Comment
Meech Tackles Static Challenges in MDO Processing: Enhancing Eff iciency, Quality and Sustainability
Converter’s editor Yasmin Nolan spoke to Ian Atkinson, sales director at Meech, to discuss their new static control technology, Material Directional Orientation (MDO).
What specific static-related challenges are emerging in MDO processing and how do they impact production efficiency and product quality? Static has always been a challenge in blown film production due to highly insulative materials, friction, and heating and cooling processes. MDO (machine directional orientation) introduces additional high friction, heating and cooling, increasing static buildup.
If uncontrolled, static causes:
1. Materials tighten on the machine, hindering transfer and process efficiency.
2. Highly charged materials attract and bind airborne particles.
3. Rewinds do not fully wind. 4. Sparking can occur (Operators shocks and damage to sensitive electronics).
5. Print quality suffers due to poor ink laydown, blocked ink heads and surface contamination.
Without proper control, static affects quality, process speeds, and operator safety.
How does the number of rollers in MDO processing contribute to static buildup? MDO systems use 8 to12 rollers to heat and stretch material, altering its properties. The increased friction and then cooling, generates very high static levels. Without the right static control bars, issues like material misbehaviour, contamination, shocks and poor print quality increase. With the additional static from MDO, these problems can become critical if not managed effectively.
How do changes in material chemistry contribute to contamination issues? The push for recyclable materials has led to changes in material chemistry. Some MDO lines use different additives, such as anti-slip agents, to improve roller grip. This has led to an increase in flakes and particles detaching from the material, accumulating on surfaces
and production machinery.
Some lines require cleaning every 24 to 36 hours, with each session taking 5 to 6 hours. This disrupts high-speed production, increasing productivity losses, energy costs and labour demands. To counter this, a specialist web cleaning system is needed alongside static control solutions. Meech has developed an adapted VacClean web cleaning system to effectively remove contaminants and minimise disruptions.
How do the four key MDO processes— heating, stretching, annealing and cooling—enhance material properties? Meech’s research confirms MDO improves PE material properties. The process: • Increases mechanical resistance (stiffness). • Enhances gas barrier properties (moisture and oxygen retention for food freshness).
• Improves gloss and wettability (better printing performance).
This allows single-material packaging, making recycling feasible and reducing packaging weight. Applications include stand-up pouches, paper substitutes, graphic arts, diaper films and self-adhesive labels.
Are static-related challenges unique to specific materials or an industry-wide issue?
Static has always been a challenge in roll-to-roll web systems using insulative film materials. However, increased stretching, heating and cooling in high-productivity setups amplify static generation to unprecedented levels.
Beyond contamination control, what additional benefits come from an advanced static management system? Meech’s static neutralisation and contamination removal solutions benefit blown film lines by: • Preventing unnecessary stoppages, optimising production runs and reducing energy losses.
• Minimising contamination and static buildup on materials and equipment.
• Offering Smart Control modules that monitor and control multiple static control devices remotely. This is especially useful for large lines where operators cannot easily access DC bars. Smart Control enables real- time monitoring, programming, adaptive settings and data logging.
How adaptable is your system to different manufacturing setups and materials?
Meech’s solutions are customisable based on production layouts, web widths, speeds, mounting spaces and bar-to-web distances. Web cleaning systems can include pneumatic engage/disengage mechanisms for easier initial setup. PLC interfaces also allow seamless integration of web cleaning and static control systems into machine HMIs.
Which industries have successfully deployed these solutions? Meech has thousands of installations worldwide for roll-to-roll web cleaning, both contact and non-contact. Static control bars are widely used in blown film machines and end-user equipment.
For blown film line optimisation with MDO, Meech collaborates with major international machinery manufacturers. Active trials and bespoke solutions have shown excellent results, improving production uptime and material quality through targeted equipment installation.
8
March 2025
www.convertermag.com
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