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NovaStar, PC286, Automatic Filling Line, Shredding, Opening, Mixing and Filling (New)

Description

  1. Overview
    1. The whole line is combined with a fine fiber opening system, ball fiber making system and recycle foam shredder, finished material mixing, weighing system and filling station.
    2. The whole line is controlled by a Siemens PLC control system that can be handled by only 2 operators.
    3. High accuracy weighing and mixing system that is able to mix recycle foam and opening fiber, recycle foam and ball fiber with uniform blending quality.
    4. High accuracy opening fiber machine that is able to process any type of synthetic fiber with high opening rate and high capacity; the opening rate could be maximum 100% and capacity 480 kg per hour.
    5. High accuracy weighing system that is able to have tolerance around 15 g and 8 pieces in a minute capacity.
    6. High accuracy dynamic balance process, so that the machine runs without vibration and noise.
    7. Dust collection system to keep the working shop clean.
    8. Main motor power currency detection system that will protect the motor safe away from high pressure.
    9. Most of the electrical key parts are adopted by the most famous world brands such as Siemens, Schneider and ABB, etc.
    10. Highest ratings for safety standard in EU market.
    11. CE certification.
  2. Working Mode
    1. Polyester fiber opening, weighing and direct filling.
    2. Ball fiber processing, weighing and direct filling.
    3. Opening fiber and recycle foam mixing, weighing for filling.
    4. Ball fiber mix with recycle foam, weighing for filling.
  3. Material Application
    1. Hollow siliconized polyester fiber.
    2. Conjugate hollow siliconized polyester fiber.
    3. Recycle foam without plastic skins.
    4. Flame retardant polyester fiber.
    5. 0.8 d to 15 d, 25 mm to 64 mm.
  4. Specifications
    1. Layout diagram: 18900 x 7970 x 4440 mm.
    2. Power: 107.25 kW.
    3. Voltage: 480 V, 60 Hz, 3 phase.
    4. Fiber opening capacity: 200 to 480 kg/h.
    5. Ball fiber capacity: 200 to 260 kg/h.
    6. Recycle foam shredding capacity: 100 kg/h.
    7. Filling system mechanical capacity: 8 pc/min according to different material, different production.
    8. Weighing tolerance: 15 g.
    9. Mixing tolerance: 1%.
    10. Air pressure: 6 to 8 bar, 1 m³.
    11. Bale breaker working width: 1200 mm.
    12. Fine fiber opening machine working width: 1000 mm.
    13. Ball fiber machine working width: 1000 mm.
    14. Filling pipe diameter: 100 mm.
    15. Filling station: 1.
    16. Operator need: 1 to 2.
    17. Weight: 15270 kg.
  5. Equipment Details
    1. Bale Breaker
      1. The bale breaker is mainly used to load 1 or 2 bales of fiber raw material automatically to the next program, in order to save operator at this program.
      2. Feeding quantity adjustable by photo cell.
      3. High capability and capacity.
      4. Easy to operate.
      5. Dynamic balance without vibration and noise.
      6. Working width: 1200 mm.
      7. Power: 4.05 kW.
      8. Voltage: 3 phase by order.
      9. Capacity: 1 to 2 bales.
      10. Capacity: 400 to 600 kg/h.
    2. Fine Fiber Opening Machine
      1. It is able to be used for both down-like fiber and regular fiber with high opening rate and capacity.
      2. Main motor circuit detection relay protection, so machine will not get stuck, meanwhile avoid motor broken.
      3. V to wire roller and cylinder produced.
      4. Electrical metal alarm system.
      5. Anti to deviation raw material feeding.
      6. Anti to stuck shaft design, so that we don’t need wasting time for the machine cleaning.
      7. Reasonable air flow structure designed.
      8. Power: 13.2 kW.
      9. Voltage: 3 phase by order.
      10. Capacity: 200 to 480 kg/h according to different material.
      11. Material application: polyester fiber 0.5 to 15 d, 8 to 64 mm.
      12. Fiber opening rate: max. 100%.
    3. Ball Fiber Machine
      1. The down-like ball fiber machine is able to make 2.5 d fiber up and 25 mm to 64 mm polyester fiber according to different requirement.
      2. Adjustable ball fiber size and capacity that is able to reach different range of the fiber ball and finished production quality requirement.
      3. But reasonable design and technical balling date adjustment, the finished ball fiber is able to hold warm air and keep the production fluffy enough.
      4. It is able to pass the top range washing testing requirement by top range productions.
      5. Power: 13.25 kW.
      6. Working width: 1000 mm.
    4. Foam Shredder
      1. The foam shredder is mainly used to process the foam waste in home textile area.
      2. The finished foam size can be adjusted by exchanging the shredding net with different size.
      3. Power: 29 kW.
      4. Voltage: 3 phase by order.
      5. Capacity: 100 to 300 kg/h.
      6. Shredding net: 3 pc / 3 mm, 18 mm, 30 mm.
      7. Shredding size: 3 to 22 mm.
      8. Weight: 900 kg.
    5. Fiber Distributor and Metal Separator
      1. Aluminum blower blade with dynamic balance process.
      2. Metal separator is used to catch up the metal and needles while coming through the duct after opening machine.
      3. Easy to clean.
      4. High capability.
      5. Power: 2.2 kW.
      6. Voltage: 3 phase by order.
      7. Capacity: 600 kg/h.
    6. Electrical Weighing Mixer
      1. Different material can be mixed by the electrical weighing mixer with adjustable mixing ratio and weight.
      2. It can be used to mix different material for 2 or 3 different materials.
      3. Different material feeding one by one adjusted by Siemens PLC program.
      4. Uniform mixing quality.
      5. Clean discharging.
      6. Dust collection.
      7. Power: 2.95 kW.
      8. Voltage: 3 phase by order.
      9. Mixing capability: fiber, fiber cluster, recycle foam, feather, etc.
      10. Capacity: 200 to 360 kg/h according to different material.
    7. Silo
      1. The silo is mainly used to keep enough material after mixing ready for the next program supplying as soon as receive signal from the filling system.
      2. By screwing design that is specially for mixed material and recycle foam storage and supplying.
      3. Dust collection.
      4. Volume: 5 cbm.
      5. Power: 1.5 kW.
      6. Voltage: 3 phase by order.
    8. Electrical Weighing System
      1. It could be used for both single opening fiber, ball fiber.
      2. The finished fiber will be loaded into a vibration hopper on the top of the load cell with a separated frame which will not affect the load cell accuracy.
      3. The material will be dropped down to the first and top box which will hold it for a while and then drop to the load cell start weighing in order to save time and increase the capacity.
      4. As soon as the target fiber quantity comes that will be filled into case.
    9. Vacuum Filling System
      1. There are 2 vacuum filling cabinets arranged next to the weighing system and 2 nozzles in each cabinet that can be handled by only 1 operator.
    10. Control System
      1. All machines are able to reach the top safety standard from Europe, American.