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

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

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

Current System

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

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

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

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

Detailed Design

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

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

Construction Attached all system components

Test Set Up Victor

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.

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

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

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

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

Questions ?