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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