Description Overview PP fibrillated yarn extruder line Model: Novastar-120 Extrusion line for production of PP fibrillated yarn Raw material: PP granule Finished products: non-twisted tape yarn, fibrillated yarn for twine Range of product: 10,000 to 30,000 denier 10,000 denier approximately 17 to 19 yarn 16,000 denier approximately 11 to 12 yarn 22,000 denier approximately 8 to 9 yarn 28,000 denier approximately 6 to 7 yarn 32,000 denier approximately 5 to 6 yarn Extrusion throughput: 300 kg per hour Extrusion capacity: 180 to 250 kg per hour (product capacity depends on filament size) Extruder screw diameter: Ø SY116 mm T-die width: 1300 mm Take-off roller width: 1200 mm Take-off line speed: 160 meters per minute (maximum) Operation side: right to left, or left to right Extrusion Item 001 Extruder Screw diameter: Ø SY116 mm Screw L/D: 28:1 Screw barrel material: SACM-645 steel nitride harden, normalization HRC 55-60° Gear box: SL-150 (1/10) helix gear Gear box lubricant system: with oil pump lubrication Driving motor: 150 HP AC motor with ABB inverter control Heating zone: 6 zones (cylinder and head) Heating system: by band heater Heating capacity: 42 kW (approximately) Cooling for hopper jacket: water cooling system Cooling of cylinder: air cooling system by 1/4 HP blower x 6 set Screw extractor tool: 1 set (attached with gearbox) Based rack for extruder Device type: station type based rack For supporting the extruder and gearbox T-die set T-die width: 1300 mm x 1 set Die-lip width: 1200 mm Effective width: 1100 to 1050 mm T-die gap: 1.2 to 1.8 mm Die lip set: flat or grooved Heating zone: 5 zones Heating system: cartridge heater (rod heater) Heating capacity: 28 kW Quenching Item 002 Quenching water bath Device type: water circulation system, movable and height adjustable Inner bath: stainless steel #304 Tank size: 1400 mm L x 1200 mm W x 550 mm D Water distribution system: 1 set Take-Up Nip Roller Item 003 Take-up nip rollers: Ø 215 mm x 1300 mm L - 1 set (by pneumatic cylinder) Take-up motor: 3 HP (0.75 kW) AC motor with ABB inverter control Water stripper: 3 HP suction blower with suction pipe and water stopped roller Slitting Item 004 Slitting unit Slitting device: adjustable cutting blades x 1 unit Position adjustable: up/down, and L to R adjustable Cutting blade: slitting knife x 16 pieces Production calculation (based on running 10,000 to 32,000 denier range) 10,000 denier approximately 17 to 19 yarn (slitting width 55 mm) 16,000 denier approximately 11 to 12 yarn (slitting width 90 mm) 22,000 denier approximately 8 to 9 yarn (slitting width SY116 mm) 28,000 denier approximately 6 to 7 yarn (slitting width 155 mm) 32,000 denier approximately 5 to 6 yarn (slitting width 180 mm) Godet roller unit no. 1: (take-off unit A) Take-off unit type: oil immersed gear drive - 5 rollers Take-off roller: Ø 295 mm x 1200 mm L Roller surface: chromed plated Driving motor: 10 HP AC motor with ABB inverter control Take-off speed: 10 to 50 meters per minute Rubber press roller: Ø 150 mm x 1150 mm L - pneumatic operated x 1 set Attached with: control panel with on/off switch, speed meter, and EMG stop button Edge trims reclaim system Trims crusher: 1 HP Conveyor blower: 2 HP conveyor blower Chip screw feeder: 1/4 HP with silo hopper Stretching Item 005 Stretching hot air oven Device type: double deck heating circulation hot air oven Oven size: 4500 mm L x 1200 mm width Hot air circulation system: 2 HP circulation fan x 2 set with inverter controller Heating method: electric heater pipe Heater capacity: 36 kW Auto. thermos-controller: 2 set Attached with: control panel with A-meter, on/off switch Oven open/close: 2 stages by pneumatic cylinders Item 006 Godet roller unit no. 2: (take-off unit B) Take-off unit type: oil immersed gear drive - 7 rollers Take-off roller: Ø 295 mm x 1200 mm L - 5 pieces Water cooled roller: Ø 295 mm x 1200 mm L - 2 pieces (with rotary joint) Roller surface: chromed plated Driving motor: 20 HP AC motor with ABB inverter control Take-off speed: 0 to 160 meters per minute Rubber press roller: Ø 150 mm x 1150 mm L - pneumatic operated x 1 set (roller B7) Attached with: control panel with on/off switch, speed meter, and EMG stop button Fibrillating Item 007 Fibrillator unit Fibrillating roller: Ø 138 mm x 1200 mm L x 1 set (integrated in godet unit no. 2) Fibrillating width: 1100 mm Needle strip density: 1 set - 8 needle/cm x 36 slots (2 stagger off-set) - by Burckhardt Fibrillator driving motor: 10 HP (7.5 kW) AC motor with ABB inverter control Line speed: 60 to 240 meters per minute Attached with: control panel with on/off switch, speed meter, and EMG stop button Item 008 Godet roller unit no. 3: (take-off unit C) Take-off unit type: oil immersed gear drive - 5 rollers Take-off roller: Ø 295 mm x 1200 mm L - 5 pieces Roller surface: chromed plated Driving motor: 10 HP AC motor with ABB inverter control Take-off speed: 0 to 160 meters per minute Rubber press roller: Ø 150 mm x 1150 mm L - pneumatic operated x 1 set (roller B7) Attached with: control panel with on/off switch, speed meter, and EMG stop button Control Cabinet and Control System Item 009 Control cabinet Air ventilation cooling design - with air ventilation for optimum component performance Process control system: 1 unit Main supply: with main switch Emergency system: by emergency switch Inverter: AC-drive system by ABB inverter control Auto temp. controller: on/off switch, thermo controller x 12 set Main drive: power switch, A-meter, RPM and potentiometer x 1 set Main drive control: 150 HP (112.5 kW) inverter controlled x 1 set Unit drive control: 10 HP (7.5 kW) inverter controller (draw-stand no. 1) x 1 set 20 HP (15 kW) inverter controller (draw-stand no. 2) x 1 set 10 HP (7.5 kW) inverter controller (fibrillated unit) x 1 set 10 HP (7.5 kW) inverter controller (draw-stand no. 3) x 1 set Draw stand control: on/off switch, A-meter, potentiometer, meters per minute gauge x 3 set Synchronized control: manual/automatic switch, speed up and down switch x 1 set Accessories and Spare Parts Take-off unit gear reducer cooling device x 2 set Take-off unit emergency stop foot-pad and temperature gauge x 3 set Toolbox and assorted tools x 1 set Standard spare parts x 1 set Optional Equipment Item 010 Central process monitoring and control system upgrade Control and monitoring complete extrusion line and take-off unit System type: by Fatek PLC with 12” ADT HMI touch screen PLC and program configuration for JC-MNP series: temperature control module + analog module + digital input module Features: extruder temperature digital control (SV/PV/AMP display) Extruder control (RPM/AMP/% display) Pressure monitoring system (BAR display) Stretching bath and oven temperature digital control (SV/PV/AMP display) Line speed control (meters per minute)
