Die Control Wizard with FILMEX II

All about Die Control Wizard

Nowadays, manufacturers of flexible packaging are facing a wide range of challenges in the cast film extrusion business. In a highly competitive and dynamic market they continuously have to increase their production efficiency and quality. At the same time they need to react quickly in managing bigger film varieties and smaller orders to satisfy their customer’s needs. Hence, product changes in daily film production schedules become increasingly vital to secure the business and the ability to compete.

The problem is: Based on present machine technologies every product changeover involves manual die bolt adjustment of the cast film die lip at full output, until acceptable profile tolerances are achieved. Only then conventional automatic die control systems can be started. The procedure essentially needs highly skilled operators and takes long time, involving large quantities of scrap. Furthermore, even the best manual pre-adjustments bear the risk of producing inconsistent film qualities. In a nutshell: time, money and resources are wasted.

W&H’s DIE CONTROL WIZARD (DCW) is a game changing solution to erase this status quo. It allows fully automatic width and thickness changes in shortest time without any manual die adjustment needed. Being independent from the operator, the system hence ensures repeatable and consistent film quality. So it increases the flexibility and the efficiency of the machine, plus its ease of use at the same time!

• Fastest changeover times give you the ability to react quickly and flexibly to your customer inquiries
• Superior film profile control leads to excellent web and process stability
• DCW offers potential for line speed increase, as well as for further savings due to reduction of edge trim losses

Compared with other systems DIE CONTROL WIZARD saves up to 70% time and scrap. E.g. where typically a thickness change previously took more than 30 minutes of manual adjustments with scrap involved, Die Control Control Wizard today performs the job in less than 7 minutes.. A complete width change from one production job to another can be performed within 20 minutes, where in the past this meant up to 90 minutes of manual work for the operator. FILMEX “ and Die Control Wizard (DCW) are hence providing significant additional revenue potential and contribute to a more sustainable production.