Technology of the Year

MTI Polyexe
Technology: Anti-Skid Film

FORT MILL, SOUTH CAROLINA, USA -- The Association of Industrial Metallizers, Coaters and Laminators (AIMCAL) honored MTI Polyexe, Brentwood, New Hampshire, with its Technology of the Year Award for its Anti-Skid Film at a banquet on Thursday, March 15th during its March Management Meeting, March 14-18, 2007, at the Hyatt Regency Lost Pines Resort in Austin, Texas. Proprietary chemicals added during the extrusion process result in a blown film with a rough surface for building and construction applications. Ultraviolet (UV) barrier additives enhance weather resistance of the material, which is designed to become an integral part of the building rather than a disposable item. The rough-textured material not only permits safe walking in wet conditions, especially on roofs, but also protects the underlying structure from weather until final roofing materials are applied. Unlike most competing materials, MTI Polyexe's Anti-Skid Film is produced in one pass and provides better UV protection and coefficient of friction at a lower cost. It exhibits good strength properties, anchors to a wide variety of substances, and can be laminated to virtually any substrate. It also can be made in an unlimited number of colors. In addition to roofing and other construction applications, Anti-Skid Film currently is used by manufacturing companies around equipment where improved footing or traction is needed and to provide cushioning for workers who must stand for long periods. Future applications include sporting equipment and ladders where better traction or gripping action is needed. The judges were completely intrigued by the Anti-Skid Film and liked the fact that it eliminates the grit typically used in roofing films and other non-skid surfaces. They also were excited about its potential for widespread use far beyond its initial applications in building and construction especially if it costs less than competing materials. "We see all sorts of applications -- from icy steps to slippery boat decks," they concluded.

Coated, Laminated or Metallized Product Category Finalist

DuPont Teijin Films
Product: MylarŽ ECO13 Film

The finalist in the Coated, Laminated or Metallized Product Category is DuPont Teijin Films, Richmond, Virginia, for MylarŽ ECO13 Film, a polyethylene terephthalate (PET)-based lidding film for polylactide (PLA) containers used for fresh produce. Mylar ECO13 is a thin-gauge (1 mil nominal) product with a blended coating that provides a strong, yet peelable seal to PLA that does not deteriorate with time. A novel blend of sealant resins, other proprietary coating ingredients and precise control of coating thickness provide the low-temperature sealability required by PLA and balances seal strength with peelability at a thinner gauge than competing laminates and extrusion-coated films, thus reducing packaging waste. Compatibility with existing packaging machines allows end users to accelerate the adoption of sustainable PLA containers. Up until now the lack of a good lidding material has slowed adoption of PLA containers despite retailer interest in sustainable packaging. Several co-packers already are using ECO13 Film for fresh produce packages.

Judges liked the positive environmental impact of the lidding film that permits more widespread use of biodegradable PLA containers. "It's an improvement in film technology worthy of recognition," they concluded.

Coating and Laminating Equipment/Accessories Category Finalist

PRUFTECHNIK Service, Inc.
Product: PARALIGNŽ Service for Roll Alignment

A new member of AIMCAL, PRUFTECHNIK Service, Inc., Blackwood, New Jersey, was named the finalist in the Coating and Laminating Equipment/Accessories Category for its PARALIGNŽ Service for Roll Alignment. Properly aligned rolls improve product quality, increase machinery availability and decrease the probability of production loss especially on today's high-speed equipment. Other benefits include smoother running machinery and concurrent energy savings, minimization of breakdowns and the need to cope with unscheduled maintenance, and extension of felt life and time between scheduled maintenance intervals. Suitable for any industry that uses rolls in its production process, the handheld patented and patent-pending system, introduced in Germany in mid-2003 and now available as a service throughout Europe, Asia and North America, is the first roll alignment system that uses inertial measurement based on ring laser gyroscopes to determine parallelism of rolls in space. Automatic output and an integrated, easy-to-use software interface on a laptop linked to the handheld measurement device via wireless Bluetooth technology provide the maintenance technician with instructions on how to move rolls into perfect alignment. Dozens of rolls can be measured in a day. A survey using PARALIGN Service supports continuous process improvement as well as simplifies machine installation or overhaul. Future applications include perpendicular measurement of rolls and absolute elevation of rolls, which currently rely on optical instruments.

Judges believe more attention to roll alignment could solve many efficiency and quality problems. The ring laser gyroscope design appears to be a "faster, less expensive process," noted one judge. "It looks like it would be easier to use than laser alignment," added another. Although currently provided as a service, judges felt the PARALIGN system has potential for sale for in-house use by metallizers, coaters and laminators

Metallizing Equipment/Accessories Category Finalist

Applied Materials GmbH & Co.
Product: High Rate Evaporator

TThe finalist in the Metallizing Equipment/Accessories Category is Applied Materials GmbH & Co. KG, Alzenau, Germany, for a High Rate Evaporator. This system is integral in Applied's TopMet high-volume metallizing systems for web-based materials and meets demands for equipment that provides improved productivity and quality, and shortens manufacturing time. Optimized evaporation boats, a redesigned source box, and improvements to mechanical and electrical systems allow for a 20% higher aluminum evaporation rate compared to current systems. This allows metallizers to produce product with an optical density of 2.3 at rates in excess of 15 meters per second. This higher evaporation rate also enables greater uniformity as well as one-pass production of metallized substrates with a higher optical density.

Judges noted this technology improves equipment productivity, material utilization and metallization uniformity. "This development has merit due to its ability to enhance productivity," they agreed.