Keith Machinery - ISO Package Info

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ISO Regulations

The prime concern of the ISO regulations is to set up manufacturing procedures that will ensure that the item produced is always the same. In the case of the manufacturing of ink in general, & in the three roll milling step in particular, this translates as follows:
1. The ink manufacturer must determine what variables must be controlled, & how these are to be monitored.
  1. The variables that would normally be considered on a three roll mill are as follows:
    1. Roll Pressure
    2. Roll Speed
    3. Roll Temperature
    4. Apron Knife Pressure
    5. Product Temperature at the rear nip
2. The ink manufacturer must then determine how the variables will be monitored. The choices are as follows:
  1. Of course, the simplest way to monitor these variables would be to have a mill operator regularly record the items. So long as there is a regular procedure to record these figures, we believe that this is acceptable under the ISO regulations.
  2. The next step up would be a system that automatically records the variables chosen.
    1. The simplest system would be a unit installed on the mill that might record say 100 hours of operation.
    2. A second type of system would send the variables to a PC computer. This PC computer could be set up by the mill, or it can be remote.
    3. A third type of system would be very similar to (b) above, except one PC computer could record data from a number of mills.
  3. The next step would be "closing the loop". An example of "closing the loop" would be the standard "Buhler type" roll temperature control system. In this system, outlet cooling water temperature is constantly monitored, & a device (in this case a thermostat) opens a solenoid valve at the appropriate time to keep the temperature at the preset point.
Keith Machinery is capable of supplying any of these systems. Our computer/electrical engineer, Vladimir Lipyanskiy, regularly designs much more complicated systems which go into the pharmaceutical industry. The system supplied by us would be state of the art in 1999, not an evolution of a 10-year-old system, as you would get from Buhler, et al.
Another choice, which has to be made, is how the variable is measured.
1. An example of this could be roll pressure. Normally, we would measure & control the hydraulic pressure being supplied to the adjustment point. We believe that this is perfectly acceptable for the ink industry. On the other hand, we have actually installed "load cells" between the bearing blocks to exactly measure the force being exerted at that point. We have only done this for some "Silicon Valley" type customers.
2. Another example would be how we measure roll temperature. This can be monitored indirectly by the cooling water temperature. It can also be monitored directly using an infrared sensor. If an infrared sensor is chosen, is it stationary or does it move back & forth across the roll surface?
The final item that needs to be considered is cost. We here at Keith Machinery firmly believe that an ink manufacturer needs to control the variables on the mill, & further that they need to be repeatable. In this way the ink manufacturer will always produce the same product.
1. In the ink industry, repeatability is normally acceptable with a mill that has hydraulic roll set (either manualhydraulic or electrohydraulic), & outlet water temperature gauges. We also recommend a mill set up with VFD for varispeed, but this is more to maximize production, rather than repeatability. Of course, if a mill does have varispeed, then roll speed becomes a factor, which must be set at the same speed for each successive batch of a particular ink.
2. Having a mill with the above recommended options can bring the operation of the mill off the shop floor & into the production/engineering department of the ink manufacturer. Production/engineering can specify that for this ink, the mill is run with these settings. It is exactly analogous to the specification of the ink formula. Of course, an ink manufacturer would never tell the mill operator to change the formula as he sees fit!
3. The monitoring/controlling system discussed in #(1) (b) above can then be specified based on cost vs. benefit. There are two major cost jumps. The first is the jump to a mill that records its variables. The second major jump is for a mill, which "closes the loop".

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34 Gear Avenue · Lindenhurst, NY 11757
Email: sales@keithmachinery.com
Phone: 631-957-1200 Fax: 631-957-9264

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