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1. Stretch film casting equipment
Here we take Nanjing Sumino Seiko's stretch film casting equipment as an example.
(1) Main parameters of equipment
¢ÙStructure
Three-layer co-extrusion A/B/C (the proportion of each layer can be adjusted according to different product uses).
¢Ú Film width
2000mm (the film width can be cut online to 300mm).
¢ÛLinear speed
Up to 200m/min.
¢ÜFilm thickness range 0.02~0.1mm.
¢ÝThickness deviation
The thickness deviation of the automatic control production line is 2%; the thickness deviation of the manual control production line is 5%.
¢ÞMaximum output
2500t/a (calculated based on film thickness 20¦Ìm and annual operation of the production line 7000h).
¢ßComplete machine capacity
550kW.
(2)Production process
Raw materials ¡ú negative pressure feeding ¡ú two-component ratio feeding ¡ú extrusion ¡ú filtration ¡ú metering pump (optional) ¡ú melt pipeline ¡ú distributor ¡ú mold ¡ú quenching and shaping ¡ú online
Thickness measurement ¡ú corona treatment (optional) ¡ú three-way traction and online slitting ¡ú center winding ¡ú unloading of finished products.
(3) Equipment process description
¢Ù Negative pressure feeding
Use a powerful negative pressure fan to control the entire suction and feeding process through PLC.
¢ÚDouble-component ratio feeder
Each auxiliary machine uses two sub-hoppers for the masterbatch. Through two feeding screws with different speeds and different pitches, the raw materials and functional masterbatch are sent to the masterbatch hopper according to the set proportion and stirred evenly. The main hopper of the main machine is equipped with a sub-hopper, and an online recycling side hopper is added in the center of the sub-hopper. The recycled materials and raw materials are quantified, timed and evenly mixed through the feeding screw before being sent to the extruder inlet; the online recycling rate of the side materials can reach 99% .
¢ÛExtrusion
Equipped with three extruders (one main extruder and two auxiliary extruders), it can produce both single-sided self-adhesive wrapping film and double-sided self-adhesive wrapping film.
Membrane, flexible selection of raw materials. Taking into account the applicability of metallocene ethylene, a PE-specific screw structure (mixing type, with barrier section) is used to reduce the shear force of the screw on the material; the barrel is heated with a heater with toothed fins to ensure Temperature control accuracy; equipped with a hydraulic screen changer, which can quickly and easily change screens. There are pressure sensors in front of and behind the screen to monitor melt pressure fluctuations.
¢ÜMetering pump, distributor and mold
According to different requirements of customers, domestic parts (produced by Zhejiang Jingcheng Company) or imported parts (produced by Italian Simplas Company) can be selected.
The mold lip adjustment adopts a manual single-point push-pull structure, and the distance between the adjustment screws is 25.4mm. All melt flow surfaces are chromium-plated, and the surface roughness is below R.0.03¦Ìm; due to the high mold production temperature (around 260¡ãC) , the heating tube power should be slightly higher, and the temperature control accuracy should be within ¡À1¡ãC.
¢ÝDouble cavity negative pressure air box
A double-cavity negative pressure bellows is installed under the mold and close to the film casting roller, and vacuum is used to remove the air between the extruded film sheet and the film casting roller to achieve forced film attachment. The vacuum box consists of two boxes, namely the pre-evacuation box and the vacuum box. The function of the pre-evacuation box is to ensure that the main chamber can reach high vacuum and eliminate volatile matter, and its vacuum degree can be controlled above 1470Pa; the main chamber is a high vacuum box, and the vacuum degree can reach above 7840Pa. The use of a double-chamber negative pressure box can greatly increase the film casting speed (making the production speed reach 220m/min), ensure the stability of the cast film, reduce the amount of film necking, and increase the effective width of the film. The vacuum box is made of stainless steel, and the inner surface is easy to clean. There is an insulation layer between the vacuum box and the mold, and there are baffles on the sides to adjust the tightness of the box.
¢ÞElectronic edge locking
The use of electronic edge locking devices can better adapt to the needs of high-speed production and reduce shrinkage.
¢ßFilm casting device
The film casting device consists of a film casting roller, a quenching roller, a cleaning and flattening roller, an independent drive motor, a positive pressure air knife, a mobile lifting motor, a frame, etc. The film casting roller is
The matte roller and the quench roller are mirror rollers. The cooling channel of the quenching roller adopts a bidirectional backflow spiral flow channel design. The surface temperature difference error of the quenching roller surface can reach a level of ¡Ü¡À1¡ãC to improve product quality. In order to obtain the best production process conditions and adapt to the changes in the processing degree and speed of many different raw materials, the row lift can be raised and lowered, and can also move forward and backward, and the cleaning gauge can also be adjusted on the gauge, in order to meet the production needs of thicker solubility. , equipped with a positive pressure air blower on the film casting machine and using electric adjustment, the staff can adjust its position and angle according to production needs.
¢à Thickness measurement
According to the different requirements of users, domestic thickness gauges or imported online thickness gauges can be selected.
¢á Traction (online slitting) and center winding
Using three traction devices and three tension detection rollers respectively, the film can be trimmed (and online slit) between the first traction and the second traction. The slit film is pulled by the third traction, which is smooth and smooth. Send the film to the winding machine, and always keep a certain distance between the winding machine and the approach roller to ensure that the winding is wrinkle-free. Because the stretch film has excellent toughness, the cutting knife provided is particularly sharp and moves during slitting to ensure that the edges of the film are neat and lint-free. The production line adopts a dual-station roll-changing system. When one station is fully rolled, the rewinding motor drives the other station to the winding position. At the same time, the sawtooth flying knife cuts the film, and the photoelectric sensor guides the approach roller to approach the winding reel for the next step. Winding.
¢âUnloading device
The rewinding area is equipped with an imported electric crane to facilitate unloading of semi-finished film, reduce labor intensity and improve work efficiency.
⑪1 Scrap recycling device
The edge material recycling adopts negative pressure edge suction, online crushing and the crushed edge material is directly sent to the upper hopper of the main extruder by air, mixed with other raw materials and then enters the extruder.
(4) Electrical control system
Using SIEMENS human-machine interface device, various operations can be performed on the entire production line through the human-machine interface device. Including data monitoring, real-time monitoring of work stations, querying fault records, and information exchange between teams. The transmission part of the production line adopts Sie-mens vector frequency converter and high-precision rotary encoder group for closed-loop speed regulation; the casting roller, quenching roller, three-way traction, and winding adopt synchronous tension closed-loop adjustment control; the double-station center winding and collecting The roll can realize functions such as automatic diameter calculation, tension calculation and taper adjustment; the speed of the whole machine is automatically tracked, the speed regulation accuracy is 0.01%, and the entire production line can realize single and linkage control. The temperature part adopts the intelligent integrated temperature control module of Japan's RKC Company to complete signal collection, control, setting and monitoring, all of which can be realized through the human-machine interface.
Nanjing Sumino Seiko Machinery Co., Ltd. has a professional cast film production line. The company's main cast film manufacturing production lines include: TPU hot melt adhesive film production line, CPP/CPE cast film production line, EVA solar encapsulation adhesive film production line, PE hygienic and breathable film Film production line, PVDF cast film production line, PP three-dimensional film production line, medical blood purification film production line, multi-layer co-extruded barrier film production line, LLDPE stretch film production line, etc.
Here we take Nanjing Sumino Seiko's stretch film casting equipment as an example.
(1) Main parameters of equipment
¢ÙStructure
Three-layer co-extrusion A/B/C (the proportion of each layer can be adjusted according to different product uses).
¢Ú Film width
2000mm (the film width can be cut online to 300mm).
¢ÛLinear speed
Up to 200m/min.
¢ÜFilm thickness range 0.02~0.1mm.
¢ÝThickness deviation
The thickness deviation of the automatic control production line is 2%; the thickness deviation of the manual control production line is 5%.
¢ÞMaximum output
2500t/a (calculated based on film thickness 20¦Ìm and annual operation of the production line 7000h).
¢ßComplete machine capacity
550kW.
(2)Production process
Raw materials ¡ú negative pressure feeding ¡ú two-component ratio feeding ¡ú extrusion ¡ú filtration ¡ú metering pump (optional) ¡ú melt pipeline ¡ú distributor ¡ú mold ¡ú quenching and shaping ¡ú online
Thickness measurement ¡ú corona treatment (optional) ¡ú three-way traction and online slitting ¡ú center winding ¡ú unloading of finished products.
(3) Equipment process description
¢Ù Negative pressure feeding
Use a powerful negative pressure fan to control the entire suction and feeding process through PLC.
¢ÚDouble-component ratio feeder
Each auxiliary machine uses two sub-hoppers for the masterbatch. Through two feeding screws with different speeds and different pitches, the raw materials and functional masterbatch are sent to the masterbatch hopper according to the set proportion and stirred evenly. The main hopper of the main machine is equipped with a sub-hopper, and an online recycling side hopper is added in the center of the sub-hopper. The recycled materials and raw materials are quantified, timed and evenly mixed through the feeding screw before being sent to the extruder inlet; the online recycling rate of the side materials can reach 99% .
¢ÛExtrusion
Equipped with three extruders (one main extruder and two auxiliary extruders), it can produce both single-sided self-adhesive wrapping film and double-sided self-adhesive wrapping film.
Membrane, flexible selection of raw materials. Taking into account the applicability of metallocene ethylene, a PE-specific screw structure (mixing type, with barrier section) is used to reduce the shear force of the screw on the material; the barrel is heated with a heater with toothed fins to ensure Temperature control accuracy; equipped with a hydraulic screen changer, which can quickly and easily change screens. There are pressure sensors in front of and behind the screen to monitor melt pressure fluctuations.
¢ÜMetering pump, distributor and mold
According to different requirements of customers, domestic parts (produced by Zhejiang Jingcheng Company) or imported parts (produced by Italian Simplas Company) can be selected.
The mold lip adjustment adopts a manual single-point push-pull structure, and the distance between the adjustment screws is 25.4mm. All melt flow surfaces are chromium-plated, and the surface roughness is below R.0.03¦Ìm; due to the high mold production temperature (around 260¡ãC) , the heating tube power should be slightly higher, and the temperature control accuracy should be within ¡À1¡ãC.
¢ÝDouble cavity negative pressure air box
A double-cavity negative pressure bellows is installed under the mold and close to the film casting roller, and vacuum is used to remove the air between the extruded film sheet and the film casting roller to achieve forced film attachment. The vacuum box consists of two boxes, namely the pre-evacuation box and the vacuum box. The function of the pre-evacuation box is to ensure that the main chamber can reach high vacuum and eliminate volatile matter, and its vacuum degree can be controlled above 1470Pa; the main chamber is a high vacuum box, and the vacuum degree can reach above 7840Pa. The use of a double-chamber negative pressure box can greatly increase the film casting speed (making the production speed reach 220m/min), ensure the stability of the cast film, reduce the amount of film necking, and increase the effective width of the film. The vacuum box is made of stainless steel, and the inner surface is easy to clean. There is an insulation layer between the vacuum box and the mold, and there are baffles on the sides to adjust the tightness of the box.
¢ÞElectronic edge locking
The use of electronic edge locking devices can better adapt to the needs of high-speed production and reduce shrinkage.
¢ßFilm casting device
The film casting device consists of a film casting roller, a quenching roller, a cleaning and flattening roller, an independent drive motor, a positive pressure air knife, a mobile lifting motor, a frame, etc. The film casting roller is
The matte roller and the quench roller are mirror rollers. The cooling channel of the quenching roller adopts a bidirectional backflow spiral flow channel design. The surface temperature difference error of the quenching roller surface can reach a level of ¡Ü¡À1¡ãC to improve product quality. In order to obtain the best production process conditions and adapt to the changes in the processing degree and speed of many different raw materials, the row lift can be raised and lowered, and can also move forward and backward, and the cleaning gauge can also be adjusted on the gauge, in order to meet the production needs of thicker solubility. , equipped with a positive pressure air blower on the film casting machine and using electric adjustment, the staff can adjust its position and angle according to production needs.
¢à Thickness measurement
According to the different requirements of users, domestic thickness gauges or imported online thickness gauges can be selected.
¢á Traction (online slitting) and center winding
Using three traction devices and three tension detection rollers respectively, the film can be trimmed (and online slit) between the first traction and the second traction. The slit film is pulled by the third traction, which is smooth and smooth. Send the film to the winding machine, and always keep a certain distance between the winding machine and the approach roller to ensure that the winding is wrinkle-free. Because the stretch film has excellent toughness, the cutting knife provided is particularly sharp and moves during slitting to ensure that the edges of the film are neat and lint-free. The production line adopts a dual-station roll-changing system. When one station is fully rolled, the rewinding motor drives the other station to the winding position. At the same time, the sawtooth flying knife cuts the film, and the photoelectric sensor guides the approach roller to approach the winding reel for the next step. Winding.
¢âUnloading device
The rewinding area is equipped with an imported electric crane to facilitate unloading of semi-finished film, reduce labor intensity and improve work efficiency.
⑪1 Scrap recycling device
The edge material recycling adopts negative pressure edge suction, online crushing and the crushed edge material is directly sent to the upper hopper of the main extruder by air, mixed with other raw materials and then enters the extruder.
(4) Electrical control system
Using SIEMENS human-machine interface device, various operations can be performed on the entire production line through the human-machine interface device. Including data monitoring, real-time monitoring of work stations, querying fault records, and information exchange between teams. The transmission part of the production line adopts Sie-mens vector frequency converter and high-precision rotary encoder group for closed-loop speed regulation; the casting roller, quenching roller, three-way traction, and winding adopt synchronous tension closed-loop adjustment control; the double-station center winding and collecting The roll can realize functions such as automatic diameter calculation, tension calculation and taper adjustment; the speed of the whole machine is automatically tracked, the speed regulation accuracy is 0.01%, and the entire production line can realize single and linkage control. The temperature part adopts the intelligent integrated temperature control module of Japan's RKC Company to complete signal collection, control, setting and monitoring, all of which can be realized through the human-machine interface.
Nanjing Sumino Seiko Machinery Co., Ltd. has a professional cast film production line. The company's main cast film manufacturing production lines include: TPU hot melt adhesive film production line, CPP/CPE cast film production line, EVA solar encapsulation adhesive film production line, PE hygienic and breathable film Film production line, PVDF cast film production line, PP three-dimensional film production line, medical blood purification film production line, multi-layer co-extruded barrier film production line, LLDPE stretch film production line, etc.