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Formulas | Material Handling | Static Control
These formulas are the most commonly used in the plastic film business. By consulting the information contained in our brochures, these formulas will make it easy to calculate various requirements. Conversions are approximate based on yield values issued by the manufacturer. (The word "Label" may be interchanged with "Patch" or "Tag")
To determine: CONVERTING SQUARE INCHES INTO POUNDS OF MATERIAL
SI ÷ YIELD = POUNDS
To determine: POUNDS OF FILM NEEDED
Length x Width of label x Number of labels needed divided by Yield of gauge required.
L x W x Labels ÷ YIELD = POUNDS NEEDED
To determine: NUMBER OF ROLLS NEEDED
Length of label as it feeds into machine in inches ÷ 12 x Number of Labels needed gives lineal feet needed. Divide by Roll length listed on price sheet.
L ÷ 12 x Labels ÷ ROLL FOOTAGE = ROLLS NEEDED
To determine: COST PER THOUSAND SQUARE INCHES
PRICE PER POUND ÷ YIELD IN THOUSANDS (Point off 3 places to left, i.e. 21,040 becomes 12.040) = $ PER MSI
To determine: COST PER THOUSAND (M) LABELS
Multiply Length x Width of one label x prefigured MSI prices on price list. (This is an easy way to compare costs of various gauges and types of plastic films)
L x W x $MSI = $ PER M LABELS
Material
Handling
Quality Control
Multi-Plastics, Inc. has taken some standard but very important precautions
to assure you receive your film in good condition. As you will see from
manufacturing and through most of the converting process, our materials
are suspend packed to avoid any damage to the material. In fact, the materials
are not even handled by hand until the rolls have been slit and are ready
to be removed from the slitters. Then the rolls are carefully packed flat
on their sides, ready for shipment.
Before, during and after converting of our products, Multi-Plastics, Inc.
performs a series of quality tests to assure our customers that they are
receiving the highest quality film available.
Master rolls suspend
packed with headers
|
Master
rolls suspend packed with headers
|
Slit
Suspend
|
 |
 |
Rolls are
suspended on steel shafts called mandrels during the converting process.
The mandrels are then carefully removed from the slitters using an overhead
hoist and put on a mandrel holder. At this point the rolls are then slid
off the shafts and packed onto the skid. This is the first time the rolls
are handled by hand.
Skids are
carefully packed with core posts through every roll andcardboard interleaved
between each layer of rolls.
1)
Corrugated sleeve, top sleeve &
bottom tray.
2) Ship to Labels - one on the bottom
tray and one either on top tray facing
out or top lid.
3) Product Information Label - Clear,
easy to read and total product
information.
back to top
Material Receiving and Handling
All material packaging should be evaluated at the time of the delivery. Any suspected damage to materials should be documented at the time of delivery and noted on the bill of lading. It is also recommended that you report the damage through your proper company channels just in case there would be a need for replacement materials.
Unpacking to Handle and Use Rolls
1) Straps are removed from skid.
2) Remove top lid and save to re-cover material to protect it against dust & dirt contamination when restoring.
3) Carefully lift and remove surrounding skid sleeve. (Do not use a knife to cut sleeve off.) Save sleeve to repackage and restore materials.
4) Remove core posts from center of rolls are needed.
5) Carefully slide roll on the cardboard packing to the edge, then carefully grab roll as seen in the below picture.
Things to watch out for
1. Normally the presence of lines indicates either a slight gauge variation
or compressed rolls from double stacking of skids during shipments. Usually
only the bottom rolls will be compressed when double stacking occurs.
Any visible problems with the rolls while they are still on the skid and
before they are removed should be reported through your proper channels.
2. Dropped Roll (crushed core)
3. Telescoped rolls are caused by poor handling of loosely would rolls.
No matter if the roll is would loose or tight using the proper handling
technique will eliminate this problem.
4. Dirt, glue & ink contamination. This is a common problem and can
cause many different problems; rip outs, cutting back of rolls, etc.
5. Scuffed rolls cause rip outs. Dragging, sliding or setting things on
rolls can all cause scuffing, leading to rip outs.
Loading
Materials onto the Machine
There are many ways of handling rolls to avoid damage. Below are some
standard methods used to handle roll stock. Multi-Plastics, Inc. recommends
that you consult a local material handling company or consultant to explore
what will work best for you.
Do's
and Don'ts
Materials should NOT be laid flat on the floor unless you are trying to
reduce a static charge. (In the event of this situation, make sure the
floor is clear of debris contamination.)
If you have to double stack rolls of material, be sure to interleave cardboard
in-between rolls. It is preferred that rolls are stored standing up prior
to being put on the machine. This method will allow you to insert the
roll shaft and handle the roll avoiding telescoping, roll contamination,
scuffing of edges and possible personal INJURY!
Avoid setting items that could contaminate or damage rolls directly
onto the material.
back to top
Restoring & Reusing Materials
Restoring and reusing old inventories is a very important part of running
a profitable business today. Holding butt rolls, odd sizes, or cosmetically
unattractive bad materials can cost your company money... Normally the
additional (extra) costs incurred have not been factored into the job
the material was originally purchased for. Restoring materials for further
use is very important.
When restoring materials you should use the same packaging techniques
as discussed above. This will assure you that the next time you go to
run the material that it is in good condition.
Running non-standard sizes that are used once in awhile in place of the
standard size can help turn your old inventories and save money.
This is a diagram of two racking systems that you can build in house to
help reduce damage.
Material
Returns
Multi-Plastics, Inc. has designed a total quality control program to reduce
to a minimum the potential of bad material getting through our system
and into our plant, however, occasionally bad rolls make it out into the
market. In the event that this occurs at your plant, Multi-Plastics, Inc.
would like to ask you, our Customers / Partners, to do the following:
1) Notify your plant manager or supervisor immediately of the situation
so they can contact their Multi-Plastics Sales Representative in order
to assess the problem. All creditable returns must be authorized by Multi-Plastics,
Inc.
2) Handle the suspect material with the exact care and handling techniques
as explained above. Remember we can only credit and address material problems
that we can identify. Should the rolls be destroyed by improper handling
and deemed unsalvageable it's possible that no credit will be issued.
3) Any materials authorized for return should be re-packed in the same
fashion as indicated above. Although the materials may be suspect of a
defect of some sort, depending on the problem, they may be subject to
a battery of testing or re-slit and used again. This can only occur if
the materials are returned in good condition.
Static
Control
What is Static?
Despite it being a widespread problem, static still remains very difficult
to understand and deal with. The biggest problem: you can't see, touch
or smell charges. In addition, static may be present one day and disappear
the next, only to reappear again because variables affect the level of
static electrification.
Whenever two solid materials come into contact and then separate, a transfer
of electrons from one material to another takes place. As a result, one
material acquires an excess of negative charges and the other material
an excess of positive charges.
The polarity
of the charges on each of the materials is not accidental and depends
on the materials in the pair. Contrary to popular belief, static electrification
is never caused by just an air flow hitting a solid surface, however,
a radical temperature change combined with either Hot n Dry or Cold n
Dry conditions can cause static to flare up.
The electrostatic charging has a measurable effect when at least one of
the two contacting materials is a non-conductor. Non-conductors such as
PLASTICS and rubber materials maintain acquired static charge for a long
time since the charges cannot be conducted away, even if the material
is in a direct contact with grounded metal. Information to know: 1. Uncharged
materials have an equal amount of electrons. 2. A negative charge will
repel a negative charge as will a positive charge repel itself. 3. Negative
charges attract positive charges, ala a magnet. 4. Static electricity
exists everywhere. Knowing and understanding this will allow us to work
towards reducing and controlling static in our production environment!
Static Causes Havoc
As machine technology advances and the speeds increase to meet the changing
demands of service and competitiveness, the static phenomenon will become
increasingly more important to understand. Static has been around since
the first electric powered envelope machine and has caused havoc in production.
Most typically seen problems are: patches flying, materials won't cut,
poor quality or just bad production.
For years, plastic window films have been named as the culprit in many
of these situations when in reality the machinery played an intricate
part of the static equation as well. Knowing how to identify static can
save both time and money. The best and most inexpensive way to do this
is with devices that measure static charges, either a Static Meter or
a Static Locator. Remember, the best Defense is sometimes an Offense.
Detecting Static
There are many different operating tests for static in the field. In most
cases, the most effective is a device designed for detection. It is recommended
that the investment be made for a Static Meter. This will provide the
most effective means of detecting static.
Other means of detection are less scientific and require no equipment
such as: 1) Looking for miscued window patches on the envelope. 2) Patches
flying at high speeds can indicate the presence of static. 3) Unwinding
about 1 foot of clean film, then observing if the roll snaps back or repels
itself (remember, static on the roll is only one part of the equation,
the other variable is what static charge exists on your equipment). 4)
Looking for dust (dirt) particles accumulating on the roll can indicate
the presence of static, however, it is the level of static that is important.
We must not forget static exists everywhere! It's the level of the static
charge!
Controlling Static
There are many ways to combat STATIC, everything from home remedies to
ionized air blowers. It is identifying what will work best for you in
your production environment that is the question. Multi-Plastics, Inc.
recommends you contact the static experts at the end of this page, however,
below you will find the five most common methods in reducing static to
a manageable level:
1) Old Faithful (the quick fix) - You can reduce static by carefully
placing a roll of plastic on its side, flat on a concrete floor prior
to being put on the machine. This will help reduce the static charge to
a lower, more manageable level. Anti-static tinsel is another quick fix.
By simply placing copper tinsel in the problem area and then properly
grounding it, you can reduce the static charge at that spot.
2) Preconditioning - One method is to precondition the substrates
for a few days in the environment in which it is going to be run. Using
the preconditioning method will help avoid sharp moisture or temperature
changing that are known to cause static to flare up.
3) Humidification - Moisture in the air can control static charge
in your plant. By installing a humidifier you can reduce your static problems,
but at the same time causes other concerns. Raising the relative humidity
levels can cause equipment to rust and can prove to be a costly long term
solution.
4) Electrically Activated Devices - Commonly referred to as Static
Eliminators. Although they don't really eliminate static they are one
of the most widely used devices to control static in any production environment.
Static Eliminators are a cost effective way to break down positive and
negative ions to runable levels.
5) Ionization is the process in which air molecules are broken
down into ions of both positive and negative charges. (An ion is an atom
or molecule which is electrically unbalanced.) The generated positive
and negative ions interact with a static laden surface in such a fashion
as to reduce or completely neutralize the static charge by returning the
static charges to electrical balance. This method is the most effective
static control available, while also the most costly.
Static Experts
Although Multi-Plastics, Inc. has put this information together, we are
far from being static experts. However, what we can do is provide you
with some names of companies that are regarded as static experts as a
starting point.
Takk Industries Incorporated
8665 East Miami River Road
Cincinnati, OH 45247
www.takk.com
Phone:
513/353-4306
Fax: 513/353-4315
Tantec Incorporated
630 Estes Avenue
Schaumburg, IL 60193
www.tantec.com
Phone: 847/524-5506
SIMCO
World Headquarters
2257 North Penn Road
Hatfield, PA 19440
www.simco-static.com
Phone: 215/822-3600
Fax: 215/822-6316
Alpha
Innovation
237 Washington Street
Marblehead, MA 01945
www.stopstatic.com
Phone: 781-639-9796