Blown and Cast Film Extrusion Course

March 12-14
Tuesday, March 12, 2019 to Thursday, March 14, 2019

Participants in this course will learn about common resins used, and equipment from the extruder through to the winder utilized in both Blown and Cast Film applications processes.

March 12-14, Savannah, Georgia USA A 3-Day Course Providing a Better Understanding of Film Extrusion Technology

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Attendees will benefit by receiving a better understanding of film extrusion technology and the ability to use this information to improve existing film extrusion processes.

In this introductory-to-intermediate level course, participants will learn about common resins used, and equipment from the extruder through to the winder utilized in both Blown and Cast Film applications processes. In addition there will be discussions on troubleshooting problems such as occurrence of gels, and winding defects. Experts in the field will discuss commonly faced problems in the cast film and blown film industry. Please bring your questions to the class, as it is conducted in an interactive format with the attendees.


Who Should Attend?

  • Extrusion Engineers, Extrusion Supervisors, and Packaging Engineers
  • Extrusion Line Operators
  • R & D Personnel
  • Technical Service Personnel
  • Technical Directors, Superintendents, and Technical Assistants
  • Blown Film Converters
  • Cast Film Converters
  • Equipment and Resin Suppliers
  • Auxiliary Equipment Suppliers
  • Process Engineers
  • Quality Control Personnel
  • Plant Managers
  • Set-up Technicians
  • Purchasing Managers

For maximum benefit, participants should have a very basic knowledge of film extrusion coating technology and the ability to use this information to improve existing film extrusion processes.

This course is designed to help participants learn to:

  • Understand properties and processing issues of various film resin
  • Identify capabilities, specifications, and limitations of various film extrusion & winding equipment components
  • Evaluate equipment and resin requirements for differing co-extrusion application
  • Methodically approach processing problems and gel issues during extrusion
  • Comprehend terminology, general theory, and troubleshooting techniques used in designing extrusion screws
  • Address safety concerns in extrusion processes

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, and Product quality control personnel.

Instructors for Blown and Cast Film Extrusion Course

Scott Marks - DuPont Performance Materials - Course Chair

Scott Marks is a Senior Technical Consultant at DuPont. He holds degrees in mechanical engineering and business administration from Rutgers University of New Jersey. Since graduating from Rutgers in 1982 and joining DuPont, Scott has worked in several engineering and technical positions. From 1986 through 2008, Scott worked for DuPont's packaging materials business covering the Asia-Pacific region performing technical troubleshooting, market development, application development, training (both internal and external), and mentoring new sales personnel. His processes background includes extrusion coating and laminating, blown film, and cast film, including multilayer co-extrusions and end-use packaging equipment. He has also worked with coextruded sheet extrusion and tubing extrusion. Since April 2008, Scott has worked on several revitalization projects in DuPont's Lab Extrusion Facilities specifying and commissioning new equipment. He is a key member for global technical support of co-extrudable adhesive polymers, consults on technical applications with North American extrusion converters, and conducts global training programs internally and externally for technical proficiency.

Since 1984, Scott has been as a member of TAPPI's International Flexible Packaging & Extrusion Division (formerly called PLACE in 2001-2016, and PLC in 1984-2000). He was co-chair of the International Planning Committee, has held all the Division Council positions for PLACE, remains a Chair Emeritus of the Division, and serves as Council Member At-Large. Scott has served multiple times as session chair in the Tappi PLACE conference, presented papers, and currently chairs the Peer Review committee for the conference. He has been an instructor for the Extrusion Coating Short Course and the Film Extrusion course for many years.

Andy Christie - SAM North America

Andy Christie is currently Managing Director of SAM North America. This company is the sales, service, and support group of SAM (Sung An Machinery), a South Korean converting machinery manufacturer of printing, coating, laminating, and extrusion coating machinery. SAM North America, is sales and service organization for North and South America, and operates a state of the art high speed co-extrusion coating and laminating line with up to 14 layer co-extrusion for converter customers product development needs.

Prior to working for SAM, in 2002 had Andy founded Optex Process Solutions, an extrusion process consultancy. Optex provided extrusion system design and technical process support to the continuous extrusion converting industry, particularly coatings and films. Optex worked with OEM's as well as packaging and specialty converters worldwide until 2016 when it discontinued operation due to the growth of SAM's American business.

Prior to starting Optex, Andy spent 15 years with Black Clawson Converting Machinery in engineering design, applications, and management. After graduating with his BSME degree from Rochester Institute of Technology he held various machine design engineering positions at several companies.

Andy has been active in SPE & TAPPI where he has authored, co-authored, and presented at many conferences and symposiums. He is a past Chair of the TAPPI Film Extrusion Committee, and has been a co-instructor at several TAPPI short courses. He is the inventor of three US Patents relating to screw design and a co-extrusion feed-block, and has an additional patent application pending for an improved extruder screw mixing device. Andy lives in the heart of New York State with his wife Mary. They enjoy outdoor activities with their two sons families including their three grandchildren.

Christine Ronaghan - Cloeren Incorporated

Christine Ronaghan holds BE and ME degrees in Polymer Engineering from Stevens Institute of Technology as well as an MBA in Management of Innovation and Technology from Rutgers University. She spent many years at Davis-Standard LLC responsible primarily for extrusion and screw design for Cast Film and Extrusion Coating. Chris is currently Technical Director at Cloeren Incorporated, working on feed-block and die design as well as providing extrusion process support industry wide. She has been involved in various technical organizations, including Tappi and the Society of Plastics Engineers among others. Chris has been a speaker in a variety of training classes, and has presented papers in a number of conferences throughout her career.

Sam Iuliano - Nordson/Extrusion Dies Inc.

Sam Iuliano has 25 years of experience in the industry for extrusion dies and related components. He graduated in 1992 from McMaster university in Hamilton, Canada with a Bachelor's degree in Engineering and Management, specializing in Chemical Engineering. As Senior Technical Manager at Nordson EDI, he consults with processors to provide recommendations for high performance extrusion tooling and brings the voice of the customer back to Nordson EDI for new product development. Sam is a frequent presenter at industrial conferences and a long-time TAPPI Extrusion Coating Short Course Instructor.

Laura Martin - Brampton Engineering

Laura first joined the plastics industry as an undergraduate in Chemical Engineering, and has since worked in numerous technical and market segments including compounding, injection molding, blow molding, profile extrusion, and extrusion lamination, for rigid packaging, automotive, and electrical applications. Since joining Brampton Engineering as Director, Process & Rheology in 2015, she has enjoyed learning about blown film extrusion, particularly multi-layer film structures for food packaging. At BE, the Process & Rheology Team is charged with ensuring that the provided equipment is optimal for producing the required films, which includes communicating with the potential customers prior to quotation, specifying the right components, designing the SCD® co-extrusion die, and providing process expertise afterwards. Laura is also a key member of the Product Development team behind the innovative new single-entry, streamlined Vector® air ring. She is a firm believer in asking the right questions and using the appropriate analyses and visualizations to enable the best data-based decisions.

Bill Hellmuth - Davis-Standard

Bill has over 38 years in the Film industry. He spent the first 10 years as a Process Engineer and Production Manager, working with flexible PVC packaging films, modified PE stretch wrap films, and TPU blown films. The past 28 years, Bill has worked in Technical Sales and Marketing for Gloucester Engineering (now part of the Davis-Standard Group), supporting Blown Film machinery globally. Bill is a profession member of Tappi and SPE, and had published numerous papers on Blown Film equipment and processing. Film has taught in a number of training seminars around the world. Bill is a past chair of the Tappi Film Extrusion committed, and has been a co-chair of the Film extrusion class.

Rory Wolf - ITW/Pillar Technologies

Rory Wolf is currently the Business Unit Manager for ITW's Pillar Technologies, Hartland, WI, USA and a recognized industry resource in the field of polymer surface modification. He has 31 years of experience within international positions in the plastics and packaging industries, and specific experience in polymer-based flexible packaging, polymer surface modification systems, and printing industry segments. Prior to joining Pillar, Rory worked for several companies including Enercon Industries where he championed the growth of plasma treating technologies. He has published 33 technical papers,41 industry articles, and 3 books on the topic of plastic surface modification by atmospheric plasma technology. Rory is a professional member of Tappi, SPE, and AIMCAL.

Ted Schnackertz - NDC Infrared Engineering

Ted has over 40 years of experience in the process control industry with real-time on-line measurement and control systems in the paper and plastics industry. He has held positions as a field engineer, systems engineer, project manager, applications engineer and currently is the OEM Sales Manager for NDC. Ted studied electronics engineering at CCNY (New York) and electrical engineering at Lowell Institute of Technology in Lowell, MA. Ted is a TAPPI member and has instructed in a variety of Short Courses and delivered TAPPI PLACE conference papers since 1998.

Jim Stobie - Macro Engineering

Jim has been involved in the Film and related industries throughout his career. Prior to his current position at Macro Engineering, held sales positions with Sherman Treaters, and Brampton Engineering. Jim was a Sales Manager for Macro Engineering, and then Brampton Engineering. He returned to Macro Engineering to become VP Sales & Marketing and then moved up to his current role as CEO of Macro in March 2013. Overall, Jim has over 30 years in the film and sheet extrusion machinery sector, with the past 19 years spent in leadership roles. Jim is a former President of the Plastic Film Manufacturers Association of Canada and an active member of TAPPI and SPE.

Joe Lutz - Pelletron Corporation

Currently the R&D Manager for the Pelletron Corporation, Joe has a decade of experience developing bulk material handling products and processes for the plastics industry. He earned his B.S. degree in Mechanical Engineering from West Virginia University and began his work career developing novel automated manufacturing equipment. His career at Pelletron began as an R&D Engineer spending a lot of time in the pneumatic conveying test lab but over the years he has designed and commissioned countless pneumatic conveying and dedusting systems in the “real world” too. This combination of experience makes him a unique asset to the industry.

Scott Weber - Celanese

Scott Weber is an Application Development and Technical Support Engineer at Celanese working in their EVA Polymers group. Scott holds a BS in Mechanical Engineering Technology which he earned at Miami University of Oxford, Ohio. As an industry veteran, Scott has over 25 years of experience in extrusion coating and lamination, blown and cast film which focused on flexible packaging applications. Scott currently has one patent and has been involved in the development of other products that have also been patented during his career. Continuing to help others develop and grow in the industry is very important to Scott. This has led him to become involved with TAPPI. Scott has chaired the TAPPI Extrusion Coating Short course for the past four years and will be chairing again in 2017. Scott resides in West Chester, Ohio his wife Lori. Together they enjoy spending time at Lake Cumberland, Kentucky with their family and friends. Scott is the proud father of two daughters and grandpa of three grandsons.

R. Duane Smith - Davis-Standard

R. Duane Smith is Process Manager, Web Handling & Specialty Winding at Davis-Standard, LLC.  Duane has over 45 years of experience, and is widely known throughout the paper, film and nonwoven industries for his technical knowledge on web handling and winding. He has been awarded two patents in winding. Duane has made over 85 technical presentations, and published over 30 articles in major international trade journals and magazines. He is the author of the Winding Chapter of the TAPPI Film Extrusion Manual and is currently working on the Unwinding/Splicing and Winding chapters of the upcoming 5th edition of the TAPPI Extrusion Coating manual. He has been an instructor at 18 TAPPI short courses and has published three books through TAPPI Press. He is the editor of TAPPI Press' first e-book, The Ultimate Roll and Web Defect Troubleshooting Guide. Duane has been active in TAPPI for over thirty five (35) years. In 2011 Duane was named a TAPPI Fellow by the TAPPI Board of Directors.

Lou Piffer - Davis-Standard

Lou Piffer is a Senior Sales Engineer for Davis-Standard LLC, Converting Systems for the past 28 years. He received a BS in Chemical Engineering from Drexel University in 1985. Lou is a former Tappi Chairman and Leadership award winner. He has taught at the extrusion coating course for over 15 years. Lou supports the Extrusion Coating and Cast Film product lines for Davis-Standard.

Richard Kanarski - Davis-Standard

Rich Kanarski is a chemical engineer who began his professional career in polymer extrusion process development. He held a process engineering role at Coperion, responsible for conducting twin screw extrusion technology scale-up, various process developments, and developing research programs serving the polyolefin, bio-plastics, food, ceramics, and pharmaceutical industries. Rich than has expanded his process expertise by joining Davis Standard where he focuses on the process development of larger scale polymer converting lines, including the single screw extrusion technology and many of the various upstream and downstream technologies composed in cast film and extrusion coating products. His responsibilities extended on projects across the world and correspondences with people of various cultures, gaining business experiences with a vast network of other polymer professionals and industrialists. Rich has been a member of the SPE Extrusion Division since the beginning of his career in the plastics industry and now serves on the Board of Directors Extrusion Division.

Vipul Padman - Berry Global

Vipul Padman is a Sr. Research Scientist at Berry Global in Mason, OH. He received his Bachelor's degree from Pune University, India in Polymer Engineering and his Ph.D. from the University of Southern Mississippi in Polymer Science and Engineering. He has also received an MBA degree from Kelley School of Business, Indiana University. His research experience covers various aspects of polymer rheology, cast extrusion processing, extrusion lamination, material selection, formulation design and simulation. While working in the rheology field for more than a decade; he has successfully derived and established several structure-property relationships for a wide range of polymer systems, such as solutions, gels, and colloids. His current focus is largely on understanding polymer melt behavior during extrusion processing. He has successfully established structure-processing relationships of polymer melts and developed models that can predict processing behavior. His expertise includes designing rheological tests and using simulation software to resolve processing issues.

Norm AubeeNorm Aubee -NOVA Chemicals

Norman Aubee graduated from the Plastics Engineering Program at the Northern Alberta Institute of Technology in 1984. Norm joined NOVA Chemicals in 1985 and performed various functional roles in the technical service laboratories. In 1991 Norm transferred into NOVA Chemicals flexible packaging technical services group for polyethylene products. Over the past 30 years, Norm has focused on various areas within flexible packaging including; stretch film and food packaging with specific emphasis on moisture barrier and oxygen barrier applications within the food packaging segment. In addition to the technical service responsibilities, Norm is involved with NOVA Chemicals in the areas of field market development and application development for flexible packaging applications.

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, and Product quality control personnel.

Blown and Cast Film Extrusion Course

This course is brought to you by the International Flexible Packaging and Extrusion Division of TAPPI.

COURSE AGENDA - Downloadable version

Andaz Savannah Hotel - Savannah, Georgia USA
14 Barnard Street Savannah, GA 31401

Tuesday, March 12, 2019
8:00 - 8:15 Welcome / Opening Comments / TAPPI Antitrust

8:15 - 9:15 Introduction to Product Structures - Scott Marks, DuPont

9:15 - 10:00 Polyethylene Resins for Film - Norm Aubee, Nova Chemicals

10:00 - 10:15 BREAK

10:15 - 10:45 PE Plastomer Resins for Film - Wes Hobson, Dow Chemical - NEW TOPIC!

10:45 - 11:45 Special Resins for Film - Scott Marks, DuPont

11:45 - 12:45 LUNCH

12:45 - 1:30 Polypropylene Resins for Film - Francisco Carlos Ruiz, Braskem

1:30 - 2:15 Rheology and Hot Stage Microscopy Vipul Padman, Berry Plastics - NEW TOPIC!

2:15 - 2:30 BREAK

2:45 - 3:30 Extruders and Configurations for Blown vs. Cast - Rich Kanarski, Davis-Standard

3:30 - 4:15 Cast Film Feedblock Technologies: Fixed Plane, Movable Vanes, Layer Multipliers and Nanolayer, - Christine Ronaghan, Cloeren Incorporated

4:15 General Q & A with any instructors from the day

5:00 - 7:00 Reception / Networking Hour (Sponsorship opportunities available)

Wednesday, March 13, 2019

8:00 - 8:10 Welcome / Opening Comments / TAPPI Antitrust

8:10 - 9:00 Cast Film Feedblock Technologies - Christine Ronaghan, Cloeren

9:00 - 9:45 Cast Film Dies - Sam Iuliano, Nordson

9:45 - 10:00 BREAK

10:00 - 10:45 Film Casting Section Configurations - Lou Piffer, Davis-Standard

10:45 - 11:45 Blown Film Dies and their Differences in Design - John Perdikoulias, Compuplast

11:45 - 12:45 LUNCH

12:45 - 1:30 Air Rings for Blown Film Production - Laura Martin, Brampton Engineering

1:30 - 2:15 Blown Film Haul-Off Systems, Collapsing Frames and Bubble Cages - Bill Hellmuth, Davis-Standard

2:15 - 2:30 BREAK

2:30 - 3:15 Corona & Plasma Treating Systems - Rory Wolf, ITW/Pillar Technologies

3:15 - 4:00 Purging and Resin Transitions - Scott Marks, DuPont Performance Materials

4:15 General Q & A with any instructors from the day

Thursday, March 14, 2019

8:00 - 8:10 Welcome / Opening Comments / TAPPI Antitrust

8:10 - 8:50 Online Gauging Systems - Ted Schnackertz, NDC Infrared Engineering

8:50 - 9:40 Winders for Blown & Cast Films - Jim Stobie, Marco Engineering

9:40 - 10:00 BREAK

10:00 - 10:50 Tools for Process Improvement - Andy Christie, SAM North America

10:50 - 11:30 Pneumatic Conveying Systems - Joseph Lutz, Pelletron

11:30 - 12:45 LUNCH

12:45 - 1:30 Gel Troubleshooting in Blown & Cast Film - Lou Piffer, Davis Standard

1:30 - 2:15 Safety" & Process Troubleshooting - Scott Weber, Celanese

2:15 - 3:00 Challenges of Web Handling and Winding in Cast & Blown Film - Duane Smith, Davis-Standard

3:00 - 3:15 BREAK

3:15 - 4:00 Case Studies in Winding Cast & Blown Film - Duane Smith, Davis-Standard

4:00 - 4:15 Class Wrap Up / Evaluation Form Submittals/ Pick Up Certificates

4:15 Adjourn

Learn with Your Peers

This course is ideal for: Corrugator operators, Box plant supervisors, Production managers, Maintenance personnel, and Product quality control personnel.

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