Description
Overview
Double-sided coating production line for PVC tarpaulin and cover cloth, suitable for knife coating on both faces, knife coating on one face, plasticizing and drying, and stentering / heat-setting.
New line, built to order, complete from the twin-position unwind through to the twin-position A-frame centre winder.
Roller face width 4,000 mm (157.5 in), finished product width 1,200 to 3,800 mm (47.2 to 149.6 in).
3 coating heads: 1 double-sided vertical knife coater and 2 multi-function knife coaters, plus 3 gravure lacquer surface treatment units each with its own 6 m (19.7 ft) vertical oven.
Main Technical Parameters
Mechanical width (roller face): 4,000 mm (157.5 in)
Product width: 1,200 to 3,800 mm (47.2 to 149.6 in)
Width adjustment range: 1,200 to 4,000 mm (47.2 to 157.5 in)
Mechanical speed: 3 to 30 m/min (10 to 98 ft/min)
Handing: supplied as a left-hand or a right-hand machine
Oven heating: the first 3 ovens are natural gas heated; the 3 rear surface-treatment ovens use thermal-oil hot-air circulation
Maximum oven temperature: 230 C (446 F)
Stenter oven temperature control range: 100 to 230 C (212 to 446 F), 1 heating zone every 3 m (9.8 ft), 6 zones in total
Ironing and calender heating: thermal oil
Drive and control: AC motor drive, PLC program control, touch-screen operation
Control power supply: AC 380 V, 50 Hz, plus or minus 10 %
Installed power: about 280 kW (375 hp)
Overall length on the general arrangement drawing: about 70,113 mm (230 ft)
Line Configuration
Twin-position unwind with cloth splicing and clamping device
40 m (131.2 ft) cloth accumulator
Two-roll hot ironing and single-roll cooling
Vertical knife coater, coating both faces
6 m (19.7 ft) vertical oven, 2 temperature zones
Two-roll draw, two-roll cooling and single-roll draw
First multi-function knife coater
9 m (29.5 ft) idler-roll horizontal oven, 3 temperature zones
Two-roll calender and two-roll cooling
Second multi-function knife coater
Infrared edge detection and pneumatic brush pinning
27 m (88.6 ft) pin-and-clip dual-purpose stenter oven with tail main drive
Far-infrared heating hood, calender and four-roll cooling
Edge trimming and centre slitting
3 gravure lacquer surface treatment units with 3 further 6 m (19.7 ft) vertical ovens
Two-roll draw and twin-position A-frame centre winder
Coating Heads
Vertical knife coater: 1 vertical paste-holding doctor blade on each of the 2 faces, 2 coating blades per contact face, adjustable paste dams, adjustable rubber bow roll and 150 mm (5.9 in) dia. guide rolls, blades moving fore and aft with handwheel angle adjustment, 16 mm (0.6 in) plate wall plates, 304 stainless drip tray, and a 200 x 4,000 mm tension rubber roll with a 200 N magnetic powder tension controller.
Multi-function knife coaters, 2 off: knife over roll and floating knife, with 1 type and J type blades on a 360 degree rotating blade holder, the J blade for knife over roll and the 1 blade for knife over table.
Blade holder moves fore and aft with motorised and manual angle adjustment; cylinder lift with geared-motor gap fine adjustment and a separate gantry control cabinet.
Precision-ground main coating rolls 370 mm (14.6 in) dia., 20 mm (0.8 in) wall on the first head and 25 mm (1.0 in) wall on the second, radial runout not more than 0.02 mm (0.0008 in), on imported precision bearings.
Blade-to-roll gap fit not more than 0.02 mm (0.0008 in) and blade holder repeat accuracy not more than 0.02 mm (0.0008 in), with dial-gauge gap control and manual and automatic blade lift.
Backing-roll drive motors 2.2 kW (3.0 hp) on the first head and 4 kW (5.4 hp) on the second, each with reducer and sprockets.
Rodless-cylinder reciprocating paste feeders, stainless drip troughs, pneumatic solenoid valves, pressure gauges and air preparation units.
Ovens and Drying
6 m (19.7 ft) vertical oven: hot-air circulation, 2 temperature zones, 140 mm (5.5 in) channel-steel welded frame, 120 mm (4.7 in) mineral-wool insulation panels in 1.5 mm (0.06 in) steel sheet, insulated access doors with silicone rubber seals, PID temperature controllers, three-way pneumatic diaphragm control valves, PT100 probes, aluminium finned heat exchangers with filter screens, 5.5 kW (7.4 hp) variable frequency centrifugal circulation fans and a 3 kW (4.0 hp) exhaust fan; 2 upper draw rolls 240 mm (9.4 in) dia. x 3,200 mm (126.0 in), PTFE coated and water cooled.
9 m (29.5 ft) horizontal idler-roll oven: hot-air circulation, 3 temperature zones, 120 mm (4.7 in) channel-steel frame, 120 mm (4.7 in) mineral-wool insulation panels, PID temperature controllers and three-way control valves per zone, 5.5 kW (7.4 hp) variable frequency circulation fans and 2 exhaust fans of 3 kW (4.0 hp); supplied with a 2-level platform, railings and stairs.
27 m (88.6 ft) pin-and-clip dual-purpose stenter oven: thermal-oil hot-air circulation, 100 to 230 C (212 to 446 F), 1 heating zone every 3 m (9.8 ft) for 6 zones, 2 symmetrically arranged circulation fans per zone, 1 heat exchanger set per heating sub-zone, electric three-way temperature control valves, PT100 probes, oven frame in 120 mm (4.7 in) channel and 50 mm (2.0 in) angle, 100 mm (3.9 in) insulation at the bottom and 120 mm (4.7 in) at the top, rock-wool filled, insulated doors with silicone seals, 4 exhaust groups in welded carbon steel round duct, explosion relief doors and marked damper adjustment.
Stenter track and width control: cast-iron cloth-entry, cloth-exit and intermediate tracks lined with manganese steel wear plates, cylinder-type chain tensioner with swing-angle limit, pin-and-clip dual-purpose drive chain, width adjustment 800 to 3,200 mm (31.5 to 126.0 in) by motor and gearbox with a clutch on each oven section, head width indicator and tail pointer-type indicator, non-contact infrared upper edge detection under variable frequency control that also works on black fabric, and an 18.5 kW (24.8 hp) main drive motor with reducer, gearbox and spline drive.
3 further 6 m (19.7 ft) vertical ovens, 1 on each gravure lacquer unit: hot-air circulation, 2 temperature zones each, the same construction as the front vertical oven, each with 2 upper draw rolls 240 mm (9.4 in) dia. x 4,000 mm (157.5 in), PTFE coated and water cooled, and a 3-level frame, platform, stairs and railings.
Vertical oven platform: 3-level frame and platform outside the oven in H-beam and channel, with upper and lower stairs and railings all round.
Ironing, Calendering, Cooling and Winding
Two-roll hot ironing and single-roll cooling: 3 sleeve-type rolls 570 mm (22.4 in) dia. x 4,000 mm (157.5 in) x 12 mm (0.5 in), machined then chrome plated 0.05 mm (0.002 in) and polished, gear linked, 4 kW (5.4 hp) drive with worm reducer; hot-oil tank, 4 kW (5.4 hp) hot-oil circulating pump, DG50 temperature control valve, three-way pneumatic diaphragm valve, filter and PT100.
First calender: 2-roll horizontal, front roll mirror steel and rear roll silicone rubber; steel roll 420 mm (16.5 in) dia. x 35 mm (1.4 in) x 4,000 mm (157.5 in) chrome plated and precision ground; silicone roll 420 mm (16.5 in) dia., Shore 80 plus or minus 2, 25 mm (1.0 in) covering per side, 0.5 to 0.8 mm single-side crown; 11 kW (14.8 hp) drive; roll loading by cylinder, working pressure 0.5 to 5 t with 20 t maximum design pressure; far-infrared heating hood over the calender roll at the oven exit, height adjusted by cylinder and temperature controllable.
Second calender: 2-roll horizontal, front roll rubber and rear roll steel, 420 mm (16.5 in) dia. rolls, 11 kW (14.8 hp) direct-coupled cycloidal reducer drive, hydraulic roll loading from a 4 kW (5.4 hp) pressure-holding hydraulic station, working pressure 1 to 12 t with 25 t maximum design pressure, galvanised sheet fume hood.
Cooling: two-roll cooling and draw, single-roll draw, a second two-roll cooling and a four-roll cooling machine, all on jacketed or sleeve-type rolls 570 mm (22.4 in) dia. x 4,000 mm (157.5 in) x 12 mm (0.5 in), chrome plated and polished, gear linked, with 2.2 to 4 kW (3.0 to 5.4 hp) worm-reducer drives.
Edge trimming and draw: driven shear type with a 0.55 kW (0.7 hp) trim motor, 1 set of opposed edge trimmers and 1 set of pneumatic centre knives, draw nip of a 200 x 4,000 mm natural rubber roll against a chrome-plated steel roll, 4 kW (5.4 hp) draw drive.
Twin-position A-frame centre winder: wind-up roll diameter 1,200 mm (47.2 in), bearing supports with bayonet shaft coupling, encoder motor and reducer drive of 11 kW (14.8 hp), A-frame winding stand in welded channel with an aluminium alloy spreader roll, A-frame winding roll 180 x 4,000 x 15 mm chrome-plated steel, universal sliding transfer shaft and A-frame draw trolley.
Twin-position unwind: unwind roll diameter 1,000 mm (39.4 in), bearing supports with shaft head snap coupling, clamp-band manual brake, welded plate and channel frame, unwind trolley with automatic edge guiding ahead of the accumulator.
Cloth splicing and clamping: pneumatic cloth clamping with a splicing table topped for sewing, roll-change press unit, nip of a 250 x 12 mm natural rubber roll with 1 mm single-side crown against a chrome-plated steel roll.
40 m (131.2 ft) cloth accumulator: pneumatic lift, 40 m (131.2 ft) storage length, chrome-plated lifting and fixed guide rolls, a drive shaft, bearing, hydraulic cylinder and sprocket lifting mechanism, H-beam frame with safety railings, 2 cylinders 125 x 2,000 mm and a synchronising cylinder with linear transducer.
Gravure Lacquer Surface Treatment
3 gravure lacquer treatment units, each fed from the edge-trimming section and each followed by its own 6 m (19.7 ft) vertical oven.
Each unit carries a 165 x 4,000 mm aluminium spreader roll, 2 press-roll cylinders with fine adjusters, a 270 x 4,000 mm rubber press roll and a 270 x 4,000 mm steel gravure printing roll.
Anilox engraving of the printing rolls is made to the buyer's requirement.
Each unit has a swivelling and lifting printing-roll doctor blade device, a stainless steel paste trough on a rack-driven lift, a welded quality steel plate frame, a 2.2 kW (3.0 hp) cycloidal reducer drive and 2 guide rolls 125 x 4,000 mm.
Drive, Control and Instrumentation
Upright electrical control cabinet holding the main control of the main motor, the circulation and exhaust fans and the oven temperature control, with coloured indicators, push buttons, ammeters, voltmeters, temperature meters, operating switches, motor protection switches, inverters, relays, wiring ducts, terminals, internal wiring and cooling fans.
Operating desk with individual start, run and stop of the main motors, indicator lamps, emergency stop buttons, buzzer and motor tachometers.
PLC control with touch screen, inverters and a colour monitor.
Specified main components: Mitsubishi PLC, A/D converter, PLC accessories, touch screen and inverters; Honeywell (USA) temperature instruments and temperature control valves; a Yaskawa dedicated tension inverter on the centre winder; SMC precision regulators; Airtac pneumatic components and cylinders.
8 tension control devices fitted as required, using linear displacement and angular transducers with pneumatic synchronising cylinders.
Scope of Supply and Exclusions
Included in the supply: mechanical design, electrical design, mechanical manufacture, component purchasing and the cost of building the electrical control cabinets.
Included spare parts: 20 links of chain, 100 pin plates, 4 upper pin discs, 1 set of each of the 2 knife types, and 1 automatic metre counter fitted at the winder.
Available at extra cost, subject to confirmation: an on-line single-point fixed laser thickness gauge, 1 set.
Installation and mechanical no-load commissioning are carried out at the buyer's site by personnel sent by the manufacturer, with the buyer assisting.
The colour of the machinery and of the control cabinets is chosen by the buyer. Major design changes after the contract takes effect are agreed separately.
Condition and Supply
Condition: New, manufactured to order.
Quantity: 1 complete production line.
Delivery: 120 days from signature of the contract.
Transport: collected by the buyer, or arranged on the buyer's behalf.
Warranty: 12 months from the date of equipment acceptance, or 15 months from the date the goods arrive, whichever comes first.
Acceptance: against the configuration and structural requirements of the maker's technical annex, with the equipment suited to the operating conditions of the buyer's region, and against the content, quantity and delivery time of the technical documents supplied.
HS code: 8451.80