Success stories
Controlled Humidification of Calenders in the Manufacture of Technical Film
Project Description
A manufacturer of technical polymer film needed to replace uncontrolled steam with a uniform, adjustable steam supply tailored to the geometry of its calender in order to improve TPU release without damaging the micro-relief and to ensure continuous operation during 72-hour production runs.
Original Situation
What challenges did the client present us with?
A manufacturer of technical polymer film (primarily TPU) uses a calendering process: the molten polymer exits the die head and passes between two textured rollers, 350 and 450 mm in diameter, which laminate it and impart a matte micro-embossed pattern. The rollers are internally cooled with water at 5–10 °C, but their surfaces operate at room temperature due to the heat transferred by the film.
The problem was adhesion. The hot TPU stuck to the roller that receives the polymer and had trouble peeling off, both at the main point of contact and at the exit of the second roller. The customer had empirically verified that a thin layer of moisture on the surface solved the release issue and had built their own solution: an open stainless-steel channel through which water at about 70–90 °C flowed, located beneath the roller, with the steam condensing on the surface.
The system worked, but with serious limitations. Flow control was poor: there was no way to precisely regulate how much moisture reached the roller. And the margin for error was narrow, because excess water eliminates the micro-relief and ruins the film’s finish. Added to this were the machine’s limitations: the rollers move along two axes and tilt by about 20° to adjust the pressure between them, so any device had to be compact, lightweight, capable of accommodating those movements, and easily removable. Production runs last 72 hours in succession, so the solution had to operate continuously and uniformly along the entire generatrix of the roller, at the lowest possible outlet velocity to avoid generating noise and, if possible, without dripping, so that it could be positioned overhead.
The customer needed to transition from uncontrolled steam to a uniform steam supply, adjustable within a range of 0.6 to 6 kg/h and tailored to the geometry of its calender. They asked us if Giconmes could design it.
Solution Provided
Steam solution developed ad hoc by Giconmes
Proposed Solution
The approach was to replace the hot-water channel with a low-pressure saturated vapor barrier, generated by an electric unit and distributed through two custom-designed manifolds, one for each roller.
At the heart of the system is a 6-kW NGV-1706 electric steam generator, with adjustable output ranging from 0.14 to 8.6 kg/h —which easily covers the required range—operating pressure up to 4.5 bar, and unlimited runtime thanks to continuous power supply. Since it is electric, it starts up in minutes, requires no chimney or fuel, and can be integrated into the production area without any construction work.
For the distribution system, we designed two stainless steel tubular manifolds made of 22 mm in diameter and 1,750 mm in length, with dual connections and outlet holes every 10 mm, so that every centimeter of the roller receives the same amount of steam. Each manifold is mounted on a channel-type support, secured to the side frames of the calender and integrated with the rollers’ movements: the diffuser follows the roller as it moves or tilts, without the need for any readjustment. The design was based on measurements and photographs taken from a plan view and was validated in 3D before manufacturing, with the intention of replacing the manifolds with longer ones if the usable working width is expanded in the future.
The control system was designed to be deliberately simple. The client wanted to validate the concept before investing in automation, so control is achieved using a needle valve at the inlet of each manifold, preceded by a droplet separator that minimizes condensation and dripping during startup. Insulated hoses carry the steam from the generator to the calender. The system is designed to accommodate automatic temperature control at a later date, if necessary.
The project was completed in five months, from the initial consultation to commissioning, and included a technical site visit to collect data, the design of custom-made supports at Giconmes, and a single day of installation. The entire system is manufactured in accordance with the Pressure Equipment Directive 2014/68/EU.
Technology used
- NGV-1706 6-kW electric steam generator, with adjustable output ranging from 0.14 to 8.6 kg/h and a working pressure of up to 4.5 bar
- Two stainless steel tubular manifolds, 22 mm in diameter and 1,750 mm long, with dual inlets and outlet holes spaced 10 mm apart
- Channel-type supports attached to the side frames of the calender, moving in unison with the rollers
- A droplet separator at the inlet of each manifold
- Insulated hoses for conveying steam from the generator to the calender
CHALLENGES
We meet our clients’ requirements
The film no longer sticks. With the vapor barrier in operation, the TPU peels off cleanly and continuously throughout the entire campaign, without the manual adjustments required by the previous system.
The key lies in control: steam is applied evenly along the entire generatrix of the roller, with an adjustable and repeatable flow rate that allows for working at the exact right level of moisture—enough to ensure release without any excess that could damage the micro-relief.
The result is more efficient and precise manufacturing, using compact, electric equipment that is custom-designed for the machine.
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There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Understand and follow the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Do not put the installation into service or allow pressure equipment to operate if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use pressure equipment within the operating limits specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Maintain facilities, pressure equipment, safety accessories, and control devices in accordance with operating conditions and the manufacturer’s instructions, and inspect them at least once a year.
- Arrange for the corresponding periodic inspections to be carried out in accordance with the provisions of Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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USES OF STEAM IN INDUSTRY AND OTHER BUSINESSES
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The use of steam is gaining popularity in various industries due to its effectiveness and environmental benefits.
In our “Success Stories” section, you can learn more about companies that have adopted this technology and achieved successful results in terms of efficiency and sustainability. Click on the success stories to learn more.
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