Auto Gauge is Easy to Install, Use, Maintain
Billed as a reliable and effective solution for controlling transverse direction film thickness.
Unveiled at K 2022 in October, the TDK-500 Insta Gauge Automatic Air Ring fromD.R. Joseph (DRJ) is said to be a reliable and effective solution for controlling transverse direction film thickness, which ensures a uniform film gauge on blown film extrusion lines. Developed with Techflow Design of Canada and Switzerland’s Kundig Control Systems over a five-yr period, the TDK-500 has a tool-less access method for cleaning the narrow primary lip exit after process residues build up. This helps to avoid partial air flow blockage.
Moreover, the entire lip set can be removed and replaced in a matter of minutes while the air ring remains installed on the extrusion die. Meticulous design efforts have led to a unique modular design giving users what DRJ says is the industry’s best flexibility in production versatility. The TDK-500 control system can also be seamlessly integrated with the DRJ 3G IBC Control System for a single point of control for all bubble cooling.
The TDK-500 improves on the implementation of airflow modulation for gauge control by using secondary lip air modulation where the velocity changes are more effective. Firstly, this leads to a quicker reaction time and higher control resolution than primary lip air modulation. Secondly this fully permits the primary lip to achieve its job of holding a stable bubble by isolating the primary lip cooling from the gauge control air adjustments.
Photo: D.R. Joseph
Controlling transverse direction film thickness significantly reduces resin costs by only producing the required film gauge. It also simultaneously guarantees that thin spots do not effect the film integrity or processability.
The air flow from each control zone is constrained in an independent channel that extends to just before the secondary lip exit. This eliminates zone cross mixing and provides a more direct and effective control response to the film. Internal components are specified to the highest degree for consistent and reliable performance, even in harsh running conditions. Safety features are built in to prevent damage and costly downtime.
The unit was designed for easy component swap-out, to expand the range of products that can be ran on a single air ring. The lip set can be instantly swapped without tools, and without elevating the air ring off of the die, a time- and cost-saving measure that expands the versatility of the air ring. Optional weight reduction is available for easier lifting from a 3D printed polycarbonate cooling collar (patent pending).
The primary lip adjustment has been redesigned to facilitate set-up and reduce the intimidation factor of adjusting an air ring. The TDK-500 features a single adjustment point with a reference lever to adjust the primary lip.
The benefit with the easy adjust lever is that there is now a reference point for the primary lip setting. This facilitates start-up by providing a setting that can be recorded and repeated for various jobs and SOP. There is no guess work involving the current set point for the primary lip with a visual reference marker.
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