BOBST General K5000

www.bobst.com

Bobst Manchester Ltd.Pennine Business Park, Pilsworth Road,Heywood, Lancashire, OL10 2TL, UKTel: +44 1706 622442 Fax: +44 1706 622772 sales.manchester@bobst.comservices.manchester@bobst.com

ENGINEERING EXCELLENCE

K5000/02/2013

TECHNICALMax web width (mm) 2450 2850Min web width (mm) 1025 1425Max roll diameter (mm) 1200 1200Max line speed (m/min) 1000 1000Average power consumption (kW) 279 306Average water consumption (m3/hr) 49 53Overall length (mm) 19100 19900Overall width (mm) 5755 5755Overall height above floor (mm) 3280 3290Estimated annual output (tonnes) 6500 7600

HIGH PERFORMANCEVACUUM METALLIZING

SPECIFICATIONS

Film producers worldwide want toproduce optimum quality plasticfilm at maximum possibleproductivity. The K5000 metallizerfrom BOBST helps them achieve thistarget. A well accepted machine inthe industry, it metallizes at speedsup to 1000 metres/min utilizingdiameter rolls up to 1.2m. Its largecoating drum introduces highercollection efficiencies that reducedramatically the importantconsumable costs of running ametallizer – electrical power,evaporator boats and aluminiumwire.

The machine can be supplied foraluminium and aluminium oxidecoating with changeover at thetouch of a button. Additionally,defects can be monitored by ourunique BOBST General Hawkeye

Pinhole detection system.The use of medium frequencyplasma treater technology allowsthe machine owner to producehigher barrier webs with bettermetal adhesion and better surfacetension retention. The K5000’ssuperior evaporation sourcecontrol system results in fewerdefects and out of specificationcoating levels, and the use of large(50,000 litres/second) diffusionpumps ensure quick pump downtimes and hence more output.The K5000 user interface is simpleand logical and helps theproduction team keep consistenthigh quality output by using thecomprehensive recipe system. PERFORMANCE

20 µm OPPOxygen transmission rate (cm3/m2/ day) < 40Water vapor transmission (g/m2/ day) < 1OD uniformity (%) < ± 5%12 µm PETOxygen transmission rate (cm3/m2/ day) < 1Water vapor transmission (g/m2/ day) < 1OD uniformity (%) < ± 5%25 µm CPPOxygen transmission rate (cm3/m2/ day) < 40OD uniformity (%) < ± 5%

*coating thickness 2.3 OD; barrier data depending on actual substrate type; throughput depends on customer’s production parameters.

TECHNICALMax web width (mm) 3250 3650Min web width (mm) 1825 2225Max roll diameter (mm) 1200 1200Max line speed (m/min) 1000 1000Average power consumption (kW) 372 392Average water consumption (m3/hr) 64 68Overall length (mm) 20700 21500Overall width (mm) 5755 5755Overall height above floor (mm) 3290 3290Estimated annual output (tonnes) 8700 9700

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K5000

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HIGHER PRODUCTIVITYThe K5000 metallizer outputs more tonnes of metallized film per hour thanits closest competitors. The machine has a base coating speed of860m/min for 2.2OD. It is able to handle up to 1200mm diameter reels at4450mm wide, proportionately reducing the effect of non-metallizing timein the production cycle.

With its large coating drum (595m), the K5000 is able to handle heatsensitive CPP/BOPP/LDPE films at higher production speeds and coatingweights whilst keeping the film cool to avoid blocking and winding defects.

For customers where high optical density (up to 3.5) metallization isrequired at high output, then the K5000 range can optionally be fitted witha High Rate Source – 80mm pitch instead of 100mm pitch.

The K5000 metallizer also consumes lower levels of electricity andaluminium wire per square metre of metallized film produced. It alsoturns off pumps when they are not required to save power (eco mode).

EASE OF USEReducing the amount of noncoating time is key to increasing ametallizer’s productivity. Makingeasier each task that the operatorhas to perform reduces downtime.

The K5000’s higher collectionefficiency means less aluminium toclean.

Its smooth surfaces are easier toclean.

The innovative edge shields areeasier and faster to set up.Reduced noise levels mean a morerelaxed, safer environment withfewer mistakes.

Comprehensive maintenance andtrouble shooting screens make iteasier to keep the metallizerworking at peak output.

COATING QUALITYWorld leading plasma treatmentunits give the K5000 metallizer theability to coat with better WVTR,OTR and adhesion than othermachines.

Winding quality is maintained dueto loadcell control and servo drivenunwind and rewind layarms. Thelayarms can work in gap or contactmode. The gap can be set at anydesired value and automaticallymaintained.

PLASMA PRE-TREATMENTAND POST-TREATMENT

The preparation of the film surface for metallization or clear coating(aluminium oxide) is a critical step in constructing the desired properties ofthe finished structure, for both adhesion and barrier properties. The BOBSTtechnology is based on medium frequency (40KHz) powered plasma units,from pre-treatment through to full plasma coating (PECVD – plasmaenhanced chemical vapour deposition).

PLANAR PLASMA PRE-TREATMENTUNITStandard pre treater unit availableup to 3650mm (wider available onrequest) and typically utilising 10-20Kw power supplies. The BOBSTunit gives high treatment levels atlow power densities.

ROTATABLE PLASMA POST-TREATMENT UNITStandard post treater unit availableup to 2450mm and using 10Kwpower supply. The cathodes in thisunit are rotating, allowing selfcleaning performance at high oxygenconcentrations.

NARROW WEB PLASMA UNITFor development and pilot scaleproduction, BOBST manufacture arange of narrow web, fixed cathodeunits up to 500mm wide and 5Kwoperating power. These units areused for web designing and surfacepreparation.

FEATURES

Example of % improvement of oxygentransmission on OPP with plasma

Example of % improvement of watertransmission on OPP with plasma

No Plasma Plasma

No Plasma Plasma

←←

65%

79%

*OTR cm3/(m2 d) Film Plain AlOx BIF PET 12µm ≈100 <1 >50 BOPP 20µm ≈2400 <100 >24 CPP 25µm ≈2000 <100 >20 PLA 20µm ≈850 15-30 28-57

*WVTR g/(m2 d)Film Plain AlOx BIFPET 12µm ≈45 <1 >45BOPP 20µm ≈6 <6 >1CPP 25µm ≈7.5 <7.5 >1PLA 20µm ≈300 5-15 20-60

AlOx BARRIER PERFORMANCE ONVARIOUS SUBSTRATES

*WVTR 37.8 oC, 90 %RH

BIF = Barrier Improvement Factor

*OTR 23 oC, 50 %RH

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BOBST GENERAL REGISTRONHAWKEYE

An OD beam measuring up to 4.5 ODat 25mm pitch with maximum webwidth of 4m, the design is modular,robust and easy to calibrate witheasily replaceable probes. With asimple user interface, the unit canbe standalone or integrated into themetallizer control system and givesthe choice of which functionality isrequired.

Developed by BOBST's renownedoptical group in Lausanne, Hawkeyeis designed and built to the higheststandards. When a defect isdetected, the operator is alerted andthe type of defect is logged.

Hawkeye counts and classifies holesin 3 sizes, the minimum size ofdetectable holes is between 0.1mmand 0.2mm and the unit can countup to 255 max holes for eachcategory at each sensor, with asampling rate of 500ms or larger.Any holes detected which are largerthan 2mm will be classified as ascratch. The production speed iscurrently 1000m/min.

Hawkeye also provides easycleaning, modules that can easily beadded or removed as necessary,100% functionality from 10°C to45°C and a design that is so stable, itcan go for 1 month withoutcalibration and of course, vacuumcompatibility. This new product canalso be used during the AlOx processto allow greater precision controland quality assurance.

CLEAR & OPAQUE BARRIERCOATINGS FROM ONE MACHINE

With many types of packaged foods,consumers prefer to see thecontents of the package they arebuying. This has to be balancedagainst the requirements of thepackaging. The packaging mustprotect the product, beenvironmentally friendly and costeffective, whilst also being attractiveto consumers.

BOBST has launched into the marketa vacuum coated clear barriercoating which is a potentialreplacement for existing metallizedstructures and polymer clearcoatings and combines the benefitsof a clear barrier coating applied inatmosphere, with the additionaladvantages of a vacuum coatedbarrier layer. A distinctive propertyof vacuum coating is that it requiresonly a small fraction of the thickness

of the equivalent atmosphericcoating with the barrier properties ofthe two being similar. This results ina coating which has a lower cost ofproduction.

BOBST uses a standard aluminiummetallizing machine as a foundationfor this process which results inversatility as one machine can beused for two processes withoutcomprimise. BOBST technologyuses the controlled injection ofoxygen into the aluminium vapourstream causing a reaction betweenthe two elements to producealuminium oxide (AlOx). Thiscompound can be transparent if theprocess conditions are correctlycontrolled.