Method and system for optimizing film production and minimizing film scrap

Abstract

The present invention relates to a method of optimizing self-supporting film production which includes the steps of: determining at least one scrap factor which relates to a total amount of scrap in processing a film product; correlating the at least one scrap factor to at least one processing parameter; and adjusting the at least one processing parameter to reduce the total amount of scrap in processing the film product.

What is claimed is: 
     
         1 . A method of optimizing self-supporting film production comprising the steps of:
 (a) determining at least one scrap factor which relates to a total amount of scrap in processing a film product;   (b) correlating said at least one scrap factor to at least one processing parameter; and   (c) adjusting the at least one processing parameter to reduce the total amount of scrap in processing said film product.   
     
     
         2 . The method of  claim 1 , wherein said scrap factor comprises a scrap for mixing factor. 
     
     
         3 . The method of  claim 2 , wherein said scrap for mixing factor comprises scrap lost to hoses. 
     
     
         4 . The method of  claim 2 , wherein said scrap for mixing comprises scrap lost due to coating the mixer. 
     
     
         5 . The method of  claim 1 , wherein said scrap factor comprises a scrap for coating factor. 
     
     
         6 . The method of  claim 5 , wherein said scrap for coating factor comprises scrap for start-up of the film forming process. 
     
     
         7 . The method of  claim 5 , wherein said scrap for coating factor comprises scrap for shut-down of the film forming process. 
     
     
         8 . The method of  claim 5 , wherein said scrap for coating factor comprises scrap for drying. 
     
     
         9 . The method of  claim 8 , wherein said scrap for drying comprises scrap related to oven length. 
     
     
         10 . The method of  claim 1 , wherein said scrap factor comprises a scrap for slitting factor. 
     
     
         11 . The method of  claim 1 , wherein said scrap factor comprises a scrap for packaging factor. 
     
     
         12 . The method of  claim 1 , further comprising the step of modifying a processing parameter that relates to a plurality of said scrap factors. 
     
     
         13 . The method of  claim 1 , wherein the adjusting step further comprises adjusting a tank size of said film processing. 
     
     
         14 . The method of  claim 1 , wherein the adjusting step further comprises adjusting a film sheet coating width. 
     
     
         15 . The method of  claim 1 , wherein the adjusting step further comprises minimizing a hose length from a control volume of mixed material to a film sheet and construction area. 
     
     
         16 . The method of  claim 1 , wherein the scrap that is reduced comprises start-up scrap. 
     
     
         17 . The method of  claim 1 , wherein the scrap that is reduced comprises shut-down scrap. 
     
     
         18 . The method of  claim 1 , wherein the adjusting step is completed in line. 
     
     
         19 . A system for optimizing self-supporting film production comprising:
 (a) a film manufacturing apparatus, comprising a mixer, a film former, and a cutting apparatus; and   (b) a computer system for compiling and processing data related to the film manufacturing system and at least one product characteristic;   wherein the computer system is capable of controlling at least one processing parameter to optimize a yield of film dosage product.   
     
     
         20 . The system of  claim 19 , wherein the system is capable of adjusting the processing parameters in real-time. 
     
     
         21 . The system of  claim 19 , wherein the film manufacturing apparatus is remotely adjustable.