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Mitsubishi, BOPP Production Plant, 1999, 6300mm Width, 250 m/min, 2000 kg/hr Extruder Capacity

Mitsubishi, BOPP Production Plant, 1999, 6300mm Width, 250 m/min, 2000 kg/hr Extruder Capacity

Description

  1. Overview
    1. One biaxial oriented polypropylene plant (BOPP) with 6,300 mm width and 250 meters per minute line speed.
    2. Manufacturer: Mitsubishi Heavy Industries, Ltd (MHI), year 1999.
    3. Maximum extruder output capacity: 2,000 kg/hr; finished product rated capacity: 1,700 kg per hour.
    4. Process: biaxially oriented polypropylene (BOPP), plain or composite film with 2 or 3 layers in B/A/A, B/A/B, or B/A/C configuration.
    5. Resin types: base layer – polypropylene homopolymer; skin layer – ethylene-propylene copolymer.
    6. Film thickness range: plain film 12–50 microns; composite film 15–40 microns.
    7. Operation side: film flows from left to right when standing at the operation side.
  2. Production Capacity
    1. Typical mill roll film capacity at 7,000 net hours per year: 12 micron at 200 m/min – 816 kg/hr, 5,712 ton/year.
    2. 15 micron at 250 m/min – 1,275 kg/hr, 8,925 ton/year.
    3. 20 micron at 250 m/min – 1,700 kg/hr, 11,900 ton/year.
    4. 30 micron at 166.6 m/min – 1,700 kg/hr, 11,900 ton/year.
    5. 40 micron at 125 m/min – 1,700 kg/hr, 11,900 ton/year.
    6. 50 micron at 76 m/min – 1,292 kg/hr, 9,044 ton/year.
  3. Extruder Output
    1. Main extruder: maximum approximately 2,000 kg/hr.
    2. Satellite extruder: maximum approximately 180 kg/hr per set, 2 sets.
    3. Maximum total: 2,000 kg/hr.
  4. General Specifications
    1. Finished film width: maximum 6,300 mm.
    2. Finished film thickness: plain film 12–50 microns; composite film 15–40 microns.
    3. Mill roll diameter: maximum 1,200 mm.
    4. Machine speed before orientation: maximum 60 m/min.
    5. Machine speed after orientation: maximum 260 m/min.
    6. Draw ratio in longitudinal direction: 1:1 to 1:7.
    7. Draw ratio in transverse direction: 1:7 to 1:10.
    8. BOPP line net machine dimensions: total length approximately 100 m, width approximately 13 m, height approximately 5.1 m.
  5. Polymer Receiving Area
    1. Unloading hopper: 1.5 cubic meter, 1 set.
    2. Rotary valve: capacity 10 tons/hour, 1 set.
    3. Blower: roots type, 30 kW, 1 set.
    4. Diverter valve: air operated, stainless cast iron, 5 sets.
  6. Polymer Storing Area
    1. Storage silo for virgin pellet: 50 cubic meter, 2 sets.
    2. Storage silo for reclaim pellet: 50 cubic meter, 2 sets.
    3. Storage silo for master batch pellets: 15 cubic meter, 2 sets.
  7. Mixing Area
    1. Blower: roots type, 15 kW, 1 set.
    2. Rotary feeder: capacity 3 tons/hr, 2 sets; 0.6 tons/hr, 2 sets; 0.5 tons/hr, 2 sets.
    3. Screw feeder: capacity 0.5 tons/hr, 2 sets.
    4. Cushion chamber: 100 liter, 1 set.
    5. Rotary valve: 3 tons/hr, 1 set.
    6. Hopper drier: 7 cubic meter, 1 set.
    7. Blower and heater: heater 110 kW, motor 30 kW, 1 set.
  8. Raw Material Feeding Area
    1. Blower: roots type, 18.5 kW, 1 set.
    2. Rotary valve: capacity 3 tons/hr, 1 set.
    3. Cushion chamber: 45 liter, 1 set.
    4. Rotary valve: capacity 3 tons/hr, 1 set.
    5. Feeding hopper with agitator: 2.4 cubic meter, motor 7.5 kW, 1 set.
  9. Edge Trim Crushing and Feeding Area
    1. Blower: turbo type, 15 kW, 1 set.
    2. Ejector: stainless steel, 1 set.
    3. Crusher: capacity 350 kg/hr, 1 set.
    4. Blower: turbo type, 15 kW, 1 set.
    5. Cushion chamber: 50 liter, 1 set.
    6. Rotary valve: capacity 350 kg/hr, 1 set.
  10. Auxiliary Raw Material Feeding Area
    1. Storage hopper: capacity 1 cubic meter, 2 sets.
    2. Auto-loader: vacuum suction type, 200 kg/hr, 2 sets.
    3. Feeding hopper: capacity 0.2 cubic meter, 2 sets.
  11. Extrusion Area – Primary Extruder
    1. Model: HME-135.
    2. Screw diameter: 135 mm.
    3. Screw speed: 30.2–393.9 rpm.
    4. Screw L/D ratio: 20, including feed throat portion; screw is special mixing type (HM screw).
    5. Material: Cr-Mo alloy steel; surface is hard-chrome plated; top of flight is flame hardened.
    6. Cylinder: made of nitrided steel; internal surface is honed.
    7. Drive transmission: heavy duty helical gears and radial bearing enclosed in transmission with integral case; oil cooling unit including heat exchanger, pump, and strainer; oil temperature gauge and oil pressure sensor installed.
    8. Feed throat: cast iron, jacketed for water cooling; all resin passage is hard-chrome plated.
    9. Heating and cooling: each zone controlled individually by resistance heating and water cooling system; aluminum cast-in heater jacket; cylinder 5 zones, flange 3 zones.
    10. Drive motor: 550 kW DC motor; speed 115–1,150 rpm constant torque, 1,150–1,500 rpm constant power.
  12. Extrusion Area – Secondary Extruder
    1. Single screw, 175 mm diameter, 107 kW heater.
    2. Model: HME-175.
    3. Screw diameter: 175 mm.
    4. Screw speed: 11.6–152 rpm.
    5. Screw L/D ratio: 20, including feed throat portion; screw is conventional type.
    6. Material: Cr-Mo alloy steel; surface is hard-chrome plated; top of flight is flame hardened.
    7. Cylinder: made of nitrided steel; internal surface is honed.
    8. Drive transmission: heavy duty helical gears and radial bearing enclosed in transmission with integral case; oil cooling unit including heat exchanger, pump, and strainer; oil temperature gauge and oil pressure sensor installed.
    9. Heating and cooling: each zone controlled individually by resistance heating and water cooling system; aluminum cast-in heater jacket; cylinder 4 zones, flange 1 zone.
    10. Drive motor: 250 kW DC motor; speed 115–1,150 rpm constant torque, 1,150–1,500 rpm constant power.