Supercharging the packaging film supply chain: our plasma roll cleaning collaboration
When it comes to continually pushing our business forwards, ‘innovation’ is not just a marketing buzzword; it's a necessity.
At kp, we believe that every single stage of our film and packaging manufacturing process is an opportunity to shine and deliver evermore value for our customers. To see this approach in action, look no further than kp Ritterhude’s recent collaboration with industrial engineering firms Derichs Walzenmanufaktur GmbH and PlasmaGreen GmbH.
In partnership with Derichs and PlasmaGreen, our team helped to develop, hone, and validate a new contactless plasma roll cleaning machine. The resulting ED TouchlessClean(TLC) inline roll cleaning technology is an exciting step forward for the entire film-based packaging industry, offering significant benefits for our colleagues and our customers.
In the traditional film manufacturing process, the cleaning of rotating extrusion rollers is a critical, yet labour-intensive task, which carries some risks. The procedure typically requires operators to stop the machine and manually clean the rollers; a process that is pivotal for maintaining the quality and consistency of packaging films. This would also involve cleaning products such as detergent, alcohol and polishing pastes.
At kp, we believe that every single stage of our film and packaging manufacturing process is an opportunity to shine and deliver evermore value for our customers. To see this approach in action, look no further than kp Ritterhude’s recent collaboration with industrial engineering firms Derichs Walzenmanufaktur GmbH and PlasmaGreen GmbH.
In partnership with Derichs and PlasmaGreen, our team helped to develop, hone, and validate a new contactless plasma roll cleaning machine. The resulting ED TouchlessClean(TLC) inline roll cleaning technology is an exciting step forward for the entire film-based packaging industry, offering significant benefits for our colleagues and our customers.
In the traditional film manufacturing process, the cleaning of rotating extrusion rollers is a critical, yet labour-intensive task, which carries some risks. The procedure typically requires operators to stop the machine and manually clean the rollers; a process that is pivotal for maintaining the quality and consistency of packaging films. This would also involve cleaning products such as detergent, alcohol and polishing pastes.
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Although it’s been standard operating procedure in the industry for a long time, manual roller cleaning not only demands significant physical effort but also has the potential to introduce inherent risks. Safety is a top priority at kp and this breakthrough innovation has allowed us to eliminate a major risk in production – namely nip pinch incidents. These can typically occur during the manual cleaning of the plasma rolls.
The manual process can also lead to inconsistent cleaning outcomes, where even a minor oversight might result in contamination or damage to the rollers, ultimately affecting the quality of the film produced.
Furthermore, the manual cleaning of extrusion rollers generates downtime, decreased overall efficiency and extended lead times. By assisting in the development and testing of this new technology, our goal was to help change that.
The manual process can also lead to inconsistent cleaning outcomes, where even a minor oversight might result in contamination or damage to the rollers, ultimately affecting the quality of the film produced.
Furthermore, the manual cleaning of extrusion rollers generates downtime, decreased overall efficiency and extended lead times. By assisting in the development and testing of this new technology, our goal was to help change that.
For kp, the project was led by Cell Manager Extrusion, Michael Witter. For Michael and the global kp team, the project was about more than just reducing downtime. It was about improving safety, refining overall efficiency and freeing up valuable operator time to focus on higher-value tasks for our customers.
An additional benefit of the new machine is that reducing stops and disruptions makes more efficient use of energy and resources, and reducing the risk of human error in extrusion roller cleaning lessens the potential for waste, aligning with our ‘Investing in Better’ sustainability strategy and our ethos of ‘Packaging with Integrity’ to create sustainability-focused packaging that everyone can feel good about. And that doesn’t just mean in terms of materials and circularity, it can also be process-driven. As Michael describes it, the approach is about ‘building the new’ rather than ‘fighting the old’.
Sometimes, to move our industry forward, we need to challenge convention and rethink traditional methods.
Transforming the roller cleaning process
Enter the contactless plasma roll cleaning machine, a market-first technology that eliminates the need for manual roller cleaning. A dielectrically barrier-discharged plasma is generated, creating a ‘plasma zone’. The roller surface is cleaned as it passes through the plasma zone, and after a short series of passes, the roller surface is completely cleaned in a completely touchless process.
By integrating this process inline, the new machine minimises operational interruptions and enhances safety standards. This was validated through extensive trials and tests at our manufacturing site in Ritterhude, Germany. At the conclusion of prototype testing, we were so impressed that we signed up to invest in the first completed machine.
By integrating this process inline, the new machine minimises operational interruptions and enhances safety standards. This was validated through extensive trials and tests at our manufacturing site in Ritterhude, Germany. At the conclusion of prototype testing, we were so impressed that we signed up to invest in the first completed machine.
Reduced downtime translates into greater production agility and shorter lead times, ensuring products are delivered faster and are of improved quality. Why? Because the potential for contamination is eliminated.
Enhancing customer experience
The value of this innovation extends far beyond our internal operations. For our customers, the benefits are compelling. Reduced downtime translates into greater production agility and shorter lead times, ensuring products are delivered faster and are of improved quality. Why? Because the potential for contamination is eliminated.
Additionally, the enhanced efficiency and safety of inline extrusion roller cleaning mean we can put our operational focus into the quality in our film production. Time and effort saved through new roller cleaning technology means we can push ever higher production quality standards, for superior products with fewer delays. The result is a more responsive supply chain in which our customers can have full confidence.
Additionally, the enhanced efficiency and safety of inline extrusion roller cleaning mean we can put our operational focus into the quality in our film production. Time and effort saved through new roller cleaning technology means we can push ever higher production quality standards, for superior products with fewer delays. The result is a more responsive supply chain in which our customers can have full confidence.
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