Folding carton and corrugated converters will find equipment displays and educational opportunities in die-cutting, foil stamping, embossing, and more.Read more
How well do you understand the relationship between your films and your corona treater?Read more
EVOH allows conversion from foil and metallized film laminations to co-extruded barrier films.Read more
Mark Miller helps you identify the right material selection for tooling that will carry fluid to your substrate.Read more
News | New Products
ECG seminar will feature a wide range of topics and break-out sessions
The Novamelt location in Germany, where hot melt p-s adhesives are produced, is expected to play a key role in the integration of the two companies
According to a study from the Corrugated Packaging Alliance, shipping in corrugated containers saves 10.4 percent annually compared to RPCs
The 2015 North American Paperboard Packaging Competition, which recognizes excellence through the entire converting process, is accepting entries
A recent show in China was the occasion for the introduction of the modular ‘Concept’ and a carbon fibre chamber doctor blade
Visit Booth 205 at Kansas City Convention Center April 27-29
The new event, which will focus on processing and packaging technologies serving the food and beverage areas, will launch in 2017
Directories | Reports
PFFC brings you exclusive White Papers from our online sponsors.
Visit Kelly on Static from Static control expert Dr. Kelly Robinson, president of Electrostatic Answers; Kelly has 27+ years of experience in problem-solving and consulting.
Visit Tim's Web Lines to handle and wind your paper, film, foil, and similar products. Take advantage of Tim’s 25+ years just like over 100 converters have.
Visit Mark's Coating Matters from fluid coating expert Mark D. Miller; Process improvement and project management for precision roll-to-roll coating applications.
Visit Marketing Mojo for dynamic marketing insights from Stephanie Millman that inspire new ideas on how to stay on top of your customer’s mind.
Visit Yo’s Yarns to share the thoughts, impressions, experiences, and news that impact the converting industry. . . or anything else that happens to be on her mind!
Visit Tom's Poly Ploys, where Tom will be writing on various topics that the typical polymer processor would encounter on the job.
- April 30, 2004, Nsenga Byrd Thompson, Associate Editor
With help from trusted neighbor ABB, I.R. Industries increases speed and reduces waste on its coating line
As an I.R. Industries employee since the company opened 25 years ago, Robert Stasko, VP of production, has seen the company evolve from a New York-area shipping and receiving supply company to a nationwide provider of custom printed carton-sealing and commodity tapes. With 40,000 sq ft and close to 25 employees working one ten-hour shift 5- 6 days a week, the company has grown at the same rapid pace as the polypropylene tape market, which hit the US from Europe 27 years ago.
I.R. Industries maintains an econo line (for its coating operations) and a converting line (including SIAT flexo presses from Flexo Printing Inc.), as well as slitting, perforating, and laminating operations). Recently the company installed ABB’s AC motor brake system on its coating equipment in an effort to increase run speeds and reduce waste.
“We had used a air-operated brake and rewind system,” says Stasko. “We went with an ABB [because] it’s a direct motor drive that will actually increase and decrease the speed of the coater, and it works very well.”
Stasko says when working with narrow web machines, high speeds are very important. “We found out with our existing pneumatic braking system and unwind system, we couldn’t get up to speed fast enough. It was slowing us down. We were running around 160 meters per minute on our coating line. Now we’re in the excess of 200 meters per minute. Plus, what [the AC motor drive] does is get us there faster. Instead of a gradual start up to get up to speed, it’s almost instantaneous. Obviously, you don’t have as much waste. That is where the savings is—in the material,” Stasko says.
As for the company’s choice of ABB, Stasko explains convenience and familiarity played a major part in his decision. “They’re right around the corner, and they’ve done other projects for us. We’re sort of a testing facility for them,” he says. “It worked out well mainly because if we found something we thought should be improved, they were right there, and we could start working on the idea. It was an ongoing process to what we have arrived at now, so it was a learning process for both of us.”
An Equipment Facelift
Stasko says that with the high cost of purchasing new equipment, investing in a quality braking system allowed the company to maximize the efficiency of its older machines, which make up a bulk of I.R.’s converting operation.
Having older equipment, Stasko longed for more automation on the plant floor and got it with the new AC motor brake system “ our coater was showing its miles, and the price of new machines are astronomical today. So you find the need to improve what you have with today’s technology. We’ve taken machines that were 20 years old and made them almost state of the art without really having to invest in new equipment.”
“I like machines where you take all the different gauges and controls—and put it into like two buttons. Go and stop. That’s what I like a machine to do. With the ABB braking system, you just turn the unit on, and you forget about it.”
When changing adhesive formulas or material (BOPP, POLYESTER, MOPP FILMS) Stasko raves, “It took the different tension variations off of the operator and did it automatically. The machine just does it. I would say it’s 100% automation of the tension throughout the machine. We don’t have to worry about that anymore.”
2031 Route 22
Brewster, NY, USA