Replacing your QC-methods with only one technique

APLAIRS® (Analysis of Plastics by Infrared Spectrometry) is a new quality control concept in the modern polymer industry. With this concept, conventional quality control methods can be replaced with only one spectroscopic technique. Additives, physical properties, co-polymer and multi-layer composition, thickness as well as degree of polymerisation can be measured simultaneously. The speed of measurement allows real-time monitoring and therefore enables closed-loop control.

Measuring principle

A continuous flow of cast or blown film with a maximum width of 150 mm runs through a special construction of the APLAIRS® system, which is equipped with an FTIR spectrometer and a specially designed software.

APLAIRS® focuses on film measurements, although infrared spectroscopy can also be applied to melt samples. Measuring in the film has more advantages than measuring in the melt:

• Films are closer to the end product and for that reason a direct link is made with standard QC Analysis
• Physical properties not only depend on chemical components but also on the morphology of the resin. The morphology and chemical information concealed in the spectra can be abstracted by APLAIRS® and l inked with physical test data.
• Thickness of films can exactly be accurately determined. In addition, it is possible to determine the composition and thickness of different layers in co-laminates.
• Other analytical techniques can be far easier linked to a film line, making the assembled configuration inexpensive.

Software

The software utilised by APLAIRS® has many facilities: -

• The calibration facility is used to link spectral data with QC-lab data. The links which refer to the calibration models are tailor designed according to customer request. The calibration models are used to predict the QC-data from the spectrum of the moving film.
• The predicted QC-data is displayed in real-time on the monitor and can be represented in flow charts. The flow chart enables the operator to follow the process precisely
• In addition, the predicted data can be sent to the process computer to achieve a fully automatic closed-loop control

Application

APLAIRS® can be applied to a whole range of polymers, co-polymers and blends: PS, PP, LDPE, LLDPE, HDPE, PMMA, NYLON, PC, EVA, ABS, PB, PET, EPDM, PE/PP, PC/ABS, PPO/PS/NYLON, PET/PE etc. to determine - the chemical composition in the resins, varying from functional group analysis to co-polymer composition anti-oxidants, UV absorbers, slip agents, stabilisers, fillers, extenders, impact modifiers, speciality modifiers, processing aids, flame retardants and any other additives - the extruded film thickness, and the thickness of separate films in multi-layered structures - physical properties like density, melt flow index, splittyness etc.