Elocoat Invests in Major Plant Upgrade

The upgrade focused on the coating line and included a new sprinkler system, a new raw board unwind, a new automised robot transport system, one new aluminum unwind and a new more flexible flame pre-treatment.

Aug 23 2010 --- Elopak has completed a major upgrade of the Elocoat coating plant in Terneuzen, The Netherlands with an investment of over €6.5 million in new technology to bring increased reliability, a reduced CO2 footprint and more ergonomic operations.

The upgrade focused on the coating line and included a new sprinkler system, a new raw board unwind, a new automised robot transport system, one new aluminum unwind and a new more flexible flame pre-treatment.

Plant Manager Jeroen Rijnhout explains, “Many of the machines replaced were the originals from 1983 when the plant was opened, so at 27 years old they needed upgrading to improve both reliability and CO2 footprint. The raw board unwind supplied by M. Torres was the biggest project. In addition to significant improved reliability, the new equipment has helped reduce waste significantly as it allows reels to be sealed with no overlap of board.”

With the new unwind machine, a new robot transport system was introduced which as a more automised system provides increased reliability and an improved ergonomic process for operators.

In addition to the upgrading raw board unwind system, Elocoat installed one new unwind machine for the aluminum reels used to coat the inside of cartons. The unwind, supplied by Kroenert, will increase the reliability of this part of the process and reduce maintenance costs.
 
To improve the consistency of the coating line, Elocoat has also introduced a new flame pre-treatment, supplied by Aerogen, with huge efficiency and environmental benefits. Jeroen Rijnhout explains, “This new flame treatment is speed and width adjustable, making sure that the gas consumption is effectively used. The old flame treatment was always running full width and full power, giving a higher CO2 footprint. This one new addition to the coating line has provided a saving of 400 tonnes of CO2 per year, a reduction of 4.5% of emissions – which is one third of Elocoat’s total CO2 targets for 2010.”

An additional extruder was installed on print side station which enables an increase of speed and the capacity for future developments and larger volumes.

“The main purpose of the upgrade at Elocoat was to increase the reliability of the plant and to provide a platform for growth and future developments in coating technology. A key goal was the reduction of CO2 emissions and we worked closely with all suppliers to provide this in addition to a safer and more ergonomic working environment for all staff. The installations began on May 17 and the plant re-opened on June 11; the longest shutdown period in our history. It is a major upgrade programme and has brought with it a new way of working through leading edge technology, partnership and respect for the environment,” adds Director Coating, Erik Voet.