1. Inline Granulation of Stretch Film
Precision AirConvey Team 5
Jordan Bellomo
Victor Castro
Stephen Koellhoffer
Zachary Magnone
Matthew Manzione

2. Outline Problem Definition Current System Concept Selection
Detailed Design
Fabrication
Construction
Test Set Up / Testing
Path Forward

3. Problem Definition System Function Proposed Problem
Remove, Reprocess, Recycle Stretch Film
Proposed Problem
Competition has a similar, but more efficient system
Uses less machinery
Converts ribbon directly to fluff, with no intermediate steps
PAC is in danger of losing valued customers

4. Current System

5. Concept Goals Reduce amount of machinery Reduce system cost
Eliminate initial cutter
Reduce to one fan
Reduce system cost
Manufacturing cost
Operating cost
Feasible to manufacture

6. Best Concept Features Diverts some air away from material Simple
Adjustable
Easy to implement
Based on existing technology

7. Concept Refinement Several Feasible Ideas
Vertical Inlet, Cylindrical Screen
Vertical Inlet, Slanted Screen
Vertical Inlet, Dual Sided Slanted Screen

8. Material and some air flow OUT
Concept Refinement
Best Concept
Cylindrical enclosure, conical screen
Pressure membrane distributes airflow
Material and some air flow OUT
Flow restriction membrane
Conical screen, 50% open area
Low pressure Zone
Separated air OUT
100% Air and Material IN

9. Detailed Design

10. Detailed Design Dimensional justification
Used PACs existing screen separator as a starting point for our design
Maintained same open area of screen
Used approximately same screen angle

11. Fabrication Created detailed design of separator
Sent drawings to PAC’s fabricator
Received finished Prototype

12. Construction
Attached all system components

13. Test Set Up
Victor

14. Testing Measurements Taken: Target Values
Pressure: Total Drop ≤ 25 in. H2O
Air Velocity: ~6500 ft/min.
Air Pulled Through Grinder: ≥ 1000 cfm
Fan Power: ≤ 60 Hz
Bulk Density of End “Fluff”: 4-7 lb/ft3
Material Velocity: ~2000 ft/min.

15. Testing Concept Validation Diversion of air was necessary
Theoretical calculations match experimental results
Diverting some airflow
Increased system efficiency
Reduced fan speed
Increased airflow at inlet
Pressure membrane was not critical
Conical screen provided enough of a restriction

16. Granulation Success: The Rise and Fall of Stretch Film
Testing
Granulation Success: The Rise and Fall of Stretch Film

17. Path Forward Compile data CD with all relevant project data for PAC
Longer length tests need to be conducted
Install access panel for cleaning purposes
Experiment with different conical screens
May be able to further increase system efficiency

18. Summary Problem Definition Current System Concept Selection
Detailed Design
Fabrication
Construction
Test Set Up / Testing
Path Forward

19. Questions ?