Monolayer Extrusion Machine

SPECIFICATION OF 45mm GROOVE FED FILM PLANT

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1     EXTRUDER

1.1      BARREL              : Made using nitriding steel, single piece construction, ground and honed to high surface finish and close tolerance.

1.1.1   Treatment            : Gas nitriding

1.1.2   Heating Zone        : 2 Heating Zone,Out of which zone 2 is cooled by 0.25 hp blower.

1.1.3   Heating Load        : 5.0 kW

1.2      SCREW               : Made of nitriding steel, hardened and ground with special mixing head, and shear element.

1.1.1   Diameter              : 45 mm

1.1.2   L/D ratio              : 27 : 1

1.1.3   Treatment            : Gas nitriding

1.2.1   Capacity               : 60-65 kgs/hr. of HM/HDPE (As IF works on solid bed pumping, outputs can vary ±10 % depending on melt index, bulk density, hardness, co-efficient of friction and shape of pellets)

1.3      DIE                     : Made of alloy steel, ground, polished and plated. Following dies will be provided as below:

1. 75mm HM/HDPE DIE
2.         90MM LDPE DIE- Additional

1.3.1   Heating Zones       : 3 nos.

1.3.2   Heating load         : 5.75 kW

1.3.3   Candle Filter         : A special candle filter would be provided. This would ensure filter change-over time reduced by 50 %. One does not need to disturb the die or extruder while changing the filter.

1.4      DRIVE                 : 20 hp AC Variable frequency drive-Delta Make. The drive is digital and self diagnostic.

1.4.1   Gear box              : Helical gear box- Premium Greaves Make with integral thrust bearing. The lubrication is through oil splashing and the whole gear box is water cooled.

1.4.2   Motor                   : A 20hp motor- ABB Make will be provided.

1.4.3   Pulley                   : Suitable as required.

2      COOLING SYSTEM

2.1      COOLING RING  : One cooling ring suitable for die is made from aluminum alloy and has adjustable lips for air flow control.

2.1.1   Blower                 : A high capacity medium pressure blower powered by 2hp motor. A Damper Valve is provided on the suction side for control of the air quantity.

3      TOWER

3.1      TAKE OFF           : Fabricated from heavy channel and angle sections. Tower is having height of 12 feet.

3.1.1   Iris ring                : A variable height and variable diameter ring is fixed over the tower for holding the bubble properly.

3.1.2   Bubble Puncher Sensor      : An electrical bubble puncher sensor can detect punchers in the bubble, and appropriately fill the bubble up to minimize wastage of material

3.1.3Nip Rolls               : The Nip rolls can handle a tubing size of 800mm. They are actuated by two pneumatic cylinders and a solenoid valve.

3.1.4   Drive                   : The drive is through 1hp AC motor controlled by variable frequency drive.

3.1.5   Speed                  : 0 to 50 m/min.

3.1.6   Flattening board    : The board is made up of wooden slats fixed over an angle frame. The boards can be finely adjusted to get wrinkle free tubing. We also provide Universal Gusseting system.

3.1.7   Meter Counter       : A display showing total length extruded and line speed at which the current extrusion is running.

4      WINDING UNIT

4.1      WINDER             : A single station surface winder is provided along with two winding shafts. A special wrinkle remover is provided just before the winder for wrinkle free film winding.

4.1.1   Drive                   : The drive is through 0.5 hp torque motor .

5      CONTROL UNIT

5.1      PANEL                : The control panel is made of heavy sheet metal and is front opening type. The panel is painted white from inside for clear visibility. An unique feature of this panel is an interlocking mechanism between each temp. controller and the main motor. Unless the actual temp. of each zone is reached, the main drive can not be started, in order to safe guard the screw against damage which can occur due to solidified mass of polymer. In other words, this would act as a cold start preventer. A flasher unit is provided, which would continue flashing till the desired temperature is reached.

5.1.1   Temperature controller      : 5 PID Temperature controllers, indicating temp. of each zone.

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