Post on 28-Mar-2015
Inline Granulation of Inline Granulation of Stretch FilmStretch Film
Jordan BellomoJordan BellomoVictor CastroVictor Castro
Stephen KoellhofferStephen KoellhofferZachary MagnoneZachary MagnoneMatthew ManzioneMatthew Manzione
Precision AirConveyPrecision AirConveyTeam 5Team 5
OutlineOutline
Problem DefinitionProblem DefinitionCurrent SystemCurrent SystemConcept SelectionConcept SelectionDetailed DesignDetailed DesignFabricationFabricationConstructionConstructionTest Set Up / TestingTest Set Up / TestingPath ForwardPath Forward
Problem DefinitionProblem Definition
System FunctionSystem Function Remove, Reprocess, Recycle Stretch FilmRemove, Reprocess, Recycle Stretch Film
Proposed ProblemProposed Problem Competition has a similar, but more efficient Competition has a similar, but more efficient
systemsystemUses less machineryUses less machinery
Converts ribbon directly to fluff, with no Converts ribbon directly to fluff, with no intermediate stepsintermediate steps
PAC is in danger of losing valued customersPAC is in danger of losing valued customers
Current SystemCurrent System
Concept GoalsConcept Goals
Reduce amount of machineryReduce amount of machinery Eliminate initial cutterEliminate initial cutter Reduce to one fanReduce to one fan
Reduce system costReduce system cost Manufacturing costManufacturing cost Operating costOperating cost
Feasible to manufactureFeasible to manufacture
Best Concept FeaturesBest Concept Features
Diverts some air away from materialDiverts some air away from material
SimpleSimple
AdjustableAdjustable
Easy to implementEasy to implement
Based on existing technology Based on existing technology
Concept RefinementConcept Refinement
Several Feasible IdeasSeveral Feasible Ideas Vertical Inlet, Cylindrical Vertical Inlet, Cylindrical
ScreenScreen Vertical Inlet, Slanted Screen Vertical Inlet, Slanted Screen Vertical Inlet, Dual Sided Vertical Inlet, Dual Sided
Slanted ScreenSlanted Screen
Concept RefinementConcept RefinementBest ConceptBest Concept Cylindrical enclosure, conical screen Cylindrical enclosure, conical screen Pressure membrane distributes airflowPressure membrane distributes airflow
Material and some air flow
OUT
Flow restriction membrane
Conical screen, 50% open area
Low pressure Zone
Low pressure Zone
Separated air OUT
100% Air and Material IN
Detailed DesignDetailed Design
Detailed DesignDetailed Design
Dimensional justificationDimensional justification Used PACs existing screen separator as a Used PACs existing screen separator as a
starting point for our designstarting point for our design Maintained same open area of screenMaintained same open area of screen Used approximately same screen angle Used approximately same screen angle
FabricationFabrication
Created detailed design of separatorCreated detailed design of separatorSent drawings to PAC’s fabricatorSent drawings to PAC’s fabricatorReceived finished PrototypeReceived finished Prototype
ConstructionConstruction
Attached all system componentsAttached all system components
Test Set UpTest Set Up
Victor
TestingTesting
Measurements Taken: Target ValuesMeasurements Taken: Target Values Pressure: Total Drop Pressure: Total Drop ≤ 25 in. H≤ 25 in. H22OO Air Velocity: ~6500 ft/min. Air Velocity: ~6500 ft/min. Air Pulled Through Grinder: Air Pulled Through Grinder: ≥ 1000 cfm≥ 1000 cfm Fan Power: Fan Power: ≤ 60 Hz≤ 60 Hz Bulk Density of End “Fluff”: 4-7 lb/ftBulk Density of End “Fluff”: 4-7 lb/ft33
Material Velocity: ~2000 ft/min.Material Velocity: ~2000 ft/min.
TestingTestingConcept ValidationConcept Validation Diversion of air was necessaryDiversion of air was necessary
Theoretical calculations match experimental Theoretical calculations match experimental resultsresults
Diverting some airflowDiverting some airflowIncreased system efficiencyIncreased system efficiency
Reduced fan speed Reduced fan speed Increased airflow at inletIncreased airflow at inlet
Pressure membrane was not criticalPressure membrane was not criticalConical screen provided enough of a restriction Conical screen provided enough of a restriction
TestingTesting
Granulation Success: The Rise and Fall of Stretch FilmGranulation Success: The Rise and Fall of Stretch Film
Path ForwardPath Forward
Compile data CD with all relevant project Compile data CD with all relevant project data for PACdata for PAC
Longer length tests need to be conductedLonger length tests need to be conducted
Install access panel for cleaning purposesInstall access panel for cleaning purposes
Experiment with different conical screensExperiment with different conical screens May be able to further increase system May be able to further increase system
efficiencyefficiency
SummarySummary
Problem DefinitionProblem DefinitionCurrent SystemCurrent SystemConcept SelectionConcept SelectionDetailed DesignDetailed DesignFabricationFabricationConstructionConstructionTest Set Up / TestingTest Set Up / TestingPath ForwardPath Forward
QuestionsQuestions
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