Bruckner, BOPP Line, 1989, 3500mm Wide, 5-Layer Extrusion

Description

Overview
1. Original installation: 1989
2. 5-layer extrusion upgrade: 1998
3. Kampf winder replaced: 2005
4. In production from 1989 initially manufacturing 3-layer BOPP products until upgraded with 5-layer extrusion in 1998.
5. Complete 5 layer, 3.5 meter wide BOPP line with the capability to manufacture transparent and white opaque films for sale into packaging and label applications.
6. Typically, the line has been used for the production of white opaque products in the gauge range of 20 to 90 micron, of physical densities between 0.50 and 0.96 g/cm3.
Typical Production Figures
1. Transparent 30 micron: 115 m/min, 650 kg/hr
2. White/opaque packaging 30-42 micron: 120-145 m/min, 600-850 kg/hr
3. White/opaque label 60-80 micron: 70-80 m/min, 550-750 kg/hr
Resin Blending and Heating
1. Colortronic volumetric blender (core)
2. 2-off Conair Franklin Autoweigh gravimetric blenders
3. 2-off Conair TB100-4 gravimetric blenders (2007)
4. Electric heating for core and additives
Main Extruders
1. Mitsubishi Heavy Industries 135/175 mm tandem extruder
2. Primary extruder ME-135 screw diameter 135 mm, 20:1 L/D
3. Secondary extruder ME-175 screw diameter 175 mm, 20:1 L/D
4. Nominal output 1,500 kg/h
Inner Layer Satellite Extruders
1. 1-off Telford Smith 120 mm, 29:1 L/D extruder
2. 1-off Telford Smith 90 mm, 29:1 L/D extruder
Outer Layer Satellite Extruders
1. 2-off Telford Smith 75 mm, 24:1 L/D extruders
Polymer Filters
1. Beringer EA40 filter between tandem extruders
2. Custom candle-type filter at outlet of tandem extruder
3. Beringer EA20 filter on each satellite extruder
Die
1. Extrusion Dies Inc. 520 mm AF6R 5-manifold die
2. Autoflex thermal lip adjustment
Chill Unit
1. Bruckner casting machine model 42/24 WL 60
2. Chill roll 2400 mm diameter, 800 mm width directly cooled
3. Primary and secondary indirectly-cooled water baths
Machine Direction Orienter
1. Bruckner MDO
2. Roll width 800 mm, maximum web width 600 mm
3. 16-roll preheat, 6-roll stretch (draw ratio 1:1 to 1:8) and 4-roll anneal sections
4. Indirect electrical heating via heat transfer fluid
5. Scrap winder
Traverse Direction Orienter
1. Bruckner TDO with FOK 4.4.2 track and sliding chain system
2. Feeding width 350-500 mm, maximum draw width 4300 mm, exit width 3000-3900 mm
3. Direct natural gas heating
Pull Roll Stand
1. Roll face width 4000 mm, maximum incoming web width 3900 mm
2. Sherman treater electrodes with Softal 60300 generators
Winder (2005)
1. Kampf "Imperial" H40/12 automatic two-station turret winder
2. Trimmed width 3800 mm maximum
3. Finished roll diameter capability 1200 mm maximum
4. Production speed capability 300 m/min maximum
Edge Trim Removal
1. Bloapco trim cutter and Avian G40/50 granulator
Drive and Control System
1. Siemens DC drive system
2. Siemens S7-400 PLC upgrade (2008)
Gauging System
1. Measurex 2040 thick and thin scanners
2. Honeywell Measurex MXProLine gauging system upgrade (2008)
Line Grinder
1. Avian Engineering G80/100 granulator
Lag Store and Roll Handling
1. 4000 mm steel core tubes, lag store and mill roll cranes
Primary Slitter
1. Atlas CW520A modified with special heavy duty rewind arms capable of winding slit reels up to 880 mm diameter
2. Unloading crane and packing table

Capacity	1500 kg/h nominal output
Extrusion Layers	5-layer

Dimensions	3500mm width
MDO Max Web Width	600 mm
MDO Roll Width	800 mm