied winding components for the web
converting industry. His expertise ranges from reel spool solutions for primary tissue
manufacturing to differential winding and ergonomic solutions for a variety of converting
applications. He is a regular speaker for the CEMA Fundamentals for Converters Slitting
and Rewinding seminars and has been published in Converting Magazine, AIMCAL Fall
Technical Conference and AWEB publications.