Corona Treatment on blown film lines in Detail
With over 40 years of experience, AFS systems are among the best-selling corona treatment stations in the world, They guarantee reliable surface modification for the most demanding blown film applications thanks to the highest quality and safety standards. Benefit from our innovative and customizable solutions for perfect adhesion and finishing of your films. Rely on the market leader for maximum process reliability and efficiency.
AFS Corona treatment systems
Packaging today is a very complex composite of different materials. They can be laminated, metallised, printed and coated. The requirements of the customers for these packages and the materials are extremely high.
AFS products are the result of mature development processes. More than 40 years of experience flow daily into innovations and high quality standards.That’s why AFS systems are among the best-selling treatment stations in the world. Our designers also make complicated customer requests possible. Different station sizes and associated options always offer a tailor-made solution. Seven different system types cover the blown film line widths, all typical resin types and installation situations are catered for.
From the simple, hand-operated treater station to bus-controlled systems with pressure rollers, drives and water cooled rollers can be integrated into your production line. Our safety standards are subject to continuous testing.
The Corona treatment requires high voltage. We have encapsulated all live parts with a housing made completely out of metal. As insulation material we only use glazed ceramics. The electromagnetic radiation remains at the lowest level due to the metallic shielding.
We only use first class materials in our construction, a critical point for permanent corrosion resistance. With proper maintenance and care our systems are still in operation decades later.
Individually customizable systems
AFS offers a wide variety of system configurations which, depending on the respective area of application, can be easily integrated into existing and new production lines as standard or customer-specific systems. Both end customers and OEM customers benefit continuously from the great flexibility, expertise, and innovations of AFS and enjoy technical perfection with maximum ease of use.
System Highlights
- Safe and easy access for the operator for adjustment and cleaning.
- All available remote control interfaces, Profi-Bus, Can-Bus, Profinet, Ethernet, etc.
- CE conformity.
- No external high-voltage cables. Transformers are connected directly to the electrodes.
- AFS uses only ceramic insulators, and our designs ensure sufficient air gap between the electrode and side plates. Some competitors use plastic shields for a more compact, cheaper design, but over time these materials absorb salts and moisture, leading to frequent flashovers and longer downtime for cleaning.
- Fully enclosed metal housing with lower electromagnetic radiation compared to other designs with plastic shielding
Technische Details
| Attribute | Details |
|---|---|
| Application | Blown film extrusion |
| Working width | 600 - 3500 mm as standard |
| System versions | Single-sided, double-sided or four-sided |
| Electrodes depending on system type) |
- 3-, 6- or 9-finger segments - electrodes - Stainless steel tubular electrodes - Ceramic electrodes |
| Line speed | up to 300 m/min, higher speed possible |
| Treatment roller (depending on system type) |
- Silicon dielectric (sleeve or coating) - Ceramic coating - Corrosion-proof coating - Aluminium |
| Generators | 1 - 144 kW, higher output power on request |
| Technical highlights | - The best electrode mounting on the market (AFS patent) - External adjustable spray gap - Customer design-specific corona stations - Robust, reliable and compact design for extremely easy cleaning and maintenance - High efficiency of the corona generators benefits the user in capital and operating cost |
| Options | - Pressure roller - Drives for treater rollers - Water cooling - Banana guide roller - Spreader roll |
Typical Options for Blown film
Corona-Pro
For very low corona outputs, the generator can automatically activate the Corona-Pro mode. This enables homogeneous power distribution across the entire electrode width and thus ensures uniform pretreatment results even at very low speeds.
Wet start
The wet start function dries the station electrically and prevents failures due to flashovers.The system is ready for use again in a short time, as any condensation that has formed evaporates very quickly.
Lookback function
The LookBack function displays all process parameters graphically as a diagram on the generator display. An interface is available for further data evaluation.
System overview
Stainless steel washers between the individual segment electrodes. Maintains smooth operation and prevents sticking.
For larger segmented electrodes, a spring-loaded hold-down design prevents inactive segments from falling back, while the active segments remain perfectly aligned in their correct position.
Segment electrodes
Available in three different sizes: 3-, 6-, or 9-fold, made of aluminum or stainless steel, and in various widths according to customer requirements.
3-fold
6-fold
9-fold
Tube electrodes
If a segmented electrode is not required, our stainless steel tube electrode with a “swivel holder” suspension, as used in cast film systems, is a good alternative.
AFS generators for maximum production reliability and productivity
Our latest generator technology combines reliability and efficiency with optimal process integration at low operating costs.
Insulated airflow cooling for electronic components to avoid maintenance-intensive filter cleaning in our S/SE series.
The new M generator series from AFS is based on a modular approach that ensures your production reliability and productivity. The number of modules depends on the desired maximum power and can be increased for additional redundancy.
- Modern design with a clear and intuitive user interface.
- All AFS generators feature a comprehensive operator action and error message log in plain text and in multiple languages.
- The internal process parameters are monitored using an “early warning system” that enables corrective measures to be taken without any loss of production.
- The M2 generator type allows individual power adjustment at each electrode, optimizing investment costs and space requirements compared to two separate generators.
- All available remote control interfaces, such as ProfiBus, Can Bus, Profinet, Ethernet, etc.
- Changing a module is easy and takes just a few minutes. Step-by-step instructions are included in our documentation. No special tools or skills are required.
- For demanding climatic conditions, we offer suitable additional cooling units that have proven themselves over time.
AFS ozone converters
The corona treatment generates ozone, which is eliminated to ca. 99% by the KAT system, the AFS ozone destruction unit. AFS can supply the right size of ozone filter for every situation.
| Exhaust air volume | Dimensions (HxWxD) |
Weight | Connector diameter |
|---|---|---|---|
| 1000 m³/h | 690 x 1070 x 464 mm | ca. 100 kg | 160 mm |
| 1500 m³/h | 692 x 1665 x 692 mm | ca. 180 kg | 200 mm |
| 2000 m³/h | 692 x 1665 x 692 mm | ca. 180 kg | 200 mm |
| 2500 m³/h | 915 x 1715 x 915 mm | ca. 300 kg | 250 mm |
| 3500 m³/h | 915 x 1715 x 915 mm | ca. 300 kg | 250 mm |
| 4500 m³/h | 1370 x 1990 x 1145 mm | ca. 500 kg | 315 mm |
| 5500 m³/h | 1370 x 1990 x 1145 mm | ca. 500 kg | 315 mm |