3 MANUFACTURING
3.1 Drainage Net
Poly-Flex drainage net consists of approximately 97% polyethylene, 2 to 3% carbon black, and up to 1% antioxidants. The drainage net is continuously monitored during the manufacturing process. The key element to successfully manufacturing high quality drainage nets is to maintain consistency in both the raw material and the process. Raw material consistency is established in the laboratory when the resin is initially received and tested. An on-line quality control monitor establishes consistency during the processing. This representative of the quality department has been specially trained to monitor the process and the products during the manufacturing process. The on-line quality monitor can place material on hold if the material has any visual defects or dimensional abnormalities. All materials placed on hold will be further inspected and tested. If the material passes specification and is approved by the quality control manager and/or production manager, the material will then be released into stock. If the material fails to pass the specification or does not get approval of the quality control manager or production manager then the material will be reclassified or scrapped. In either case it cannot be sold as a prime Poly-Flex drainage net.
3.2 Drainage Net/Geotextile Geocomposite
Poly-Flex geocomposites consist of a geotextile bonded to one or both sides of the Poly-Flex drainage net. All geotextiles must meet the specifications before being eligible for production of geocomposites. Poly-Flex utilizes a heat bonding process to laminate the geotextile to the drainage net. An on-line quality control monitor establishes consistency during the processing. This representative of the quality department has been specially trained to monitor the process and the products during the lamination process. The on-line quality monitor can place material on hold if the material has any visual defects or dimensional abnormalities. All materials placed on hold will be further inspected and tested. If the material passes specification and is approved by the quality control manager and/or production manager, the material will then be released into stock. If the material fails to pass the specification or does not get approval of the quality control manager or production manager then the material will be reclassified or scrapped. In either case it cannot be sold as a prime Poly-Flex geocomposite.
3.3 Roll Labeling
Three labels are affixed to each roll as described below:
One label on the inside of the core.
One label on the face on the roll
One label on the end of the roll
An additional label is attached to the laboratory sample.
3.4 Storage, Staging and Shipping of drainage net and Geocomposite Rolls
All drainage net and geocomposite rolls are stretch wrapped prior to moving them to the storage area. Before shipment, all documentation is checked against the information on the roll labels. A full truckload consists of 24 rolls of drainage net and/or geocomposite material.
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