CUSTOM WIDE WEB EMBOSSER SYSTEM:

Specifications:

1. Unwind

Maximum reel diameter: 1000mm

Maximum reel weights: Approx 450kgs

Cores - 6" air chucks on 3" dia. airshaft

Spur drive gear on one end of 3" air shaft complete with hardened sleeved bearing and located with pneumatically loaded locking cap. Other end as above but without the drive gear.

All items subject to wear are of hardened steel and are replaceable.

The unwind supports would be mounted on linear bearings and guided via a Fife guiding system incorporating a CDP01 M controller, SE24 ultrasonic sensing head and D.C. actuator giving +/- 50mm movement

2. Tension Control System

The unwind batch tension shall be via an auto tension Dover Flexo system and transducer roll coupled to pneumatically operated disc brake. The tension meter would be calibrated in pounds and NOT percentage to give the total web tension reading.

3. Guide Rolls

The guide rolls are manufactured from high specification aluminium tube and machined and polished. The rolls will be fitted with free running Schatz bearings or equivalent to prevent creasing and film scratching.

4. Base Frame

Fabricated base frame comprising necessary guide rolls and aluminium support trays for ease of threading the web. In order to provide wider operator access the length of the base frame would be increased by 300mm to 4150mm. This would allow the walkway in front of the embossing nip to be 300mm wider.

The base frame also supports the unwind/rewind sections and the embosser section to form a correctly aligned structure after installation and supplied with dowels and pre-drilled holes for correct re-assembly on site.

5. Embosser Section

Comprising 2-off rigidly stayed precision ground and machined plate steel main frames supporting the following: -

a) 2 off driven nip tension rolls complete with pneumatically loaded nip roll. The nip roll would be rubber covered in hypalon 65 - 70 Shore 'A'

b) 2 off static elimination units situated one before and one after the embossing nip

c) Pneumatically loaded embossing nip comprising the two-roll configuration. The backing roll housing is mounted on linear bearings with the housings being fitted with each precision adjustable wedge assembly to provide accurate independent control of pressure between the respective rolls (NOTE: 1 shim and 1 backing roll are included in the machine price)

d) 1 off chrome plated driven cooling roll complete with rotary union(s) and flexible pipes.

e) The design of the embossing section would enable 18" 24" and 30" circumference rolls as are generally used to be accommodated

6. Rewind Section and Inspections Facility

Maximum reel diameter: 1000mm

Maximum reel weight: Approx 420kgs

Cores: 6" ID

Batch bar: 6" pneumatic chucks on a 3" air shaft

Spur drive gear on one end of 3" air shaft complete with hardened sleeved bearing and located with pneumatically loaded locking cap. Other end as above but without the drive gear.

All items subject to wear would be of hardened steel and be replaceable.

The air shaft would be driven via a variable speed A.C. inverter drive unit.

The rewind section would also incorporate a counterbalanced lay-on roll assembly with independently finely adjustable pressure controls for each side of the lay-on roll. The structure would provide an inspection area for the web.

7. Heat Generator

1 off heat generator complete with water cooling for the embossing roll.

Maximum temperature: 250º C

Pump capacity: 220 litres/min at 2.5 bar

8. Chiller Unit

1 off 60 kw chiller unit piped to supply chilled water to the 2 off backing rolls, 1 off cooling roll and to provide a rapid means of cooling the heating oil in the shim rolls to enable a speedier roll change to be achieved. In this respect the system is of the 'open' type incorporating a 'thermal buffer' tank between the heater and chiller

9. Drive

1 off complete 3-motor A.C. inverter drive system complete with machine mounted main drive panel providing drives to the following sections at the stated powers

* Draw nip: Item 5a, 2.2kw
* Emboss nip: Item 5c 5.5kw
* Cooling section: Driven off backing roll drive
* Rewind section: Item 6 11kw


Embosser Drive System

1 Rittal floor mounted control desk finished in our standard colour light grey RAL 7032 with zinc coated mounting plate and to UL specification containing:

3 x inverter drive controllers and associated control equipment

1 x Main incoming circuit breaker

1 x 415/110V control transformer (to be confirmed SK)

1 x control fuses/circuit breakers

1 x emergency stop relays

1 x AC motor force ventilation DOL starters

1 x Menu driven LCD screen and associated software

1 x AC circuit breaker for Fife edge guide unit

As well as controlling the motor tension functions the pushbuttons and lamps would also provide for control/indication of the following items

a) Stop/start control for all drives

b) On/off buttons for embossing nips with associated pressure controls and gauges

c) Digital emboss roll temperature indicators as sensed at roller inlet and outlet points

d) Lay-on roll on/off

e) Guider on/off

f) Web breaker detector on/off

Also included on the panel fascia would be 3 off analogue gauges indicating actual tensions as measured by 3 off transducer rolls situated as follows a - c

a) Unwind batch to draw nip

b) Draw nip to emboss nip

c) Emboss nip to rewind batch

The main control for the unwind guider would be situated on the main machine frames adjacent to the unwind station.

10. Electrical System

The electrical components including wiring will be suitable for use in conjunction with the main supply in the customers' location and will conform to current relevant legislation

11. Machine Finish

The machine would be finished to a high standard in high quality machinery enamel paint on top of the appropriate metal primer. Paint colour to be advised
12. Guarding and Decking

The machine will be supplied with complete aluminium decking and guarding surrounding the front of the embosser and supporting the control panel. Special attention will be paid to the guarding of the embossing nip area using polycarbonate guards to prevent operator access when only using two-roll embossing configuration

13. Wiring and Testing

The machine would be fully wired and mechanically tested in our works prior to despatch to the satisfaction of the customer or his representative. Wiring and trunking would be to the appropriate standards required by the intended country of machine siting.

14. Shim Recombination

Table A robust fabricated table complete with magnetic surface and necessary location stops etc. to enable the correct positioning of the shims on the shim roll. The table is designed to accommodate rolls of 1 metre face with a circumference of 18" minimum to 36" maximum.

Current Delivery Time:

Approximately 22 weeks from receipt of Official order and down payment to commencement of testing.

Exclusions:

1) The provision of raw materials required for testing including transport to our premises


Client Note: We have experience of building up to 1.8 metre width embossing systems, please inquire, as each clients needs are unique. We build to your requirements using our immense skills and experience in holographic production.