Spectra HETM Ultra REPLACEMENT

Existing drying system is removed/disconnected and replaced with a Spectra HE™ Ultra system that is designed to be installed on the existing frame. It usually takes only part of the footprint of the existing equipment. The new installation will meet the customer goals for maximum performance from the invested capital.

Case 1 – Spectra HE™ Ultra Dryer Replacement/Retrofit
Objective: Dry water-based inks and coating of 22 gsm, 10% solids at a line speed of 75 m/min by one station instead of having three coaters and three drying station to accomplish the same objective.

Here’s how HTI helped a specialty paper and film material producer address drying practices for increased efficiency with a single-stage Spectra HE Ultra dryer unit.

This customer wanted to streamline a process for printing with water-based inks at a heavier coat weight than they typically use. The standard business practice was to lay down two to three coats of ink at 100% coverage each to obtain the needed color saturation. Spectra HETM Ultra, HTI’s patented ultrasonic drying technology, offers an opportunity to improve the efficiency when drying water-based inks and coatings on rotogravure press operations.

Goals
  1. More efficient drying of heavy aqueous coating application
  2. Replace three drying stations with one at the following operating parameters:
    – Wet weight, 22-24 gsm
    – Percentage of solids, 10-12%
    – Line speed, 75 m/min

Solution
Custom designed and built an eight-slot ultrasonic dryer, which was installed ahead of the existing drying section.
Result of the installation
  • One Spectra HE™ Ultra drying achieved the goals listed above with a single dryer section.
  • It replaced three coating and drying decks of the existing system
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Case 2 – Spectra HE™ Ultra Replacement/Retrofit
Objective:

Provide successful transfer of the coating operations from solvent based to water-based release liner formula and achieve the same quality, line speed (250 m/min), and production schedule of existing solvent-based coating operations.

An HTI customer that produces adhesive based products transferred its coating operations from solvent-based to water-based coatings. The formulation change was necessitated by strict environmental regulation. As a result, the throughput of the equipment was reduced by the factor of 3. This also resulted in the need to extend the production operations from 8 hour shifts/5 days/week originally to an extended 24 hr/ 6 days/ week schedule.

One of HTI customers who produces various adhesive based products, transferred the coating operations from solvent based to water based coatings. It was necessitated by strict environmental regulation. As a result, the throughput of the equipment was reduced by the factor of 3. This also resulted by setting up 24/6 operation vs 8/5 originally.
Here are the design basics:
Water based release liner:
  • Web width – 1.4 m
  • Wet weight – 7.5 gsm
  • Solids – <0.5% – ≤1.5%
  • Current line speed – 80 m/min
  • Desired Line speed – 250 m/min
Solvent based release liner:
  • Web width – 1.4 m
  • Wet weight – 7.5 gsm
  • Solids – <0.5% - ≤1.5%
  • Current Line Speed – 250 m/min
  • Required line speed –to remain the same

Results:

Based on the results of the commercial scale tests HTI offered and installed its drying system that would take only 1/2 of the available area. The remaining original drying system was disconnected. HTI system was installed inside of one of two existing dryer hoods. (see the photo above). The installation allowed customer to meet environmental regulations, and recover the lost production rate. This reduced cost of the product, and brought the operation back to the original production schedule. This was a welcome relief to the extra labor and utilities costs.
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