Example
1) General Description:
The Extrusion Group Meltblown System achieves excellent throughput and is optimized for handling today’s metallocene resins as well as conventional Z-N based polypropylene. The lines feature an advanced die tip design for impressive fiber attenuation and extremely precise laydown control.
Resulting cross-web uniformity is excellent. The ultrafine web fibers are ideal for high performance applications in the filtration, wipes, sound attenuation and hygiene product market.
2) General Specifications:
a) Maximum Web Width: 24” (0.6 m)
b) Material: Polypropylene
i) Melt Flow: 500 – 1800 MFR
ii) Melt Temperature: 350 degrees F (175 degrees C)
c) Throughput: 100 lb/hr (45 kg/hr) maximum using 1800 MFR PP resin
d) Rewind Specifications:
i) Maximum Rewind Diameter: 50” (1270mm)
ii) Speed: 15 to 400 fpm (5-121 m/m)
iii) Rewind Slit Width:
(1) Maximum Slit: 24”
(2) Minimum Slit: Edge trim only
iv) Rewind Tension: .25 – 2.0 PLI
v) Maximum Roll Weight Required: 220 lbs (100 kg)
3) Physical:
a) Voltage Requirements: 480 Volts, 3 phase, 60 Hz, SCCR 10kA
b) Current Requirements: 0.8 kW/lb resin (1.8 kW/kg) +/- 10%
c) Control Voltage: 24VDC
d) Air Requirements: 80 psi (5.5 Bar), clean, dry and free of all aerosols
e) Air Supply: The air supply will have a single hand lever operated shut off valve with lockout-tag out capability.
f) Ambient Temperature Range: 40-100 degrees F (5-40 degrees C)
g) Humidity Range: Less than 95% non-condensing
h) Altitude: Less than 3000 feet (900m)
i) Environmental: Non-Corrosive, Non-Explosive
j) Machine Paint Color: Catbridge Signal White (RAL 9003)
4) Codes and Standards:
a) National Electrical Code (NEC): Wiring standards comply with the latest NEC electrical
codes, 2008 edition.
b) NFPA 79: Electrical Standard for Industrial Machinery, 2007 Edition
c) Occupational Safety and Health Act (OSHA): Catbridge will design this equipment to
conform the current requirements of OSHA. Because of varying interpretations and
conditions of use, no warranty of compliance with OSHA is expressed or implied.
d) American National Standard Institute (ANSI): Standard for Plastic Film and Sheet
Winding Machinery-Manufacture, Care and Use
e) Any additional state or local codes required must be declared at the time of order:
5) Meltblown Beam Section:
a) Resin Feeding System:
i) Hopper: A gravity-feed hopper is provided on the extruder. A vacuum-style resin
feeding system is provided for use with boxed resin.
ii) Metering and Mixing: Component metering and volumetric system will be provided
by the customer if required
b) Extruder Specifications:
i) Barrel: Approximately 1.5” (38mm) diameter barrel, 15 HP (11 kW), & 30:1 L/D
ii) Temperature: Automatically heated and cooled zones
iii) Screw Extractor Method: Manual
c) Screen Changer:
i) Specifications: (1) puck style manual screen changers will be supplied
ii) Replacement Screens: (250) Multi-ply screens
d) Melt Pump: (1) melt pump assembly complete with controls driven by a 1 HP (0.75 kW) motor
e) Melt Pipe: Temperature is controllable with closed-loop monitoring
f) Meltblown Die: General Specifications:
i) One heated die with approximately 8” -12” (200mm- 300mm) per/zone regulation.
ii) Dual air nozzle with heated process air control system
iii) Vertical die mounting system
g) Die Pack Specifications:
i) (1) Complete 24” (0.6 m) active length die with capillary design, 10:1 L/D, 35 holes/inch, including internal breaker plates and screens.
ii) (Optional) Die Replacement Parts Kit Including
(a) (1) Spare die tip assembly
(b) (2) Breaker Plates (top and bottom)
(c) (4) Re-tension clips
(d) (12) Die replacement screens
h) Process Air:
i) Process Air Blower: Rotary Lobe Blower with approximately 2 HP/inch, 40 CFM/inch
ii) Process Air Heating: Flanged Inline Heater, 8 KW/inch, 480 Volt, 3 Phase, 750 degree F max temperature.
iii) Process Air Piping: Preassembled ducting with insulation covers and guard from blower to the die is provided.
iv) Sound Enclosure: Process air sound enclosure is provided for sound adsorption at the process air blower.
6) Web Forming and Handling Section:
a) Vacuum Roll Assembly:
i) Vacuum Roll: (1) 24” (600mm) diameter steel mesh segmented vacuum roll
ii) Vacuum Roll Drive: (1) 1 HP (0.75 kW) AC Vector motor
iii) Axis of Motion:
(1) Manual Adjustment X control with 18” (450mm) of stroke, with digital read out
(2) Manual Adjustment Y control with 12” (300mm) of stroke, with digital read out
iv) Vacuum Roll Blower: (1) Direct driven pressure blower
b) Load Cell Roll: A load cell roller will be supplied to set the tension between the vacuum roll and the rewinder section.
7) Surface Winder
a) Rewind Style: Surface winder with manual cut-off and transfer system.
b) Score Slitting: Catbridge score knives with individual holders (4) knives provided.
c) Rewind shafts:
i) (2) 3” (76.2mm) diameter rewind shaft with end nuts will be supplied.
d) Load Cell Roll: A load cell roller will be supplied to set the tension between the process equipment and the rewinder.
e) Rewind Motor: A 1 HP (0.75 kW) AC vector motor will be used to power the winding drum.
f) Trim Winders: (2) Air motor driven trim winders are supplied
8) Advanced System Control Specifications:
a) Main Drive Enclosure Specifications: NEMA 12 enclosures will be used to mount and protect the control system. All terminations will be made to the bottom of the control panels, for ease of wiring and troubleshooting. Each termination will be labeled corresponding to the provided electrical drawings. Each drive section includes a 3-phase circuit breaker for branch protection, input line reactors for noise isolation and dynamic braking resistors for E-Stop braking. In addition, motor circuit protectors will be provided where fractional AC motors are required. The following components will be supplied:
b) Extruder Controls
i) 15 HP Allen Bradley Powerflex700 AC Vector drive
ii) Molded case circuit breaker for above drive
iii) Line reactor
c) Melt Pump:
i) 1HP Allen Bradley Powerflex700 AC Vector drives
ii) Circuit protection for above drive
iii) Temperature: Pressure and temperature feedback to be provided
d) Vacuum Blower Controls:
i) 50 HP Allen Bradley Powerflex700 AC Vector drive
ii) Line reactor
e) Process Air Blower Controls:
i) 50 HP Allen Bradley Powerflex700 AC Vector drive
ii) Line reactor
f) Vacuum Roll Drive:
i) 1 HP Allen Bradley Powerflex700 AC Vector drive
ii) Line reactor
g) Rewind Drive:
i) 1 HP Allen Bradley Powerflex700 AC Vector drive
ii) Line reactor
h) (1) 3-phase door disconnect switch, molded circuit breaker with lockout.
i) PLC System: The primary machine control is done with an Allen-Bradley Compact Logix PLC. All machine functions, other than safety monitoring circuits, are controlled and monitored by the PLC. The Human-machine interface (HMI) consists of (1) Allen- Bradley color VersaView 15” touch screen for drive section monitoring and line control.
Machine functions, such as tension set points, tension feedback, roll length and others can be adjusted and monitored through the interface. All variables used to make a product may be stored as recipe and later recalled. This PLC system will be interfaced to an Ethernet port, which will provide remote support for PLC maintenance. The system will be configured for the required analog & discrete I/O functions on the unwind & slitter.
i) Power supply, transformer, MSP’s, Circuit Breakers, & misc. components
ii) Enclosure light & GFI receptacle.
j) Operator Stations: Operator stations will be located near each section where operator interaction will be required.
i) Main Console: One main console will be provided that incorporates a PanelView operator interface. The HMI will be mounted on sloped console attached to drive enclosure. The HMI can be used to monitor any zone, to store and retrieve product recipes. A total of 100 recipes are available.
ii) Unwind: Operator controls are located at the unwind
k) Field Mounted Devices:
i) (4) Remote E-Stops
l) Machine Program Features:
i) Recipe Control: Store and recall setup parameters.
ii) Counter: The counter can be selected to count in feet, yards or meters. A job length can be entered into the machine for predetermined slowdown and stop.
iii) Units: The operator interface will be able to toggle between metric and imperial units.
iv) Language: The operator interface will be in English
9) Documentation:
Extrusion Group will provide the following documentation with the machine. All drawings, manuals and other related information are provided on a single CD.
a) Operators Manual:
i) Introduction
ii) Theory of Operation
iii) Start-Up Procedures
iv) Setup and Changeover Procedure
v) Calibration Procedures
vi) Lubrication Types and Recommended Frequency
vii) Preventive Maintenance Procedures
viii) Floor Plan Datum Documentation Drawings
ix) Recommended Spare Parts List
x) Troubleshooting Guide
b) Drawings:
i) Assembly drawings and BOM’s
ii) Electrical panel drawings and BOM’s
iii) Electrical elementary drawings
iv) PLC, Drive and PanelView programs
10) Software & Programming:
The control system will be tested and programmed with all the motors connected before shipping. We will supply a basic PLC & PanelView program to include the unwind tension control, recipe, counter and rewind features.
11) Remote Support:
Extrusion Group will design the system to be Ethernet enabled. The PLC, drives and OIT will all be on a local Ethernet network. The plant should provide a connection from the control system to the plant wide network. Our engineers can, by use of VPN, log onto the customer’s network and provide remote support to all devices on the control system Ethernet network.
12) Testing and Acceptance of Equipments:
The system will be set up for operation on our plant floor prior to shipping. We would require first quality material and cores for trials. The material is for testing purposes and we cannot guarantee it will be converted into usable goods. Catbridge will provide your personnel with basic operating training during checkout at our facility.
13) Startup & Installation:
The customer will be responsible for installing the machine on location. Extrusion Group can provide an engineer to oversee the installation and provide basic start-up training.
Contracting with Extrusion Group for start-up and training will extend the warranty period to one year.
Extrusion Group can provide on-site training and process support.
