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0086-15018408881

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1600MM 5-LAYER AIR BUBBLE FILM MACHINE

 

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MODEL: OG-W160FA

1600MM 5-LAYER AIR BUBBLE FILM MACHINE

--- 3 SCREW EXTRUDER DESIGN

1600mm五层气泡膜机-双挤出设计


 




Brief introduction of 5 layers machine

I Section of 5-layer bubble film 



II Sketch map of machine



III Production steps


1. raw material are melted

2. 2 layers of high temperature film are extruded

3. Forming cylinder

4. Compression cylinder

5. Cooling cylinder 

6. Third PE layer is melted

7. Third PE layer is extruded 

8. Lamination Roller 

9. Coated Film 

10. Rough edges are trimmed, slitting is performed

11. Trimmed edges are collected

12. Tension applied to finished product


 

 

Detailed Specification 


Raw material


LDPE / LLDPE / Recycle LDPE

(Can be used 100% recycled LDPE material)


Product width


Standard width adjustable 1,020mm-1,620mm


Bubble film thickness


2 layers: 0.03mm~0.20mm (abt. 25~80g/sq.m)

3 layers: 0.045mm~0.30mm (abt. 45~200g/sq.m)

Line Speed


700m--Max. 2,100m/hr；

Maximum speed depends on bubble size Φ10mm & 45-50g/sq.m.

*最快速度为标准气泡尺寸直径Φ10mm，45-50g/sq.m.

Capacity

100kg--Max. 160kg/hr（产量取决于膜的厚度和宽度）

Heating power

95kw

Consumption power


53-60kw

Voltage

380V, 60Hz / 3 Phase

Weight

10,000KGS



Machine Details


OG-W160FA

Bubble layer& Base layer

3rd PE layer 

Screw diameter


Φ75mm /Φ65mm

Φ55mm

Screw L:D ratio


1:34

Screw material


38CrMOALA

Motor

30kw / 22kw

15kw

Inverter

30kw / 22kw

15kw

Gear box


S350 / S336

S300

Vacuum pump


2.2kw

Bubble size


Φ269mm bubble mould: Φ10X3.5mm


Winder

Manual cutting winder

Unwind stand


Magnet powder tension control for unwind stands



ⅠMain extruder part (bubble layer and base layer) 

Ø Temperature controller, Ammeter, Breaker, SWISS CARLO solid state reply (CE standard)


**CARLO solid state relay is famous brand, and reliable quality, prevent spark while machine running.

Ø Bubble layer: 30kw SENLAN inverter, 30kw XINYUAN motor, S350 gear box, Φ75mm screw & barrel;

Ø Base layer: 22kw SENLAN inverter, 22kw XINYUAN motor, S336 gear box, Φ65mm screw & barrel;

**SENLAN is the most famous brand of inverter in China, for its good quality and low failure rate;

**Screw & barrelalloy treatment screw, material 38CrMoAlA, nitrogen treatment, L/d ratio is 34:1，

2 set

Ø Manual screen changer

2 set

Ø 1.1kw moving motor, WX-60 worm reducer

1 set

Ø MALEX made adjustable T-Die (40# steel, heat treatment),hard chrome plating;

Die lip width adjustable by manual external deckle type.


**advantages—when produce different thickness film, it can ensure product thickness uniformity, otherwise, the product will be uneven


1 set

Ø Stainless steel hopper & resin auto loader 

2 set


II. Sub extruder part (3rd PE layer)

Ø Temperature controller, Ammeter, Breaker, SWISS CARLO solid state reply (CE standard)


Ø 15kw SENLAN inverter, 15kw SIEMENS motor, S300 gear box, Φ55mm screw & barrel;

**Screw & barrel alloy treatment screw, material 38CrMoAlA, nitrogen treatment, L/d ratio is 34:1，

1 set

Ø Manual screen changer

1 set

Ø 1.1kw moving motor, WX-60 worm reducer 

1 set

Ø MALEX made adjustable T-Die (40# steel, heat treatment),hard chrome plating;

Die lip width adjustable by manual external deckle type.


1 set

Ø Stainless steel hopper & resin auto loader 

1 set


III. Forming part

Ø Φ269mm forming cylinder, surface chrome plating (bubble size is customized)


Bubble size (on mold): Φ10mm x3.5 mm

**advantages of Malex forming cylinder /

1. With independent water circulation at both side, ensure the cooling effect on the cylinder surface is high-efficient and uniformized;

2, By the CNC machine processing , ensure the bubbles on the mold distributed evenly; 

3, Based on years of experience and optimize the parameters of the cylinder, with advanced processing technology, every Malex forming cylinder can ensure the high-efficient, long-term and steady production.

1 set

Ø Infrared safety device

(silicon cylinder will be bounce off when finger is in close to the gap)

 

 

1 set

 

Ø Vacuum plate adjustment device

(adjust the both vacuum plates synchronously)

1 set

Ø Φ211mm cooling roller(cooling water circulate type) 

3 set

Ø Φ150mm cooling roller(cooling water circulate type) 

1 set

Ø Φ104mm cooling roller(cooling water circulate type) 

1 set

Ø Φ211mm silica rubber cooling roller(cooling water circulate type), pneumatic drive

advantages of Malex silica rubber cooling roller

1. If use the water basin for cooling, there will be water mark on the product, but Malex rollers do not have this problem;

       2. Longer life.

1 set

Ø Φ104mm rubber roller

1 set

Ø 1.2KW vacuum pump

1 set

Ø Electrical control system

1 set

Ø 2.2kw SENLAN inverter

2 set

Ø 2.2kw SIEMENS motor

2 set

Ø 3kw air compressor 

1 set

Ø Pneumatic equipment & components

2 set

Ø Length sensor

1 set

Ø Edge trimming cutter

2 pc

Ø Slitting units                                      

 

6 set


IV. Manual cutting winder ***Max. winding diameter：1000mm

Ø 2.2kw gyration motor 

1 set

Ø 2.2kw INOVANCE inverter, 2.2kw frequency motor

2 set

Ø Φ74mm air shaft

2 set

Ø  Length counter & alarm

1 set

V Magnet Powder Tension System For Lamination Rack 1 SET



(**max. diameter of lamination material roll ： 450mm)

 


Ø Magnetic tension device, pressure transducer;

4 set


Ø Magnetic controller & EPC controller; 

4 set


Ø Φ74mm air shaft

4 set


Advantages:

1. with digital display, can directly and accurately change the tension, to ensure the lamination material keeping smooth;

2. Fast response, no noise, no impact.

3. The laminated material must be PE coated ( Aluminized film, paper, PE foam, PE thin film etc.)



V Spare parts 


Part Name

Quantity

Part Name

Quantity

Tools

1 set

Temperature Controller

                                

2 pieces

Thermocouple

3 pieces

Thermal Panel & Circle

(1 piece for 1 specification)

                 

1 set

Magnet frame

2 sets

Roller Brass Rotary Joint

            

2 pieces

Scraper

2 pieces

Operation Manual

1 copy


VI. Optional Part (cost is separated) 


Tên khạch chọn mua

Số lượng

GIÁ CẢ USD

In-line perforator – servo control system

Hệ thống serrvo

1 SET


Automatic cutting winder  

máy thu cuộn cắt tự động

1 SET


Stainless Steel Mixer

Máy trộn đứng

500kg


1000kg


SCIYON PLC control system   

khống chế PLC

1 SET


Air Cooled Chiller  máy làm mát

1 SET



Φ269mm Inner Water Cooling Bubble Forming Cylinder / Width 1600mm

Quả lo thường


Bubble Diameter

Φ6-8mm

Φ9-10mm

Φ20mm

Φ25mm

Φ30mm


Standard Height

2.3-3mm

3.5-4.5mm

6-8mm

10mm

12mm


Price (USD)

7500

7000

7000

7000

7000


Φ269mm Inner Water Cooling Bubble Forming Cylinder / Width 1600mm

Quả lo cao cấp

Bubble Diameter

Φ6-8mm

Φ9-10mm

Φ20mm

Φ25mm

Φ30mm

Standard Height

2.3-3mm

3.5-4.5mm

6-8mm

10mm

12mm

Silica rubber roller, water cooling roller, auto clutch system, bearing etc.

Price (USD)







In-line perforator – servo control system  



It adopts servo control system for perforation.

It perforates the film at set length, such as 300mm, and then the film is easy to be tore up, no need cutting by knives manually.


² Convenient for packing the product with same dimension. 

² Save lots of labor. 

² Accurate perforation length by servo. 

 

l Automatic cutting winder  (**Max. diameter of roll is 1000mm)

** The price is the change price from semi-auto winder to automatic winder. 

When it reach the setting length, the film will be cut and rewind automatically. 


PLC control (INOVANCE BRAND).



l Edge trimmed recycler  

l Price (USD) 2500



This is to recycling edge trimmer. The edge trimmer will be crushed into small scrap and then recycled back to the screw again.


 

**Advantage of the recycler

Save factory space for waste film. 

Save labor cost.

Save material cost. 


l Stainless Steel Mixer 



Features:

1. Mix LDPE,LLDPE, HDPE and other recycle material and color granule. (for different formula)


(1) Without dryer function 


Capacity

500kg

1000kg

Price (USD)




（2）With dryer function 


Capacity

500kg

1000kg

Price (USD)




SCIYON PLC control system  



CHINA SCIYON PLC control system, it can control the complete production line working.


Outstanding of PLC control:

- Bubble film thickness control automatically. The system will be adjust the thickness of bubble film through trial and correcting. 

- Protect function for extruder motor. When the running temperature has not reached the specified temperature, the extruder inverter and motor can not be working even manual operation. There is fault signal shows on the HMI and warning that the heating element temperature problem. 

We can monitor the machine running status via network. 


l Air Cooled Chiller 



The chiller machine adopts air cooling system. 

It needs the chiller to enter the cooled water and recycle water system.

This chiller is helpful for saving factory space and saving recycle water. 


Capacity

15HP

Price (USD) 



l Extra bubble forming cylinder 

Good quality/ good treatment bubble forming cylinder is the most important part for stable performance bubble film machine.

Malex use special digital fully control machine to process every bubbles on the mould, to ensure that all the bubbles on the mould are the same dimension and places on the mould uniformly.


Ø 2 options for adding the extra bubble cylinder.

Option 1: the customer purchase the extra bubble forming cylinder only. The customer has to change the bubble forming cylinder manually. He has to take out the bubble forming cylinder from machine then install another size-bubble forming cylinder on the machine again.




Φ269mm Inner Water Cooling Bubble Forming Cylinder / Width 1600mm


Bubble Diameter

Φ6-8mm

Φ9-10mm

Φ20mm

Φ25mm

Φ30mm

Standard Height

2.3-3mm

3.5-4.5mm

6-8mm

10mm

12mm

Price (USD)







Option 2: We put all the extra bubble cylinders on the machine. We will supply the extra silicon rubber rollers and water cooling roller, as well as the automatic clutch change system on the machine. The customer can change the bubble cylinder automatically.


This design can help to produce different size and shape bubble film in an easier way, the bubble cylinder can be changed automatically.



Φ269mm Inner Water Cooling Bubble Forming Cylinder / Width 1600mm

Bubble Diameter

Φ6-8mm

Φ9-10mm

Φ20mm

Φ25mm

Φ30mm

Standard Height

2.3-3mm

3.5-4.5mm

6-8mm

10mm

12mm

Silica rubber roller, water cooling roller, auto clutch system, bearing etc.


Price (USD)






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Contact us
GUANGDONG CHAMPION AUTOMATION TECHNOLOGY CO.,LTD

Telephone: 020-38912384

Email :

Sales@champion-automation.com

Fax: 020-38912463

Tel: 0086-18816899059, 15018408881

Add:Room 2116,No 101-1 ,Li Xin 12th street, Xin Tang Town, Zeng Cheng District, Guang Zhou, Guang Dong province, China

 

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