The challenge: continuing to produce cost-effective packaging.
The customer: Futamura is a Japanese company with production facilities in Japan, the UK and the USA. The company employs around 2000 people and produces high-quality packaging films, fiber casings, nonwovens, activated carbon and phenolic laminated sheets.
Provided by Vaisala: HMT330 and HMT360 series humidity and temperature transmitters, followed by two Indigo520 transmitters and four HMP5 relative humidity and temperature probes
Companies worldwide are trying to reduce both waste and the carbon footprint of their products. For example, the growing demand for environmentally friendly packaging has led Futamura to become the world's largest manufacturer of sustainable cellulose packaging films, including its leading NatureFlex™ range. To produce such sustainable films, precise conditions must be maintained in the production process. This requires highly accurate temperature and humidity measurements, particularly during film drying and storage of the finished products. Futamura UK uses Vaisala instrumentation throughout its site, including Vaisala HUMICAP® Humidity and Temperature Transmitters HMT360 in its coating towers within its conditioners. As the coating towers contain highly flammable solvents, the products used in these areas must be certified for the hazardous environment. The Vaisala HMT360 transmitters, now replaced by the ATEX-certified HMT370EX, are intrinsically safe and therefore ideal for use in such hazardous areas.
Vaisala measuring instruments can also be found on Futamura UK casting machines mounted in the dryer channels to measure temperature and humidity. The Vaisala HUMICAP® HMT330 series humidity and temperature transmitters are designed to provide highly accurate measurements in demanding industrial applications. These transmitters control a valve that increases or decreases the amount of steam that is fed into the dryers. This allows the moisture content to be maintained at the set point required for drying each specific type of film. Moisture content is a key factor in the properties of the final film. Therefore, precise control is essential to ensure quality and reduce waste. As the HMT330 series is an older model, Futamura wanted to future-proof its measurement technology - so the company turned to Vaisala for advice.
The solution: service, support and leading technology
Andrew Williams, Sales Manager at Vaisala, visited Futamura's UK site in Wigton, Cumbria, to demonstrate the benefits of switching to Indigo and discuss the options available with David Carr, Electrical Engineering Chargehand, and David Mansergh and Chris Reid, Technical Engineers.
"We explained to the Vaisala Sales Manager where we were using the HMT330 range of instruments and he suggested using the Indigo520 display with an HMP5 relative humidity and temperature probe," says David Carr. "We were more than happy with the suggestion. His in-depth product knowledge and extensive engineering and process systems expertise were a big advantage in the decision making process. He also went through the calibration and set-up of the equipment with our electricians. The service and support from Vaisala has been first class - Andrew Williams has gone out of his way to support us."
The Indigo520 can be connected to two separate probes simultaneously and has a clear and user-friendly touchscreen display. Futamura particularly appreciates the screen size and easy-to-read graphics, as well as the ability to swap probes for calibration. It also helped that the HMP5 probe works mechanically in the same way as the already familiar HMT330 devices and is installed with the same mechanical hardware.
"When you find products - and a company - that you can trust, it makes good business sense to continue the relationship. At Futamura, we have been using Vaisala measuring instruments for many years. This helps us to ensure the quality of our sustainable packaging films and we will continue to do so in the future. As a factory, we like to maintain a site standard because it makes it easier to stock spare parts and replace equipment when needed. It's safe to say that Vaisala is our preferred brand due to its reliability and ease of installation and use.
David Carr, Electrical Engineering Chargehand, Futamura UK
The benefits: sustainable packaging film of consistently high quality
By using Vaisala measuring devices in production, Futamura benefits from the following advantages:
- Precise control of the production process
- Consistent product quality
- Less waste
- Trusted service and support from solution experts
- The peace of mind that comes with proven and reliable solutions
David Carr, Futamura UK