Solutions and Products Featured in This Case Study

Spray Header with CBIMV Series Pneumatic Spray nozzles

Key Reasons for Implementation

Proposal of a pneumatic spray nozzle header capable of applying very small amounts of release agent evenly.

Challenges Faced by the Customer

At a nonwoven manufacturing plant, release agent had long been applied manually to the rolls to prevent the web from sticking and causing defects.
Severe sticking could require operators to stop the line, remove the stuck material, and reset the web, significantly reducing production efficiency.

For rolls more than 2 m wide, applying release agent evenly by hand was extremely difficult. Insufficient application could cause the nonwoven web to stick to the rolls and lead to quality issues, while excessive application wasted expensive silicone oil.

Because operators had to remain at the line to carry out this work, the process also placed a significant burden on production efficiency, quality control, material costs, and labor costs.
These problems led the customer to ask IKEUCHI whether spray application could be automated.

Solutions Proposed by IKEUCHI

To automate release-agent application, IKEUCHI selected the CBIMV Series from its pneumatic spray nozzle lineup. The CBIMV nozzles atomize release agent with compressed air, and their fan-shaped spray pattern allows efficient coverage across the roll width while minimizing the number of nozzles required.
The lowest-flow model was chosen, and 20 nozzles were mounted on a header spanning the full line width and arranged to spray the upper and lower rolls.

The header was combined with a spray control panel that allows operators to adjust pressure and application rate and set timers for spray and pause durations, creating an easy-to-operate release-agent application system.

Benefits Achieved

Operation began with a repeating cycle of one minute of spraying followed by a pause lasting tens of minutes. Automation eliminated the need for operators to remain stationed at the line and achieved consistent, uniform release-agent application.

The system also reduced consumption of expensive silicone oil. As a result, labor costs were reduced, product quality became more consistent, and production efficiency improved. The system has been well received by operators on site.

IKEUCHI spray products continue to support consistent quality and high production efficiency at this nonwoven manufacturing site.

SDG Contributions

Relevant SDG goals for this case.