This document summarizes a presentation on flame treatment technology and its applications. It discusses esseCI, an Italian company that has been developing flame treatment systems since 1969. The presentation covers flame chemistry mechanisms, how flame treatment oxidizes polypropylene surfaces, and comparisons to corona treatment. It also reviews components of flame treatment systems and recent developments, including differentiated burner systems and integrated processes. The presentation concludes that flame treatment can improve film quality and adhesion compared to corona treatment.

1. Flame Treatment
Technology and its
applications
Stefano Mancinelli
esseCI srl Sales & Process Manager
esse CI
flame treaters®
BOPP FILM 2015 - Berlin – June 24th., 2015

2. Ø Located in Italy (1 hour from Rome).
Ø Established in 1969.
Ø 1972 - 1st Flame Treater for BOPP
Ø 1984 - 1st Flame Treater for automotive industry
Ø About 1000 installations in 48 Countries
Ø Pilot line with a top speed of 1000 MPM
esseCI srl
BOPP FILM 2015 - Berlin – June 24th., 2015

3. FLAME CHEMISTRY AND OXIDATION
MECHANISM.
COMPARISON WITH CORONA TREATMENT
BOPP FILM 2015 - Berlin – June 24th., 2015

4. FLAME CHEMISTRY
Chain/Radical reactions:
— M ⇒ R ; Initiating step – k1
— R+M ⇒ αR+M’ ; Chain Branching – k2
— R+M ⇒ R+P ; Propagating step – k3
— R+M ⇒ P’ ;Terminating/Production – k4
— R ⇒ P’’ ; Wall destruction – k5
M = reactants; P,P',P"= reaction products
Multiplication factor αcrit = 1 + [(k4 + k5) / k2]
BOPP FILM 2015 - Berlin – June 24th., 2015

5. H2 – O2 COMBUSTION SYSTEM
Chain Branching ⇒ RADICAL POOL
H•
+O2 ⇒ •OH+O•
•OH+H2 ⇒ H•
+H2O
O•
+H2 ⇒ •OH+H•
O•
+H2O ⇒ 2
•OH
BOPP FILM 2015 - Berlin – June 24th., 2015

6. PP SURFACE FLAME OXIDATION MECHANISM
— C-H link breaking vs. C-C link breaking;
— OH > O > H >> HO2
RH+OH ⇒ R°+H2O; Initiating step
RH+H ⇒ R°+H2
R°+OH ⇒ ROH;
R°+HO2 ⇒ ROOH; Propagating step
R°+O2 ⇒ ROO;
R°+H2O2 ⇒ ROO+OH
R°+O ⇒ RO
R°+H ⇒ RH; Terminating step
BOPP FILM 2015 - Berlin – June 24th., 2015

7. CH3 CH3 PP SURFACE
CH2-CH-CH2-CH-CH2
CH3 CH3
CH2-C-CH2-CH-CH2
CH2-C-CH2-C-CH2
CH3 CH3
OOH
OXYGEN
CORONA TREATMENT
CHEMICAL COMPOSITION OF A CORONA TREATED SURFACE
BOPP FILM 2015 - Berlin – June 24th., 2015

8. CHEMICAL COMPOSITION OF CORONA TREATED SURFACES
CH2-C-CH2-C-CH2
CH3 CH3
OOH
β-scission reaction
CH2-C
OOH
CH3
O ⇒ alkoxy radicals RO° ⇒ LMWOM
Low molecular
weight
C-OH
C=O
C=O
O
BOPP FILM 2015 - Berlin – June 24th., 2015

9. What is staining ?
oxygen level vs Power
0
2
4
6
8
10
12
14
0 5 10 15 20 25 30 35 40
Power density (Wmin/m²)
Oxygenlevel%
Threshold for formation of LMWOM in litterature = 8,3 Wmin/m²
Anchored oxygen level = 4,8%
Threshold for formation of LMWOM= 9,8 Wmin/m²
CORONA TREATMENT SURFACE OXIDATION
BOPP FILM 2015 - Berlin – June 24th., 2015

10. PP SURFACE FLAME OXIDATION MECHANISM
— O/C RATIO
— IMWOM vs. LMWOM
INCREASED SURFACE ENERGY
— Delamination
— “Aging” behaviour
— Metallizing barrier effect & Metal Bond Strength
— Printing applications
BOPP FILM 2015 - Berlin – June 24th., 2015

11. FLAME vs. CORONA SURFACE ADHESION
CORONA TREATED – SLOW PEELING FLAME TREATED – SLOW PEELING
CORONA TREATED – FAST PEELING FLAME TREATED – FAST PEELING

12. FLAME vs. CORONA SURFACE ADHESION
CORONA TREATED FLAME TREATED
BOPP FILM 2015 - Berlin – June 24th., 2015

13. FLAME vs. CORONA SURFACE ADHESION
CORONA TREATED
FLAME TREATED
BOPP FILM 2015 - Berlin – June 24th., 2015

14. FLAME TREATMENT SYSTEM COMPONENTS
AND LAST DEVELOPMENTS
BOPP FILM 2015 - Berlin – June 24th., 2015

15. BOPP FILM 2015 - Berlin – June 24th., 2015

16. BOPP FILM 2015 - Berlin – June 24th., 2015

17. BOPP FILM 2015 - Berlin – June 24th., 2015

18. BOPP FILM 2015 - Berlin – June 24th., 2015

19. s.r.l.
Societa' Costruzioni Industriali
esseCI
The information shown on this drawing is confidential and must not be copied reproduced or comunicated
to a third party wholly or in part without Our written consent
Materiale
Material
Customer/Job
Cliente/Comm.
Rugosità Gen.
Roughness
Form
Formato File
Name
Scala
Scale Sheet
Foglio di
of
Denomination
Denominazione
Progetto
Project
Rev.Disegnatore
Drwg.
Check
Contr.
Data
Date
Toll.Gen
De Divitiis M.
Gioia A.
A1
1:20
IT9
3.2
1 1
Drwg. No.
Disegno Num.
FLAME TREATER LAYOUT
FLAME TREATER PLANT
5553.LO.1.003.09.2013
BRUECKNER GSU / 5553
5553.lo.1.0.dft
A
Detail A
1:10
B
Detail B
1:10
180
170
100 ±0.2
39
+0.1
0
102±0.214
30.5±0.1
40
1.5
29
+0.2
+0.1
97.9±0.1
2
+0.2
+0.1
4.6
+0.2
+0.1
20 ±0.1
15.5
Burner 406 Type
FILM FLOW
8800BURNER FACE LENGTH = (+2x50mm SIDE PLATE)
9200ROLL FACE LENGTH =
2391
870.5±1185
425
O
600
O
475
826 920
9690 ±2
9290
870.5185
2036
650
660
100
930
1184
650
1300
15
240
120280
18
225
450 ±0.5
180
30
120
240
520
Num. 2+2 M20x40
Num. 2 Ø6H12
185±0.5
35
32.5
230
750
290
280280
230
4785
4845
4785
4845
C.L.
280370
290
280
1744
C
Detail C
1:10
310141287
230
280
775
230
12°
OPERATOR SIDE
DRIVE SIDE
(*) Mixture Inlet
Flange UNI DN 125
(*) Water Outlet
Flange UNI DN 50
(*) Water Inlet
Flange UNI DN 50
By esse C.I. s.r.l.
By Customer
SUPPLY EXTENSION
(*) = COUNTER FLANGES INCLUDED
IN SELLERS SUPPLY
Exhaust Duct
660x650x9000
824 920 200
BOPP FILM 2015 - Berlin – June 24th., 2015

20. BOPP FILM 2015 - Berlin – June 24th., 2015

21. BOPP FILM 2015 - Berlin – June 24th., 2015

22. s.r.l.
Societa' Costruzioni Industriali
esseCI
The information shown on this drawing is confidential and must not be copied reproduced or comunicated
to a third party wholly or in part without Our written consent
Materiale
Material
Customer/Job
Cliente/Comm.
Rugosità Gen.
Roughness
Form
Formato File
Name
Scala
Scale Sheet
Foglio di
of
Denomination
Denominazione
Progetto
Project
Rev.Disegnatore
Drwg.
Check
Contr.
Data
Date
Toll.Gen
De Divitiis M.
Gioia A.
A3
1:20
IT9
3.2
1 1
Drwg. No.
Disegno Num.
TYPICAL FOR INSTALLATION
MIXTURE GENERATOR TYPE 036.900/1200
036.900/120008/04/2013
esse C.I. s.r.l.
036.900/1200.dft
1002100
1000400 1000 600
2000
892 225
892 413
154
586
464
Num. 2 Flanges
UNI DN40
Cooling Water
Inlet / Outlet
Flange
UNI DN125
Mixture Outlet Flange
UNI DN50
Gas Inlet
Cable
Inlet
Cable
Inlet
Mixture Outlet
Optional
BOPP FILM 2015 - Berlin – June 24th., 2015

23. BOPP FILM 2015 - Berlin – June 24th., 2015

24. φ = EQUIVALENCE
RATIO
MIXTURE COMPOSITION
λ = LAMBDA =
= 1 / φ
BOPP FILM 2015 - Berlin – June 24th., 2015

25. BOPP FILM 2015 - Berlin – June 24th., 2015

26. λ = LAMBDA
(A/G)USED/(A/G)STOICHIOMETRIC
λ >1 mixture lean;
λ < 1 mixture rich;
λ = 1 mixture stoich.
JCS 122 Oxygen
analyzer
BOPP FILM 2015 - Berlin – June 24th., 2015

27. FLAME TREATMENT TECHNOLOGY LAST
DEVELOPMENTS
BOPP FILM 2015 - Berlin – June 24th., 2015

28. DDBS
DIFFERENTIATED DOUBLE BURNER SYSTEM
BOPP FILM 2015 - Berlin – June 24th., 2015

29. WET & DRY PROCESS
BOPP FILM 2015 - Berlin – June 24th., 2015

30. esseCI enriched flame Process
— Enriched flame;
— Film surface enhanced in line, through a low cost
process at industrial speeds, to deliver film with
improved functionality;
— Large food company is developing this technology
together with esseCI.
BOPP FILM 2015 - Berlin – June 24th., 2015

31. Summarizing…
— Flame treatment technology can warrant higher quality
on film treated surfaces (higher surface energy and
higher adhesion);
— Flame particularly useful in treating films for tape and
for metallization. Also used with good results on
sealable and cavitated webs (but with necessary higher
attention on process conditions);
— Flame process has very high improvement potential;
— Flame treatment system actually improved in its typical
point of weakness and fully electronically and
mechanically integrated in BMS lines;
— Best 5 layers extrusion line, the one where you can
produce and treat with best results all film types,
should be also equipped with a flame treater
(better if in bottom position).
BOPP FILM 2015 - Berlin – June 24th., 2015

32. THANK YOU FOR YOUR ATTENTION!
Stefano Mancinelli
Ph:+39.348.4912586
Mail: s.mancinelli@essecinet.net
Linkedin link: http://lnkd.in/aZDsbu
BOPP FILM 2015 - Berlin – June 24th., 2015