Flexible Packaging talks with QC Electronics about new technologies in corona treating that can deliver better flexibility, price and leadtimes.
Kenneth Klein, president
Q: What is the difference between bare roll and covered roll corona treaters and why is that significant?
A: The biggest difference between bare and covered roll systems used to be that the covered roll system required far less power to achieve the same dyne level. This was important to the customer for two reasons: (1) the initial purchase price was less for covered roll because you could use a smaller power supply to run the job, and (2) because of the reduced treater price, the customer could free up capital for other projects. The covered roll system also offered lower operational cost because of the lower power requirements.
QC Electronics has reversed this role by introducing the DT+2 bare roll corona treating system. The DT+2 system provides covered roll efficiency in a bare roll design.
Q: How is today’s emphasis on energy savings in the plant impacting corona treatment operations and equipment designs?
A: With the high cost of energy, QC Electronics is focused on increasing the efficiencies of its treaters and developing new roll coatings which lower the power requirements necessary to achieve dyne levels. This focus has led to the development of our number one selling system: the DT+2 bare roll system. The DT+2 system has also led to our plant expansion that is currently taking place. This expansion, expected to be completed this month (November), will allow us to further lower our price, but more importantly, shorten our lead times greatly.
Q: How can a converter get higher dyne levels with existing corona treaters and why is this important?
A: The DT+2 electrode that QC Electronics has developed can be retrofit into any bare roll system. By implementing this conversion, the converter can at minimum double their line speed and at the same time use half of the power required for their current line speeds. It’s remarkable that by simply replacing an electrode, you can cut your power requirements in half and double the line speed.
We also make recommendations to converters using covered roll systems which will increase that system’s efficiency-without replacing the system with a new one. This is a service QC has offered for the past 20 years. Replacing the system isn’t always the best solution for the customer, so we offer alternatives.
Q: What are the benefits of custom designing a corona treater? How do you balance that with versatility to handle a variety of products?
A: QC Electronics manufactures its entire product line in house, which allows us to custom design equipment for customers at no additional cost. It also allows us to minimize lead times. Custom design is a tremendous benefit to the customer as we can design one unit that accomplishes many tasks. The more flexibility the line offers, the more jobs the customer can produce.
Q: What are the benefits of using “lanes” in corona treaters?
A: The biggest benefit to lane treating is that the customer can direct the corona to where they need it. This allows them to use less energy resulting in higher profits.
Q: What is the future of corona treating for flexible packaging?
A: The future lies in efficiencies of the corona treatment process. With all of the new material coming onto the market, we are able to take different approaches in increasing the effectiveness of the corona treating process. The more effective we can make the treatment, the more profit our customers see in their companies.
QC Electronics Inc.
Efficient corona treating saves time and energy
November 1, 2008