Futura, Futura Extreme, 2006, Baby Diaper Production Line, 400 pcs/min, 200m/min

Description

Overview
1. Baby diapers production line
2. Maximum surface speed (Vop maximum): 200 m/min
3. Product with tissue: 400 pcs/min
4. Product without tissue: 350 pcs/min
5. Maximum shaft rotation speed: 500 rev/min
6. Corresponding operating speed: 500 pcs/min (210 m/min)
7. Global efficiency (EG %) at maximum speed (and out of the stacker): 85%
8. EG% = 100 effective production / theoretical production capacity
9. Scraps: < 3%
10. Production started with it in year 2006
Condition And Maintenance
1. Machine is in good running condition and well maintained
2. Preventive maintenance is done every Monday, with a general maintenance shutdown for 2 weeks yearly
3. Visits from Diatec technicians once per year
Machine Parts
1. 2 Acrison SAP applicators
2. 1 pulp and SAP recycling system
3. 2 forming drums and 2 saw tooth mills
4. 1 soundproof cabin
5. 7 glue applicators (incl. tank, filters, pumps, hoses, modules, nozzles) – see attachment
6. 1 lotion care applicator (incl. tank, filters, pumps, hoses, modules, nozzles) – see attachment
7. 1 display operator console
8. 3 hoists for raw mat application
9. Alarm overhead digital display
10. Automatic splicing (except for tapes)
11. Mechanical and electrical panels
12. Fully servo driven
13. Elau and Siemens electronic systems
Auxiliary Equipment Included
1. 1 CB Star FBV 500 automatic sealing machine + 3 belt conveyors
2. 1 CB automatic packaging machine Leonardo DX 300 (for small packs)
3. 1 manual compactor offline machine
4. 1 Mako sealing offline machine
5. 1 Aligator sealing offline machine
6. Maximum nominal speed: 400 pieces/min
Mills
1. Fluff production maximum capacity (Qop maximum): 2 x 2800 kg/h
2. Installed power: 2 x (37 + 4, 1 x 2) kW
SAP Feeder
1. Capacity: 250 x 2 kg/h
2. Diaper feeding: 2 to 16 g
Filter
1. Capacity: 50,000 mc/h
Stacker
1. Manuel bagging exits: 1
2. Manuel bagging speed: 50 cycles/min x 2
3. Manuel bagging stacks format: 10-12 pcs
4. Automatic bagging exits: 1
5. Automatic bagging speed: 50 cycles/min x 1
6. Automatic bagging stacks format: 10-35 pcs
Switchgear And Control Gear Assemblies
1. Normative reference: EN 60439-1
2. Main power supply system: three-phase + N + PE
3. Main power supply rated operational voltage: 400 VAC
4. Main power supply rated frequency: 50 Hz
5. Auxiliary circuits (switching devices) power supply rated operational voltage: 220 VAC
6. Auxiliary circuits (control, measuring, signalling, regulating equipment) power supply rated operational voltage: 24 VDC
7. Panel degree of protection: IP 55
Electrical Consumptions
1. Installed power (motors): 500 kW
2. Installed power (hot melters): 100 kW
3. Installed power (stacker): 60 kW
4. Packaging unit: 40 kW
5. Required working power: 300 kW
6. Power factor (cos Q): 0.78
7. Peak current: 800 A
8. RMS rated current: 550 A
Weights And Dimensions
1. Dimensions: 40845.83 x 4503
2. Total weight: 52.00 kg
3. Maximum load concentrated on floor supports: 1400 kg
Pneumatic System Requirements
1. Minimum required pressure: 6 bar
2. Air specific humidity: < 0.002 kg vapour/kg air
3. Residual oil content: < 4 mg oil/m³ aria
4. Air consumption: 200 L/min
Ideal Service Conditions
1. Ambient air temperature: 10°C - 40°C
2. Relative humidity: 50% - 65%
3. Pollution degree: no dusts or other pollutants
Leonardo General Machine Characteristics
1. Weight: 7,000 kg
2. Feeding: tensione secondo richiesta del cliente
3. Max power absorbed: 9 ampere
4. Air feeling: 6 bar
5. Air consumption: 300 NL/min
6. Type of welding: impulse
7. Speed (production rate): 60 cycle/min
Leonardo Machine General Features
1. Packaging machine PAN 500 double
2. Product pre-compacting mechanical group for the interface between the stacker and the packaging machine
3. Servo-driven pushers which move the products from the precompacting unit to the welding head
4. Servo-driven mechanical group of bag opening
5. Group mechanic servo-assist of bag insertion
6. Servo driver welding head and high performing cutting system
7. Servo-driven side belt for empty bags loading
8. Quick format changeover
9. All the machine functions are electrically synchronised by means of servomotors
10. Electronically controlled pneumatics mechanism
11. PLC control unit
12. Detailed and clear user interface
Alpha System Technical Data
1. Machine type: modular horizontal stacker model Vanguard B2E
2. Stacker configuration: baby diapers
3. Operation: electromechanic / electropneumatic
4. No of operators: 1 person
5. Chain type: 3/8" double chain - 1 paddle every two steps
6. Paddle geometry: 6 gear wheels
7. Product speed: 400 pcs/min
8. Max number of ejector cycles: 40 ejections/minute
9. Number of ejectors: 2 ejectors units working at the same time
10. Noise (measured at our site): < 80 dB A (according to UNI 7712 table)
Alpha System Ejection Features
1. Type of ejection: automatic
2. Designed number of cycles: max 40 cycles/min
3. Number of pieces per single ejection: min 8 max 40 pieces
Alpha System Pneumatic System
1. Air consumption: non relevant
2. Operation air pressure: minimum 6 bar (unlubricated)
Alpha System Electric System (Standard)
1. Standard voltage: 3 x 400V, 50Hz + earth (different upon request)
2. Neutral: yes
3. Voltage variation: +/- 5%
4. Power consumption: 30 kW
5. Voltage present: 230 VAC - 24 VDC
6. Auxiliary voltage: 24 VDC
7. Electric system: complying with EC standards
Diatec Diaper Line Adhesives
1. Adhesives in use: Adtek 738P (construction) and Adtek 736 (elastic)
Diatec Tissue Application
1. Unit: VL410 1.8.1.8CC
2. Part no: 780 614
3. Serial no: NC04H00010
4. Hose: 1 x 24ft, part no. 274 797
5. 1 x 4 module CF gun (upgraded to UM22 modules)
6. UCF nozzles in use (to be upgraded to signature)
7. 1 x 24 VDC MAC solenoid valve
8. Unit was overfilled, causing excessive glue waste and is detrimental to the unit
9. Cleaned all glue in the base of the unit and checked for other leaks (none visible)
10. Filters and O rings replaced and hose purged
Diatec Leg Cuff Elastic Application
1. Unit: VL430 1.8.1.8CC
2. Part no: 780