YY-1365 CONTINUOUS PRODUCTION LINE FOR IMPREGNATION, DRYING, ABRASIVE SPRAY, HEAT-SETTING OF SYNTHETIC FIBERS FOR ABRASIVE WADDINGS, WITH AIRLAY CARDING MACHINE AND FIBER PREPARATION

REFERENCE NUMBER: YY-1365 CONTINUOUS PRODUCTION LINE FOR IMPREGNATION, DRYING, ABRASIVE SPRAY, HEAT-SETTING OF SYNTHETIC FIBERS FOR ABRASIVE WADDINGS, WITH AIRLAY CARDING MACHINE AND FIBER PREPARATION DETAILS: MAIN FEATURES: - THREE LAYERS OVEN: TWO UPPER DRYING LAYERS WITH LENGTH OF 6+ 6 METERS; ONE LOWER CURING LAYER WITH A LENGTH OF 6 METERS; - HEATING: BY DIRECT HEATING WITH AUTOMATIC BURNERS; - CONVEYOR WIDTH: 2200mm; - WORKING WIDTH: 2000mm; - MAX DRYING AND POLYMERISATION TEMPERATURE: 230°C; - HEATING POWER: 4 BURNERS 350 KW EACH ONE, ABOUT TOTAL 1.400 KW; - VENTILATION: SEMI-CLOSED SYSTEM WITH 4 CENTRIFUGAL VENTILATORS; - ADJUSTABLE CONVEYOR SPEED BY A.C. MOTORS; - INSTALLED ELECTRIC POWER: 200 KW. APPROX.; - MECHANICAL SPEED: 2÷15 METERS PER MINUTE; - CONVEYOR DRIVING: BY A.C. MOTORS; - MANUFACTURED ARTICLE: SYNTHETIC FIBERS ABRASIVE WADDING. PRODUCTION PROCESS: THE PLANT CONSISTS OF ONE FIBER PREPARATION AND AIRLAY CARD TO FORM THE WEB, IMPREGNATION PADDER, 6 METER FLAT OVEN, ONE SPRAY CABIN, A THREE LAYERS OVEN (6+6+6 METERS), ONE SPRAY CABIN. THE WADDING IS FIRST IMPREGNATED BY PADDER AND THEN DRYED IN THE SINGLE LAYER OVEN. THE MATERIAL, THAT NOW HAS THE CORRECT TENACITY, IS SPRAYED WITH ABRASIVE ON ONE FACE, DRIED IN THE OVEN TOP LAYER THEN SPRAYED IN THE SECOND FACE AND DRYED IN THE MIDDLE OVEN LAYER AND FINALLY CURED IN THE BOTTOM OVEN. THEN THE MATERIAL IS READY TO BE WINDED UP ON YOUR WINDER. ONE OPENING AND BLENDING LINE: FOR THE BLENDING OF UP TO 3 DIFFERENT COMPONENTS. COMPOSED OF: THREE BALE OPENERS: - STANDARD WORKING WIDTH: 1450mm - COMPLETE WITH: - BALE FEED AND STORAGE CONVEYOR 2 METERS LONG DRIVEN BY INDEPENDENT GEARBOX - WITH 0.75 KW MOTOR. - STATIONARY BALE PLATFORMS FOR THE INTRODUCTION OF THE BALES. - INTERMEDIATE PVC CONVEYOR 1 METER LONG. - INCLINED PVC APRON WITH STEEL PINS FIXED ON INTERNAL WOOD SLATS, DRIVEN BY A VARIABLE SPEED GEARBOX WITH 2.2 KW MOTOR CONTROLLED BY FREQUENCY INVERTER FOR THE DECELERATION RAMP AT THE END OF THE PAN LOADING CYCLE. - INTERNAL OPENING AND EQUALIZING ROLLER DRIVEN BY A 1.1 KW MOTOR. - EXTERNAL DOFFING ROLLER DRIVEN BY INDEPENDENT 1.1 KW MOTOR. THREE HIGH PRECISION WEIGHING PANS: MANUFACTURED IN STAINLESS STEEL, INSTALLED ON INDEPENDENT STRUCTURES IN ORDER TO AVOID INTERFERENCES TO THE LOAD CELLS CAUSED BY VIBRATIONS TRANSMITTED BY THE MOVING PARTS OF THE BALE OPENERS AND TRANSVERSAL CONVEYOR, COMPLETE WITH LOAD CELLS (2 LOAD CELLS FOR EACH PAN). ONE TRANSVERSAL COLLECTING CONVEYOR: COMPLETE WITH A PVC APRON 900mm WIDE X 9 METERS LONG APPROXIMATELY AND FIBRE PRESSING ROLL AFTER WEIGH PAN 2. ONE HORIZONTAL FIBRE PRE-OPENER: - WORKING WIDTH 1000 mm, COMPLETE WITH: - FEED SYSTEM COMPOSED OF FEED APRON AND A COUPLE OF FEED ROLLERS, ALL DRIVEN BY A GEARBOX WITH MOTOR CONTROLLED BY FREQUENCY INVERTER AND SYNCHRONISED WITH THE SPEED OF THE TRANSVERSAL FIBRE COLLECTING CONVEYOR. - PRESSURE OF TOP FEED ROLLER ON BOTTOM ONE BY STEEL SPRINGS. - THE MAIN CYLINDER HAS A DIAMETER OF 930 mm, IS DRIVEN BY A 15 KW MOTOR AND IS CLOTHED WITH APPROX. 12000 STEEL HARDENED ROUND POINTED PINS Ø 4X43 mm FIXED IN PLYWOOD LAGS. - THE MACHINE IS SUPPLIED COMPLETE WITH VERTICAL DELIVERY TRANSITION IN GALVANISED SHEET METAL TO DUCT DIAMETER 310 mm. ONE ROTARY CONDENSER: FOR THE FEEDING OF THE FIBRES INTO THE STORAGE & BLENDING BOX. WORKING WIDTH 1100 mm, COMPOSED OF: - PERFORATED DRUM 625 mm DIAMETER WITH HOLES DIAMETER 2.5 mm WITH DIRECT DRIVE ON ONE SIDE BY GEARBOX AND 0.75 KW MOTOR. - ANTISTATIC PVC DELIVERY APRON WITH DIRECT DRIVE BY GEARBOX AND 0.75 KW MOTOR. - FEED INLET TRANSITION IN GALVANIZED SHEET METAL AND DUSTY AIR OUTLET TRANSITION ON ONE SIDE ONLY. - SUCTION FAN WITH 7.5 KW MOTOR AND DUST COLLECTOR WITH 5 FILTERING SLEEVES. ONE STORAGE & BLENDING MINIBOX: - INTERNAL DIMENSIONS: 1800 mm WIDE X 4000 mm LONG X 2500 mm USEFUL FILLING HEIGHT (MAX. FILLING CAPACITY: 18 m3), COMPLETE WITH: - SPIKED APRON WITH VARIABLE SPEED CONTROLLED BY FREQUENCY INVERTER AND PRESSURIZING FAN FOR THE INSIDE OF THE SPIKED APRON. - WALLS IN GALVANIZED SHEET METAL PREFABRICATED PANELS 50mm THICK WITH POLYURETHANE FOAM FILLING. - FULL WIDTH FRONT INSPECTION DOORS WITH PLEXIGLASS WINDOWS. - BACK INSPECTION DOOR AND SIDE LEVEL PLEXIGLASS WINDOWS. - MAT FORMING VIBRATING CHUTE WITH DELIVERY OF THE MAT ONTO AN HORIZONTAL CONVEYOR. ONE FINE OPENER: - WORKING WIDTH 1900 mm, COMPLETE WITH: - FEED SYSTEM MADE OF FEED APRON, BOTTOM SMOOTH ROLL AND TOP WIRE CLOTHED ROLL TURNING WITH PNEUMATIC PRESSURE ON A STAINLESS STEEL DISH. - PVC FEED CONVEYOR AND THE FEED ROLLS DRIVEN BY INDEPENDENT GEARBOX WITH VARIABLE SPEED CONTROLLED BY FREQUENCY INVERTER. - CYLINDER Ø 930 mm WITH 30000 HARDENED STEEL POINTED PINS Ø 4X43 mm IN PLYWOOD LAGS. - THE MAIN CYLINDER IS DRIVEN BY A 22.5 KW MOTOR. - DELIVERY VERTICAL TRANSITION IN GALVANIZED SHEET METAL TO Ø 310 mm. ONE FIBRE TRANSPORTATION FAN: FOR THE FEEDING OF THE BLENDED FIBRES DELIVERED BY THE FINE OPENER INTO THE BUFFER SILO, COMPLETE WITH ELECTRIC MOTOR 11 KW AND DUCT TRANSITIONS. ELECTRIC CONTROL PANEL FOR THE COMPLETE BLENDING LINE: COMPOSED OF: - 1 CONSOLE CONTAINING THE ELECTRONIC WEIGHTING & PROCESS SUPERVISION SYSTEM, FOR THE CENTRALIZED CONTROL OF THE PLANT AND THE RECIPES, EQUIPPED WITH SIEMENS PLC AND COLOUR TOUCH SCREEN OPERATOR PANEL, PRINTER AND DEDICATED SOFTWARE. - 1 ELECTROMECHANICAL CONTROL PANEL WITH SWITCHES, RELAYS AND FREQUENCY INVERTERS FOR THE CONTROL OF ALL THE MACHINES OF THE BLENDING LINE. BUFFER SILO FOR AIRLAY FEEDING: THE BUFFER SILO IS NECESSARY TO CONTINUOUSLY FED THE FORMING UNIT AT THE REQUESTED RATE. IN PARTICULAR THE MACHINE FEEDING THE AIRLAY HAS TO HAVE THE FOLLOWING CHARACTERISTICS: - AN EXIT FAN WITH INVERTER, WHICH RECEIVES THE SPEED SIGNAL FROM OUR PNEUMATIC FORMER; - INTRODUCING ROLLERS WITH INVERTER, WHICH RECEIVE THE SPEED SIGNAL FROM OUR PNEUMATIC FORMER. MACHINE DESCRIPTION: - ENTRY HOOD. - STORAGE SILO WORKING WIDTH 1250 mm. - TWO INTRODUCING ROLLERS DRIVEN BY GEARMOTOR AND FREQUENCY INVERTER. - ONE BOTTOM ROLLER OPENER WITH PINNED LAGS. - DELIVERY MOTOR-FAN WITH MOTOR AND FREQUENCY INVERTER. PNEUMATIC FEEDING UNIT: THE UNIT SERVES THE SCOPE OF CREATING A UNIFORM BATT OF FIBERS, TO BE CONVEYED TO THE FOLLOWING AIRLAY CARD. - WORKING WIDTH: 2200 mm; - BELTS WIDTH: 2300 mm; - BATT SHAPING UNIT TROUGH A PRESSURE/SUCTION FORMING SYSTEM; - PRESSURIZED FIBERS FEEDING FROM THE UPPER PART OF THE MACHINE; - TWO INTRODUCING ROLLERS Ø 180 mm; - SPIKED TRANSPORT CYLINDER FOR FIBERS SCATTERING, Ø 360 mm; - PRESSURIZED SYSTEM TO CONVEY THE FIBERS FROM THE SPIKED CYLINDER TO THE LOWER PART OF THE MACHINE; - BOTTOM SUCKING SECTION, COMPLETE WITH TWO DELIVERY ROLLERS Ø 180 mm; - LOWER DELIVERY APRON. WEIGHING SYSTEM: - INSTALLED AFTER THE FEEDER F. - DELIVERY APRON WITH ELECTRONIC WEIGHING SYSTEM. - INSTALLED ON TWO WEIGHING DEVICES, EACH INCLUDING THREE LOADING CELLS. - THE LOADING CELLS ARE COMPLETE WITH SPHERES FOR THE REDUCTION OF THE LONGITUDINAL AND TRANSVERSAL DISTURBS. - A CONTROL SOFTWARE MANAGES THE SIGNAL IN EXIT FROM THE WEIGHING DEVICES AND ADJUST THE PNEUMATIC FORMER ACCORDINGLY. AIRLAY CARDING MACHINE: THE SYSTEM SERVES THE SCOPE OF REFINING THE BATT OF FIBERS CREATED INTO THE PNEUMATIC FORMING SECTION, AS WELL AS SETTING THE FINAL THICKNESS AND GIVING THE DIRECTION AND ANGULATION TO THE FIBERS. TO DO SO, THE SECTION IS PROVIDED WITH A FIRST CARDING SECTION COMPLETE WITH OPENING CYLINDER, WORKERS, STRIPPERS AND DRUM, AND A SECOND SECTION WHERE THE FIBERS ARE AIR-SHAPED. - CONVERGING FEEDING APRONS. - ENTRY GROUP COMPOSED OF THREE INTRODUCING CYLINDERS WITH SAW-TOOTH CLOTHING Ø 100 mm. - OPENING CYLINDER Ø 300 mm. - MAIN CYLINDER Ø 600 mm, COMPLETE WITH TWO COUPLE OF WORKING AND STRIPPING CYLINDERS. WORKERS Ø 200 mm, STRIPPERS Ø 140 mm. - PERFORATED MAIN DRUM Ø 400 mm FOR AIR SHAPING: COMPLETE WITH HORIZONTAL AND VERTICAL ADJUSTMENT DEPENDING ON THE TYPE OF BATT TO BE PRODUCED. - AIR SUCTION SECTION LOCATED INSIDE THE PERFORATED DRUM COMPLETE WITH ANGULAR MOVEMENT. - PERFORATED CONVEYOR BELT FOR FIBERS COLLECTION, COMPLETE WITH A SECOND SUCTION DRUM. - CLEANING BRUSH FOR PERFORATED BELT. - UPPER AND LOWER AIR SUCTION FAN. THE NON-WOVEN FORMATION ZONE IS BETWEEN THE UPPER PERFORATED DRUM AND THE PERFORATED BELT. THE ORIENTATION OF THE FIBERS, AND THE HEIGHT OF THE NON-WOVEN ARE INFLUENCED BY THE INDIVIDUAL ADJUSTMENT OF BOTH AIR FLOWS. - STRUCTURE WITH FILTERING NONWOVEN SLEEVES AND DUST COLLECTION BAGS. EXCLUDING PIPES BETWEEN SUCTION FANS AND DUST COLLECTION STRUCTURE. IMPREGNATION PADDER: 1 PADDER, WITH VERTICAL ROLL ARRANGEMENT CONSISTING OF: - VAT FOR CONTACT IMPREGNATION; - 2 STEEL FRAMES WITH ELECTROWELDED TRAVERSES; - 1 PRESSURE APPLICATION BY AIR BELLOWS WORKING ON BOTH SHAFTS; - 1 SUPPORT ROLL, Ø 475 mm, SOFT RUBBER COATED; - 1 SUPPORTING ROLL, Ø 475 mm, CHROMIUM PLATED; - VAT LIFTING DEVICE AND LIQUOR DISTRIBUTING PIPE; - ROLLER FACE WIDTH: 2200 mm. DRYING CHAMBER AND VENTILATION: THE AEROTHERMIC CHAMBER IS SUITABLE FOR DRYING AND POLYMERISATION. IT IS DIVIDED IN 4 SECTIONS. FIRST ONE AFTER FOULARD, THE SECOND, THIRTH AND FOURTH FORMING A 3 MULTILAYER OVEN. TOTAL FOR N.4 SECTIONS 6 METERS LONG. TEMPERATURE IS ADJUSTABLE IN EACH SECTION AND IN EACH DRYING AND POLYMERIZATION ZONE. THE HEATING IS WITH BURNERS. THE PERFECT THERMAL INSULATION IS ACHIEVED THROUGH A STEEL FRAME FITTED WITH INSULATING PANELS. INSPECTION DOORS ARE PROVIDED FOR AN EASY ACCESS TO ALL THE DRIVING PARTS AND FOR THE OBSERVATION OF THE DRYING PROCESS. CONVEYORS ARE MADE OF METAL WIRE MESH NET. THEY RUN THROUGH A SET OF AIR DISTRIBUTORS. THE HOT AIR COMES, WITH PERFECT UNIFORMITY, FROM THE UPPER BLOWERS AND PASSES THROUGH THE WADDING BY THE SUCTION OF THE LOWER AIR DISTRIBUTORS. THE AEROTHERMIC CHAMBER IS PROVIDED WITH CENTRIFUGAL VENTILATORS. THE DRYING PROCESS IS EFFECTED IN A HALF-CLOSED CYCLE; THE VENTILATION CYCLE IS WITH CLOSED CYCLE, BUT AFTER EACH PASSAGE THE THERMO HYGROSCOPIC POWER OF THE AIR IS SET UP AGAIN BY MEANS OF THE EXPULSION OF A LITTLE PART OF DAMP AIR AND THE PASSAGE THROUGH THE HEATING DEVICE. DIRECT GAS HEATING: THE PLANT IS PROVIDED OF 4 GAS BURNERS WITH ADJUSTABLE TEMPERATURE. IN THIS CASE THE FLUE GAS IS DIRECTLY MIXED WITH THE VENTILATION AIR AVOIDING ALL THE HEAT LEAKAGE INCREASING THE PERFORMANCES. IT HAS THE FOLLOWING ADVANTAGES: - VERY LOW CONSUMPTION, - PRECISE TEMPERATURE ADJUSTMENT, - VERY EASY MAINTENANCE, - FAST REACHING OF THE RUNNING TEMPERATURE. WE ACHIEVED SUCH RESULT WITH THE FOLLOWING ADVANTAGES: - HEATING DEVICES INCORPORATED IN THE DRYING CHAMBER (NO HEAT LEAKAGE); - HEATING PLANT WITH LOW THERMAL INERTIA; - TEMPERATURE ADJUSTMENT BY FLAME VARIATION. THE BURNERS HAVE AUTOMATIC STARTING AND A PHOTOELECTRIC CELL SAFETY DEVICE. GAS FLOW IS REGULATED WITH A THERMOSTAT SET AT THE VENTILATION TEMPERATURE. THE COMBUSTION CHAMBERS, MADE OF REFRACTORY STEEL, ARE COOLED WITH THE FORCED FLOW OF THE VENTILATION AIR; IN THIS WAY THEY ACT AS FIRST HEAT EXCHANGERS. THE SPRAY CABINS: THE PLANT IS EQUIPPED WITH TWO SPRAY CABINS. EACH OF THEM IS PROVIDED WITH AN AUTOMATIC SPRAYING DEVICE WITH SPRAY GUNS MOVING OVER THE PRODUCT, TRANSVERSALLY TO THE CONVEYOR DIRECTION. A.C. MOTOR ALLOWS THE ADJUSTMENT OF SPEED FROM 20 TO 120 METERS PER MINUTE. EVERY MECHANICAL AND ELECTRIC DEVICE IS PLACED OUT OF THE SPRAY MIXTURE. THE UNIT IS EQUIPPED WITH LOW PRESSURE GUNS WITH ADJUSTABLE FLOW. ALONG THE SIDES IN THE CABIN INSPECTION DOORS ARE PROVIDED FOR EASY ACCESS TO THE SPRAY GUNS AND FOR CLEANING OPERATIONS. IT IS POSSIBLE TO CONTROL THE GUNS DURING THEIR WORK BY MEANS OF BULL'S EYES ON THE DOORS. THE WADDING, PASSING THROUGH THE CABIN, IS SUPPORTED WITH A STEEL BARS. A SUCTION DEVICE PLACED UNDER THE WADDING MAKES EASY THE PENETRATION OF THE RESIN. THE CABIN IS PROVIDED WITH AN EXHAUST UNIT WITH FILTERS FOR THE CLEANING OF THE EXHAUSTED AIR. THE FAN IS PROTECTED BY LABYRINTH AND FILTERS. END OF LINE: COMPOSED BY: - ACCUMULATOR; - LONGITUDINAL CUTTING UNIT; - TRANSVERSAL CUTTING UNIT; - CONNECTION CONVEYOR BELT; - MANUAL WINDER. ELECTRICAL PANEL: THE DRYER IS EQUIPPED WITH A MODERN AND A COMPLETE ELECTRIC PANEL TO CONTROL BY PLC AND OPERATION PANEL ALL THE FUNCTIONS OF THE MACHINERY. ALL THE ELECTRIC APPARATUS ARE RATIONALLY ARRANGED IN A PROPER CABINET. THE ELECTRIC PANEL INCLUDES: - ELECTRONIC DRIVE FOR THE MAIN ROLLS - CONTROL SYSTEM FOR THE TEMPERATURE ADJUSTMENT - SAFETY EQUIPMENTS FOR BREAKING, OPENING AND REVERSAL ROTATION OF THE ROLLS - COMPLETED WITH TEMPERATURE INDICATORS, SPEED INDICATORS POTENTIOMETERS, EMERGENCY PUSH BUTTON, LEVEL INDICATORS. - POWER SUPPLY 3PH +PE 400V AC 50Hz - CABINET IP55 - GENERAL SWITCH WITH DOOR LOOK FUNCTION - VOLTAGE INDICATOR - ILLUMINATION OF ELECTRIC PANEL - VENTILATION SYSTEM IN THE ELECTRIC CABINET - MOTOR DRIVES WITH INTEGRATED SAFETY FUNCTIONS ACCORDING TO IEC 61800-5-2 - MOTOR DRIVES SIEMENS - SERVO VENTILATION MOTORS WITH CONTINUOUS SERVICE - MOTORS CONTROLLED WITH ENCODER - TEMPERATURE CONTROL OF THE MOTOR BY PTC PROBE IF TEMPERATURE >35°C - SETTING UP REMOTE ASSISTANCE - SETTING UP INPUT REFERENCE SPEED LINE - SETTING UP OUTPUT REFERENCE SPEED LINE - CONTROL SYSTEM PLC SIEMENS S7 - SIEMENS TOUCH PANEL