Net Instantaneous out put referred to a web width of 1500 mm

Type

Web width

Thickness

Speed

Net production

mm

Micron

Mt/1’

Kg/h

Stretch

1500

15

413

500

Stretch

1500

17

363

500

Features of the rolls produced:

- 3 x500 mm

- 1 x 1500 mm

- OD 500 mm max. width +/- 1 mm

Cooling capacity:

- 280.000 Kcal /hr

- Water chiller excluded from the supply, if required to be quoted separately.

Electrical power: 400 V +/- 10 % -50 Hz three phase +N+G

Line Composition

Extrusion group composed of:

N°1 Single screw extruder 120 mm L/D 1:30 with AC motor

- Motor connected to extruder gearbox through elastic joint

- AC motor

- Extruder gearbox with flange pump and cooling system

- Barrel heating by band heaters; air cooling by one independent fan for each zone.

- Barrel and screw made of nitrided alloy steel.

- The screw is double flight barrier type

- Feed zone jacketed for water cooling.

- Granule hopper with sight glass, emptying chute and low level alarm , magnetic grind

- Granules loader included

- Extruder base frame on wheels.

N°2 Single screw extruder 60 mm L/D 1:30 with AC motor

- Motor connected to extruder gearbox through joint

- AC motor

- Extruder gearbox with flange pump and cooling system

- Barrel heating by band heaters; air cooling by one independent fan for each zone.

- Barrel and screw made of nitrided alloy steel.

- The screw is double flight barrier type

- Feed zone jacketed for water cooling.

- Granule hopper with sight glass, emptying chute and low level alarm , magnetic grind

- Granules loader included

- Extruder base frame on wheels

N°3 Adapter system extruders and die

- Manual screen changer.

- N°2 melt pressure gauges after and before the filter.

- N°1 melt temperature gauge.

No. 1 manual Flat Die of mm.2050

Suitable for the extrusion of thermoplastic materials; cast film

With the following specifications:

- Upper Lip:

Manual flexible adjustable through push thermal block every 25 mm.

- Lower Lip:

Fixed with land lenght appropriate to the opening range.

- Manifold:

Coathanger distribution channel precalculated for the media of the operational data made with computer flow simulation.

To validate the performance guarantee the customer has to provide viscosity curves of applicable polymers at the nominal operating temperature and at shear rates  between10 sec-1 through 1000 sec-1.

- Structure:

Heavy body for high output, high pressure, or very wide dies;

- Heating of die:

By special cartridge heaters opportunely grouped in zones and wired up to the multipolar connector.

The die can be open for cleaning without disassembly the wiring system.

Each zone has a drilling for thermocouples.

- Wiring of thermo bolts

Encased in a stainless steel wiring box and wiring at multipolar plug on board.

Cooled through pipe, the customer must provide either compressed dry air to the each side of the pipe.

Technical data:

- Lips width: 2050 mm.

- Lips gap adjustable from: 0,1  to 1,5 mm.

- Output: 800 kg/h of LLDPE

- Inlet: Rectangular

- Zones number: 7

- Manual adjustment bolts: 80

- Voltage: 220/240 V.

- Thermocouple holes: M 12 x 1,5 x 15 Rim. 9

- Electrical connections by: multipolar plugs on board

No. 1 Black Box Cast with 3 pos.:

- Coextrusion Black Box with feed block made for cast lines, with fan shaped entries, interchangeable insert for possible layers sequency exchange, plate with convergent passages on the outlet section, with three position pin for programmed combination of the layers;

- Virgin pin in spare to permit the custom optimization of the layers profile made with his product by varying the form of the passage;

- Heating by flat heaters outside opportunely arranged.

Technical data:

- Entries/layers: 3

- Main entry: B vertical in center

- Satellite entry sides: Right /Left

- Layers sequence: ABC

N°1 Extruders and die support:

Made by steel, complete with Carriage for linear expansion compensation of extruders

Casting section:

The unit consist of support structure with two steel heavy lateral frame sheets connected through tie rod, in order to have a strong and solid structure.

All the casting unit is mounted on a carriage moving horizontally on tracks.

N°1 Main chill roll  Chill roll Dia. 800 mm equipped with a special water circulation system that guarantees an uniform surface temperature. The roll surface is  chromed plated, grinded and polished. Chill roll is perfectly balanced either statically or dynamically. To obtain a film uniform cooling on all the roll transversal surface, the same is equipped with a cooling internal chamber with a forced differentiated water with multiple and parallel channels. All the internal surfaces near the cooling water are produced with a special anti-rust treatment. At one end of the roll the rotating joint to connect casting unit to water feeding flexible hose is foreseen. Roll is furnished with a AC.motor at variable speed, driven by inverter. To grant security during emergency stop chill is provided with an electro pneumatic disk brake. Main casting roll is provided with a cleaning steel roll whose external surface is covered with silicone with spiral grooves. Cleaning roll is installed on oscillating levers controlled by pneumatic cylinders for the contact with the main roll. Cleaning roll pressure contact is adjustable.

N°1 Secondary chill roll  Chill roll Dia. 250 mm Auxiliary chill roll with the outside surface chrome plated, polished, statically and pneumatically balanced and foreseen with forced internal cooling water circulation. Auxiliary cooling roll is controlled by an independent AC motor Gear box, at variable speed, controlled by inverter. Auxiliary cooling roll is supplied with rubber coated pressure roll with adjustable pressure contact.

Idle transmission rolls made by aluminium with hardened external surface and special finishing to avoid transverse slipping film. Rolls are assembled on ball bearings at high smoothness.

N° 1 Air suction blade (Vacuum box) Plate steel body., adjustment independent from the die., The mechanical design incorporates ease of maintenance and cleaning by a swing out split chamber design. All stainless steel construction.

Adjustable blades are provided at the pre sweep section and between pre sweep and primary chamber. Smoke collecting manifold with suction control shutter Each chamber is designed with a suction manifold connected to a suction fan with speed adjustment by inverter.

Suction fan speed regulation and the depression degree into the cambers is set on the basis of the values set up on the operator panel of the cooling group and/or on the supervising system and consider the type of film to produce, the thickness of the same and the production speed.

Note: All the free roll from chill roll to winder are silicon protected for anti-stick material.

N°2 Edge keeping electrostatic devices for high speed

N°1 Oscillating frame with continuous movement  +/- 100 mm Max for each side. Speed and transversal movement .

N°1 Nip roll before the winder for web separation

N°1 Automatic winder mod. GAP 1500

Structural steel frame complete with levelling screws.

Couple of steel shoulders joined by cross pieces and covered by protection panels.

Aluminium idle rolls.

Couple of nips with pneumatic open/close powered by electronically controlled ac. motor-reducer.

N°2  inner longitudinal blades and N°2 lateral longitudinal blades for scraps.

Millimetric ruler to register the longitudinal cuts.

Winding roll with special surface pattern and powered by a.c. motor-reducer

Pneumatic rubber coated pressure roll.

Hydraulic system for pressure control between roll and winding roll

Antistatic bars.

Roll change unit, operated by a motor-reducer.

Change per meter and per diameter.

N°1 transversal cut.

Couple of arms.

Couple of shaft holder arms powered by motor reducer for rolls discharge from the winder to the receiving table. Thanks to this system the shafts take only few seconds during the working cycle to be ready for the change.

Variable speed shaft launching unit.

N°2 pneumatic shafts for cardboard cores Dia. 76 mm

Electrically operated shafts loader.

Control panel.

Accident prevention guards.

Optical and sound alarms and emergency push button

N°1 In line scraps recovery system

2 suction pipes,1 injector, 1 blowing fan for edges suction with silencing box,1 hopper with Plexiglas cover and inspection panel, 1 scraps exchange valve for safety or maintenance purposes by pass, 1grinder unit with silencing box,1 blowing fan for grinder scrap conveying with silencing box, 1 cyclon..

N°1 Scraps recovery extruder Dia. 75 mm

Nitrided barrel.

Treated steel screw.

AC motor

Motor reducer ( parallel axis ) Made by Rossi motoriduttori

N°1 thermoregulation zone by means of armoured heaters and controlled by thermocouple.

N°1 melt temperature gauge.

Water cooled feeding zone.

Special hopper with inspection door and antistatic bars.

Steel frame

Water mixing tank and pumps:

Mixing tank capacity 5000 lt , N°4 delivery pumps complete with 3-way valves , manifold for delivery/return , connection pipes to the machine not included

Note : Water Chiller excluded.

N°1 Thickness control system supplier NDC

Complete with :

8000TDi Operating System

The 8000TDi software is designed for ease-of-use whilst providing the user with the key and critical displays to enable them to run and operate the production line.

The NDC Model 8000 TDi Scanning Thickness Gauge and Display Software and Hardware Platform includes Desktop Operator Work Station (OWS) 17” Colour LCD with touch screen

Single Board Computer (Embedded PC) running Embedded Windows CE™ Operating System

Dedicated Operating System provides secure operating environment, Operator can only access gauging system functions ,System essentially immune to viruses, Trojan horses, worms, and other virulent software Flash based for “instant on” operation

Features

- Recipe storage

- Advanced streak detection

- Automatic screen printing

- Roll defect mapping

- Multi language displays

- Compatible with plant networks

- Optional speed, side-to-side, and centre zone MD controls

- Optional SPC/SQC

- Optional OPC or DDE two-way communications with a host computer

Infrared transmission sensor for film thickness measurement

The FG710 is one of the most advanced sensors for high-precision measurement of film thickness and is rapidly replacing more traditional sensors, such as Kr85 beta transmission, for this measurement. Whilst the FG710 is not appropriate for customers running black (carbon black loaded) films it can be used without major problems for other coloured films including TiO2 and CaCo3 loaded films. One of the powerful features of the 710 series of sensors is that it can be fitted with up to 10 filters providing NDC with a Virtual Real Spectrum that enables us to analyse and then remove the influence of pigments and fillers. Colours typically found in medical applications such as blue, green and pink can also be accommodated for by the sensor. It is insensitive to humidity, barometric pressure, or gap temperature.

Features

- High measurement precision

- Fast response time

- Measurement of many types of polymers

- High tolerance to changes in ambient condition and web flutte

MiniTrak-O Frame Scanner

When it comes to making precise scanners to assure the cross-web performance of our extremely accurate sensors, NDC Infrared Engineering excels. With its new MiniTrak scanning family, we continue this trend.

The MiniTrak-O frame is designed for small webs (2.2 meters or less) scanning up to two transmission or single sided sensors. With its small footprint, it can fit into many places that other scanners cannot. It's also designed for high reliability, easy service access, and long life.

Control Cabinet:

- Heat, control, providing zones to control extruders and die heating via PLC.

- Drive system: AC Drives for extruder.

Drive is engineered, mounted, wired, and provided with appropriate protection; Main chill roll , second chill roll , in let nip roll on the winder , trimming nip roll , winding drum  motor reducer

- Control Station for chill roll, winding through PLC - controlled functions: winding speed, tension, hydraulic unit, automatic cutting device, meter counter, remotely mounted enclosure with controls and readouts.

- Local panel for extruders, chill roll up and down, forward-inward movement, start-stop for blowing air knife and movement adjustment, starts-stop for vacuum air knife, interface with control cabinet of winder for controlling winder from remote location.

- Pressure and temperature indications with LDC display with: first "sound alarm" on primary threshold, "second shut down alarm" on secondary pressure threshold

- Photocell and limit , prossimity switch.