masterbatch & compound cast stretch film bubble wrap blown ... · flexographic printing blown...

FLEXOGRAPHIC PRINTING

BLOWNFILM

BUBBLE WRAP

CAST STRETCH FILM

MASTERBATCH & COMPOUND

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PLASTIC MACHINERY?TORNINOVA DOES IT BETTER!

Masterbatch & Compound Machinery

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Cast Stretch FilmMachinery

pag. 22

Air BubbleFilmMachinery

pag. 30

FlexographicPrintingMachine

pag. 66

BlownFilmMachinery

pag. 56

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Plastic, Passion and Technology, together.

The experience of the Mencarelli family in the mechanical field begins.

1925 19931969 2005 2010 Today

Birth of Torninova “Costruzioni Meccaniche”

Our new Headquarters

Over 250 working machines on overfive continents

Our First Air Bubble FilmMachine

We go Globalwith Torninova Corporation

Milestones

The experience of the Mencarelli family in the mechanical field began early in the last century, in 1925. At the time of its foundation in 1969, Torninova’s experience had already developed, leading the company to specialize in technical support for flexographic printing machines and extrusion lines.

Later, in 1993, Torninova started designing and manufacturing air bubble film machines.

The company has always been highly involved in research and development in order to offer its customers versatile and flexible systems that combine the most innovative electronic and mechanical technologies.

A commitment to meeting the highest possible standards has led the Torninova Corporation to design its complete range of air bubble film machines, stretch film machines, flexographic printing machines, masterbatch & compound machines, blown film machines and to acquire top know-how in the field, now available to its customers.

About Us

8 9

STRETCH AND SHRINK FILM

Europe

IPACK IMA

Milan / Italy

INTERPACK

Dusseldorf / Germany

PLAST

Milan / Italy

K


Market Leaders for nearly 40 years Torninova Corporation provides technologythat expands the possibilities of your company and your life.

Global Markets Conferences& Fairs

DRUPA


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Torninova Corporation - located in Bastia Umbra (Perugia) in Italy - is a company which specializes in designing, developing and manufacturing machines for air bubble film, stretch film, masterbatch & compound, blown film and flexographic printing production as well as converting machines for each market.

Thanks to our patented systems and our technicians with over 40 years of experience, Torninova Corp. provides the best solutions in a demanding market and guarantees a high-tech end product.

Continuous technological advancement and ever increasing commitment enables Torninova Corp. to operate all over the World-efficiently, professionally and more importantly, effectively.

Torninova Corporation provides technology that expands the possibilities of your company and your life.

Production

Supported by its young, dynamic yet experienced staff, the company is able to produce machines tailored to customer needs, paying particular attention to production versatility.

Innovative design ideas, manufacturing precision, highly reliable components and the constant support of our technicians, ensure our customers receive a solid, long-term service.

These features mean that our company has become a market leader, with hi-tech machines all over the World.

Italy, Qatar, Spain, India, United States, Japan, United Kingdom, Germany, Canada, Russia, France, Argentina, Australia, Saudi Arabia, China, Indonesia, South Africa, Mexico,Turkey, South Korea, Brazil.

January 2013: Torninova Corp. began production at its new hi-technology 13.000 m2 Plant in Bastia Umbra.

The Plant provides 746 kWp from its own solar power system.

New Plant

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Technical Assistance Torninova Corp.’s integrated use of pioneering

mechanics, electronics and information technology is the company’s real strength and guarantees efficient after-sales service. The diagnostic software and display panels on the machines ensure the operators mantain high levels of efficiency.

With the development of new technologies and its skilled staff, Torninova Corp. can provide its customers with a remote, internet-based supervisory support system which carries out machine diagnostics and any necessary software modifications.

TELESERVICE

Our technicians perform scheduled maintenance on our machines.

SCHEDULED MAINTENANCE

Torninova Corp. guarantees its customers rapid supply of spare parts that may be needed during a machines’s entire life-cycle.

SPARE PARTS

Open during working hours (8 am - 12 pm and 2 pm - 6 pm GMT+1, Monday to Friday), the call center offers immediate assistance and provides guidance throughout the process always putting you in direct contact with a qualified engineer able to resolve your particular issue.

CALL CENTER

The company is constantly attentive to customer needs, so specialized technicians are available to provide assistance at the machine installation site. Torninova Corp. is able to ensure rapid intervention.

ON SITE SERVICE

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Masterbatch & Compound Machinery

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Torninova Corporation has a strong history of innovation and development of technologically advanced solutions modelled on customer needs; the twin-screw corotating extruder, like all Torninova Corp. installations, is based on an attentive and specific design and guarantees reliability, user-friendliness, low maintenance costs, high performance rates and energy saving. The Torninova Corp. range includes:

A) Extrusion line for colored masterbatches, for additives and multifunctional types.

B) Extrusion line for compounds of technopolymers and polymeric alloys.

The Torninova Corp. installations are completed by all accessories and components necessary to carry out the compound and masterbatches production, such as the degassing groups, the side feeders of polymer mixes or additive charges and the dosing units for the additives and the pigment powders.

COROTATING TWIN-SCREW EXTRUDERSThe Torninova Corp. twin-screw corotating extruders offer advanced and versatile solutions for the production of tecnopolymer compounds, polymeric alloys and colored masterbatches, for additives and multifunctional types.

All components of the Torninova Corp. extruders are treated in every design and technological detail to increase their efficiency and durability, enabling an immediate major benefit in terms of energy savings.

The Torninova Corp. corotating twin screw extruders have screw diameters available from 30 mm to 92 mm and process lengths reaching up to 42D. Larger diameters are also achievable on request.

ScrewsThe screws are entirely modular according to the needs and the work type; the geometric configuration of the screw is featured with self-cleaning elements mounted on splined shafts even HT (high torque).

The modular elements used for the geometric composition of the screw, either used for transport, kneading blocks, mixing or special, are bilobed or trilobed mounted along with the bilobes and can be realized with high OD/ID ratio.

The screw’s geometryThe screw’s geometry is designed to blend and uniform the compound or masterbatch viscosity in order to reduce the thermal and mechanical stress which may deteriorate the product quality, but also to ensure a maximum dispersion and distribution of additives and pigments in the polymeric matrix.

MASTERBATCH & COMPOUND MACHINERY

CylindersThe cylinders are featured with modular elements, providing the possibility to have an internal insert in special steel or bi-metallic alloys which increases its resistance to wear, to abrasion and corrosion.

The rectangular shape of the cylinder elements ensure that the temperature distribution inside the chamber is constant and homogenous.

Cooling and thermo-regulationThe cooling system of the barrels composing the extruder cylinder is specifically conceived and designed by Torninova Corp. to achieve a better control of the temperature on both screws, along with a high energetic efficiency.

The integration of the cooling system of the barrels with the double-intervention thermal regulation and integration device guarantees the same process temperature on both screws, ensuring the optimization of the extrusion process, especially for those compounds that are thermo-sensitive to the temperature.

ConstructionThe transmission group, composed of the electric motor, the joint limiting the torque and above all the gearbox, are highly-technological components used by Torninova Corp. and feature twin-screw extruders because they guarantee a precise transmission and distribution of the power needed for the compounds and masterbatches. The transmission group and the extruder cylinder are fixed to a frame on a thermo-welded base; the cylinder can be supported by two saddle supports (three for special applications).

The electric motor is an AC type, with a high electric and mechanical efficiency, but it is possible to use new technologies on request as well (e.g. new motor-reducers).

The electric panel is fitted with a control unit with MMI-interface and with the possibility to connect the production data logger by means of an Ethernet input.

Production process completely controlled through a simple and user-friendly interface with the possibility of remote assistance and data logger through Internet or Ethernet.

The double intervention thermoregulation is integrated in the main control system with a preheating automatic system start production and it permits to obtain ∆t of 1/ 2°C in comparison to the desired set-point.

A solution with independent thermoregulators is available as an alternative.

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1. BUSH INSERT

2. SELF-CLEANING SCREW ELEMENTS

3. RECTANGULAR BARRELS

4. EXTRUDER SCREW

5. CONTROL PANEL

6. EXTRUSION HEAD FOR MASTERBATCH

7. HIGH TORQUE GEARBOX

8. SIDE FEEDER

.1

.1 .3

LATERAL FEEDER

Lateral feeders for mineral charges and polymers in general, both in powder and in granules.

LATERAL TWIN-SCREWED EXTRUDERS

Lateral twin-screwed extruders for the plasticization of mixtures of additives and polymers.

TECHNICAL DATA & ACCESSORIES

DETAILS

Extruder ø (mm)

RV 40 RV 50 RV 58 RV 70 RV 83 RV 92

Power (kW)

Machine RPM MP CP MB CP MB CP MB CP MB CP MB CP

RV™

300 40 50 60 100 100 160 130 235 250 450 355 500

600 60 80 80 150 170 300 250 380 320 580 480 830

.2 .3

.4 .5 .6

.7 .8

The RV™ machines can be equipped with screw shafts mod. High Torque for other specific torques.MB stands for masterbatch production and CP stands for compound.

DOSING SYSTEMS

Dosing systems for the gravimetric and volumetric feeding of mixtures of additives in plastic powder or granules.

PUMP TO INJECT HIGH-PRESSURE LIQUIDS

Pump to inject high-pressure liquids for plasticizing oils (e.g. pharmacopoeia, cosmetics and special applications) or denaturalized paraffin oils for non-food use.

DEGASSING GROUP

Degassing group of volatile substances, monomer residuals and humidity by means of single units or custom-designed systems.

VENT PORT STUFFER

Vent port stuffer for a timely and accurate extraction of volatile substances.

The Torninova Corporation installations are complimented by accessories and components, necessary for the extrusion process of technical compounds and masterbatches, such as:

THE RV™ MACHINES

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The Torninova Corporation twin-screwed corotating extruders for the production of colored masterbatches, additives and multifunction types are treated in every design and technological detail and ensure:

A) A high energetic efficiency, allowing an immediate benefit in terms of energy saving. B) Optimisation and timely control of the screws/cylinder system temperature allows reduction in thermal stress, especially for those pigments,

additives and polymers that are thermo-sensitive to temperature. C) A maximum dispersion and distribution of additives and pigments in the polymeric distribution.

The Torninova Corporation twin-screwed corotating extruders for the production of techno-polymer compound and polymer alloys ensure:

A) a high quality of the extruded product along with a high energy efficiency.B) through the timely and constant optimization of the temperature of the extrusion process it is possible to reduce the degradation for those polymers and additives that are sensitive to

thermal and mechanical stress, ensuring at the same time their maximum dispersion and distribution.

EXTRUSION MACHINE FOR MASTERBATCH

EXTRUSION MACHINE FOR COMPOUND

A

B C

D E

F F

G

H I

L

A) RV twin screw corotating extruderB) Gravimetric feeder for polymers

C) Gravimetric feeder for additivesD) Gravimetric feeder for fillers

E) Gravimetric feeder for fibersF) Side feeders

G) Venting systemH) Cooling bath

I) Air dryerL) Strand cutter

A

B C

D

E

F

G H

I


C) Gravimetric feeder for additivesD) Gravimetric feeder for fibers

E) Side feedersF) Venting system

G) Cooling bathH) Air dryer

I) Strand cutter

A

B C

D D

E E

F


C) Gravimetric feeder for additivesD) Gravimetric feeder for fillers

E) Side feedersF) Venting system

G) Cutting System

G

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StretchFilmMachinery

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Torninova Corporation brings to market the very best in stretch film production technology thanks to its thorough research and development in collaboration with Italian and American University professors, renowned European manufacturers of extruder components and experienced figures from the field of extruded stretch film.

Some of our Client partners (Italian and foreign) have also supported our research and development phases by purchasing prototype systems to scientifically test and continuously monitor each single component and process.

During such tests, appropriate adjustments were made in response to real time controlsunder actual production conditions. The result is a perfectly integrated system of cutting edge components, calibrated and arranged into a compact, high performance cast line that provides maximum flexibility with minimum energy consumption.

Consider some hallmark components of the COMPACT STRETCH™ system:

The LLPOWEREX™ extruder series with screw profiles (AC motors and infrared heaters ensure limited maintenance and low energy consumption) have been specifically developed to guarantee perfect LLDPE extrusion.

The SWIFTCOOL™ chill-roll unit’s dual cooling rollers guarantee total material stabilisation. A dual-chamber vacuum box with automatic die adjustment and an integrated x-ray device to measure material thickness (guaranteeing accuracy even with coloured stretch film) offers the finest and fastest control features for the film extrusion process.

Customers can choose from three different winding systems:

The fast and reliable QUICKSILVER-4S™ winder (rewind cycle time of 10 seconds) directly rewinds stretch film into rolls on 2-inch or 3-inch cores (suitable for hand and machine use), in formats ranging from 100 mm to 250 mm, 450 mm and 500 mm.

The QUICKSTANDARD-2S™ winder is the best solution for production of machine and jumbo rolls up to a maximum diameter of 500 mm, on 3-inch cores.

The QUICKGOLD-4S™ is Torninova’s patented, universal, all-in-one evolution of hand and machine roll winders. Maintaining the same characteristics, it can also produce jumbo rolls up to a maximum diameter of 420 mm. The winding cycle still remains extremely fast (around 15 seconds) without compromising the production of hand rolls, even at very high speed.

Optional roll handling features can be integrated into each winder to assure steady, high-speed cast stretch film production. For instance, the automated packaging system packs hand rolls in a 6-unit cardboard box.

Another component which sets the machine apart from others is the FULLFEED™ trimming system with a force-feed device specifically designed for the type and quantity of trimming required by a stretch film machine. A suction device completely recovers all chopped trimmings for re-use by the main extruder line, thus preventing variations in pressure and film thickness even in the event of frequent changes in production and operating speed.

The FULLFEED system eliminates potential non-uniformities in film thickness, including those in longitudinal sections.

On request, instead of the flake re-feeding system, it is possible to equip the COMPACT STRETCH with a recycling machine that completely re-granulates edge and bleed trims.

The new COMPACT STRETCH series is not a simple combination of standard components from various processes but, on the contrary, is a well-developed, well-tested, made-to-measure integrated system affording maximum simplicity and flexibility in the production of high-quality rolls of co-extruded cast stretch film.

INTEGRATEDSOLUTIONS

Everyday, producers of stretch film have to face the increasing cost of raw materials, labour and energy. Producers thus find themselves in an increasingly competitive market in which prices are constantly driven down.

In these circumstances, profitable production is only attainable with a system that guarantees elevated and continuous production, 24 hours a day. Torninova Corp. has focused all of its attention on this aspect, developing and designing affordable systems for high-output production. The result has been an increase in sales and satisfied Clients in a very competitive market.

FAST AND RELIABLESOLUTIONS

All machines are equipped with a PLC-managed control system which runs touch-screen operated supervisory software for programming and managing the entire system.

The operator can use customized formulas to manage production according to the required percentage of co-extrusion and the needed production speed.

Via Internet, the machine can be remotely diagnosed to provide immediate customer assistance.

AUTOMATED SOLUTIONS

PERFECTLY INTEGRATED, HIGHLY FLEXIBLE SYSTEM

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The COMPACT STRETCH 2.000 series, characterised by an incredibly compact design, is a powerful cast co-extrusion line for the production of excellent, multi-layer PE stretch film.

Various co-extrusion configurations and production outputs can be chosen according to specific customer needs (3, 5, 7-layer and multi/nano layer configurations). An auto-adjusting flat die, a double chill-roll system with inner axial “torque”motors, an integrated thickness measuring device and super compact gear motors on the extruders are only a few of this machine’s special features.

The COMPACT STRETCH 2.000 is an “integrated-system” developed to ensure maximum production reliability, minimum energy consumption, a user-friendly automation interface and extensive control of the winding process.

The results are excellent rolls of stretch film (including “down-gauged” film) in hand, machine and jumbo formats.

COMPACT STRETCH 2.000™

Cast stretch film machinery.

TECHNICAL DATA

RAW MATERIALSLLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend and PP pellets

WEB WIDTHS2.000 mm (production of rolls in widths: 125, 250, 450, 500 and 1.000 mm)

NET OUTPUTUp to 1600 kg/h

MECHANICAL SPEEDMax. 800 m/min

LAYER CONFIGURATIONS3, 5, 7 and multi/nano layer

FILM THICKNESS RANGE7 - 50 µm

ACTUAL POWER CONSUMPTION< 0,40 kW/kg

RAW MATERIALS HANDLING By pneumatic loaders or gravimetric dosing system of up to 6 ingredients for each extruder

EXTRUDERSDiameters: 55, 70, 100, 120 and 160 mmL/D ratio: 32 D

Barrel:- standard grooves- helical grooves for high extruder output (+30%)

Drive:Gearbox and AC motor or internally cooled gear motor with a compact layout of either 2 or 4 three-phase, asynchronous motors for each gear motor

CHILL-ROLLS GROUP1.200 mm diameter, matted or polished chromed-surface primary chill-roll; 450 mm diameter chrome-surfaced secondary chill-roll.

EDGE TRIMMINGDouble-blade, in-line cutting of edge and bleed trims. Granulator and extruder force-feed recycling or dedicated regranulation unit.

WINDERShafted double-turret systems for 2-inch or 3-inch cores- QUICKSILVER-4S for hand and machine rolls- QUICKSTANDARD-2S for machine and jumbo rollsAutomatic loading of cores and automatic unloading of finished rolls with balanced weight control; automatic packaging system for hand rolls available on request.

AUTOMATIONSIMATIC WinCC; Three user-friendly touch screens.

OPTIONAL EQUIPMENT

QUICKSILVER-4S winderhand and machine rolls

QUICKSTANDARD-2S windermachine and jumbo rolls

AUTOMATIC HAND-ROLL packaging systemFor the production of:

- hand wrap film - machine wrap film

- jumbo wrap film - cling film

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QUICKGOLD-4S™

Hand, machine and jumboroll winder

TECHNICAL DATA

• Web widths: 1 and 1,5 m• Mechanical speed: 800 m/min• Film thickness range: 7 - 50 µm• Core diameters: 2 and 3 inch• Min. winding tension: 30 N• Min. cycle time: 17 s• Automatic core loading and

extraction of finished rolls• Max. diameter for jumbo rolls:

420 mm (50 kg/each)

QUICKSILVER-4S™

Hand and machine roll winder

TECHNICAL DATA

• Web widths: from 1 to 3 m• Mechanical speed: 800 m/min• Film thickness range: 7 - 50 µm• Core diameters: 2 and 3 inch• Min. winding tension: 30 N• Min. cycle time: 14 s• Automatic core loading and

extraction of finished rolls

The patented Quickgold-4S winder is the most advanced turret winder for cast stretch film machines.

This single-module universal winder includes all the characteristics of the Quicksilver-4S but is capable of producing rolls of stretch film in all 3 possible formats: hand, machine and jumbo (2 and 3-inch cores).

This winder is suitable for widths of up to 3 meters and can be installed on any new or existing stretch film machine another value-added upgrade.

The genuine, completely automatic Quicksilver-4S winder is the fastest stretch film turret winder capable of winding both hand and machine roll formats (2 and 3-inch cores).

The specially developed automatic system for core loading and roll extraction ensures a very short cycle time (10 seconds) and perfect-quality film rolls. Very sophisticated electronic controls and algorithms, customised mechanical components and unique materials used on the contact and satellite rolls, allow winding of very thin film onto very thin cores-with flat edges and no wrinkles or entrapped air.

A precision scale also checks the production weight of each roll. The result is high-output of perfect, ready-for-sale rolls, even for the most demanding markets.

This winder is suitable for widths of up to 3 meters and can be installed on any new or existing stretch film machine a truly value-added upgrade.

AUTOMATIC HAND-ROLL PACKAGING SYSTEM

OPTIONAL

TECHNICAL DATA

• Output: approx. 8 boxes/min• Carton storage capacity: 100 pcs.• Adjustable carton magazine• Boxes opend and moved by vacuum• Automatic box filling station with

interchangeable groups• Quick production changes with mini-

mum adjustment• Box closure by means of self-adhesive

taping group

OPTIONAL OPTIONAL

The COMPACT STRETCH 1.000 series is the World’s smallest and most reliable 1-meter stretch film machine. All components of this extremely compact, cast co-extrusion system (occupying less than 75 m2) have been specifically developed to enhance the flexibility offered by the machine’s specific dimensions as well as to ensure production of the highest quality stretch film with the utmost reliability and energy efficiency.

The COMPACT STRETCH 1.000 produces rolls of stretch film in hand, machine and jumbo formats at surprisingly high outputs (850 kg/h), all without compromising product quality (available in 3, 5, 7-layer and multi/nano layer co-extrusion configurations). An auto-adjusting flat die, a double chill-roll system with inner axial “torque” motors, an integrated thickness measuring device and super compact gear motors on the extruders, are only a few of this machine’s special features.

COMPACT STRETCH 1.000™

Cast stretch film machinery

OPTIONAL EQUIPMENT

QUICKSILVER-4S winderhand and machine rolls

QUICKSTANDARD-2S windermachine and jumbo rolls

QUICKGOLD-4S winderhand, machine and jumbo rolls

AUTOMATIC HAND-ROLL packaging system

TECHNICAL DATA

RAW MATERIALSLLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend and PP pellets

WEB WIDTHS2.000 mm (production of rolls in widths: 125, 250, 450, 500 and 1.000 mm)

NET OUTPUTUp to 850 kg/h

MECHANICAL SPEEDmax. 800 m/min

LAYER CONFIGURATIONS3, 5, 7 and multilayer

FILM THICKNESS RANGE7 - 50 µm

ACTUAL POWER CONSUMPTION< 0,45 kW/kg

RAW MATERIALS HANDLING By pneumatic loaders or gravimetric dosing system of up to 6 ingredients for each extruder

EXTRUDERSDiameters: 55, 70, 100, 120 and 160 mmL/D ratio: 32 D

Barrel:- standard grooves- helical grooves for high extruder output (+30%)

Drive:Gearbox and AC motor or internally cooled gear motor with a compact layout of either 2 or 4 three-phase, asynchronous motors for each gear motor

CHILL-ROLLS GROUP1.200 mm diameter, matted or polished chromed-surface primary chill-roll; 450 mm diameter chrome-surfaced secondary chill-roll.

EDGE TRIMMINGDouble-blade, in-line cutting of edge and bleed trims. Granulator and extruder force-feed recycling or dedicated regranulation unit.

WINDERShafted double-turret systems for 2-inch or 3-inch cores- QUICKSILVER-4S for hand and machine rolls- QUICKSTANDARD-2S for machine and jumbo rolls- QUICKGOLD-4S for hand, machine and jumbo rollsAutomatic loading of cores and automatic unloading of finished rolls with balanced weight control; automatic packaging system for hand rolls available on request.

AUTOMATIONSIMATIC WinCC; Three user-friendly touch screens.

For the production of:

- hand wrap film - machine wrap film

- jumbo wrap film - cling film

The automatic packaging system is the ultimate downstream accessory for stretch film machines.

With the addition of this packing station, any stretch film machine can achieve fully automatic (no operator), “granules-to-box” production of stretch film hand rolls.

The automatic procedure builds the cardboard box, fills it with 6 finished rolls, and lastly, tapes the package shut.

The closed box is then delivered to the end of the line for stock handling. This system can be implemented in any size machine and can manage rolls coming from 2 or more lines simultaneously.

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Air BubbleFilmMachinery

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Today Torninova Corporation is synonymous for Hi-Tech bubble wrap machinery all around the World.

For over 20 years Torninova Corp. has been engaging in the production of top-level equipment, presenting state-of-the art technology applied to air bubble film production lines: all of this has been possible and realized thanks to the Company’s constant engagement in finding innovative, better performing and cost-saving processes and solutions.

Torninova’s know-how is also based on the willingness to listen to reccomendations and suggestions provided by our clients, who have been helping us to enhance and adapt every single installation, making them suitable for each project’s specific necessity and technical requirements.

Completely focused on this specific line of equipment, Torninova Corp. strives to take the best possible advantage of market feedback and requirements, updating its equipment to comply with the newest regulations each of our lines components are homogeneous and perfectly connected to their counterparts, resulting in a perfectly integrated vanguard installation for the production of air bubble film.

All machines are modular and for this reason the whole Torninova Corp. system is easy to upgrade, based on each Client’s specific needs, and applicable on existing machines even if supplied by other companies.

Amongst Torninova’s outstanding specialized bubble foil production equipment the following lines deserve mention for their very special features:

The COEX BUBBLE (10)™, an authentic masterpiece, represents the most advanced available technology for the production of high-performance air bubble film. In fact, the special co-extrusion configuration allows the production of a symmetrically structured (ABCBA+ABCBA), multilayer air bubble film containing an integrated air retention barrierof Nylon-PA6 (layer C). The result is the production of an ultra-light bubble foil with enhanced cushioning and protective properties, far superior to the same-weight mono-extruded bubble wrap film. In practice, better results are ensured with less material and this means an unbeatable competitive edge in the film market.

HI-TECH AIR BUBBLE FILM MACHINERY

The AIR BASIC™ belongs to the family of the off-line process plants, and is a patented system based on the hot-air thermoforming process, which processes LDPE rolls to produce air bubble film both for technical packaging and reflective insulation. The specialty of this line, compared to traditional off-line systems, is that it significantly reduces energy consumption and provides maximum production-plan flexibility with its “stop-on-phase” procedure. The AIR BASIC series is still one of the most purchased lines for the production of air bubble film for technical packaging and reflective insulation.

The TWIN BUBBLE™ is the answer to a new profitable sector which produces air bubble film for use as thermo reflective insulation in costruction applications. Requests from Customers involved in such specific markets have moved Torninova Corp. to design and produce a new patented extrusion system,

called TWIN BUBBLE. This machine allows the production of multi-layer compound (sandwich) bubble foil, PE-foam and aluminum foil, all in one-single process. The TWIN BUBBLE system can even produce flame-retardant materials certifiable for all different Worldwide Standards.

Further, the POWER BUBBLE™, POLYBOLL™ and MAC BUBBLE™ air bubble film production lines complete the Torninova Corp. range. All Torninova Corp. equipment lines offer highly developed electronics, mechanical parts especially designed and created in the Company workshop and 24/7 teleservice assistance.

Torninova Corp., a journey of quality and tradition in plastic machinery which continues through generations and stands as a guarantee for Clients Worldwide.

A solid technical base, constant focus, continuous development and customised solutions, make Torninova Corp. the reliable partner in air bubble film production, ensuring the most effective and worthy results.

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The World’s largest packing corporations use the COEX BUBBLE (10) as it represents the most advanced technology for in-line production of air bubble films containing an integrated air retention barrier.

The COEX BUBBLE (10) is a cast co-extrusion system with three extruders. It processes LDPE, TIE and Nylon-PA6 pellets to produce high-performance, symmetrically structured (ABCBA+ABCBA), multilayer air bubble film.

The 10-layer structure allows for integration of an air-tight, Nylon-PA6 barrier for longer bubble-air-retention, thus improving the film’s cushioning and protective properties, even at reduced thicknesses.

For example, a 35 g/m2 of coex film has the same resistance of a 60 g/m2 mono film- a definite competitive advantage!

Especially suitable for technical packaging and envelopes, the COEX BUBBLE (10) series is fully automatic and includes touch screen controls for custom configuration of production recipes. Thanks to an on-board network connection, machine function can be remotely monitored via Internet.

The modular configuration of COEX BUBBLE (10) lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc...

COEX BUBBLE (10)™

high-speed/high-output,in-line co-extrusion.

TECHNICAL DATA

RAW MATERIALLDPE, TIE and Nylon-PA6 pellets

THERMOFORMING PROCESSWith three cast extruders

WEB WIDTHSFrom 1,25 to 3,5 m

FINISHED AIR BUBBLE FILM WEIGHTmin. 25 g/m2 - max. 600 g/m2

MAX. PRODUCTION SPEED100 m/min

FORMING ROLLER DIAMETERØ 450 mm

STANDARD BUBBLE SIZEØ 10 x 3 mm spherical

CAST DIETwo separate dies with feed-block for variable geometry co-extrusion

CO-EXTRUSION GEOMETRYbase (ABCBA) + bubbles (ABCBA)

REFERENCE Machine2,5 m - two layers

STANDARD PRODUCTION SIZE700 kg/h (75 g/m2)

STANDARD PRODUCTION SIZE15.000 m2/h (35 g/m2)

DIAMETER OF SCREW EXTRUDERS: A= Ø 130 mm L/D=30 (LDPE) B= Ø 45 mm L/D=30 (TIE) C= Ø 45 mm L/D=30 (Nylon-PA6)

AVERAGE POWER CONSUMPTION170 kW-h

OPTIONAL EQUIPMENT

- TRIPLEX winder- DUPLEX PLUS winder- VIR winder- Third layer extrusion lamination unit- Third layer diathermic oil lamination unit- Third layer hot-air lamination unit- Fourth layer unwinder- Perforation unit- Forming cylinders- Chiller unit


air bubble film packaging - reflective bubble foil

insulation - bubble solar pool cover - air bubble film

laminated with PE-foam - air bubble film laminated with

LDPE film - air bubble film laminated with HDPE film - air

bubble film laminated with coated kraft paper - air bubble

film laminated with coated aluminium foil - air bubble film

laminated with MPET film - air bubble film laminated with

printed film - air bubble film laminated with non-woven -

bubble wrap - etc...

WHY COEX BUBBLE (10)?

Better film performance ensured with less material means an unbeatable competitive edge in the film market!

Tie

Polyethylene

Polyethylene

Nylon

Tie

Air Air

Single-layerPolyethylene

5% thickness lost after 14 days

1 kg

50% thickness lost after 14 days

1 kg

CO-EXTRUSION AIR BUBBLE FILM MONO-EXTRUSION AIR BUBBLE FILM

Note: Independent Comparison

36 37

The POWER BUBBLE system is the pinnacle of standard mono-extrusion technology. Thanks to its power and flexibility, this machine produces a vast array of air bubble films.

Starting from an appropriate formulation of LDPE pellets with HDPE, PP, hexene - octene LLDPE and mLLDPE, the universal single-screw extruder produces high-performance, low thickness materials.

A single operator can fully control the entire POWER BUBBLE manufacturing process with the system’s fully integrated touch screen controls. Using its on board network connection, the machine’s operation can be remotely monitored via Internet. The system’s modular configuration is adjustable for any production output and lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc…

POWER BUBBLE™

high-speed/high-output, in-line mono-extrusion










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALLDPE pellets

THERMOFORMING PROCESSWith cast extruder





STANDARD BUBBLE SIZEØ 10 x 4 mm

CAST DIETwo separate dies

REFERENCE Machine2,5 m / two layers

Standard production size600 kg/h (75 g/m2)

Standard production size13.500 m2/h (40 g/m2)

Diameter of screw extruderØ 130 mm L/D=30

Average power consumption125 kW-h

POLYBOLL is Torninova’s authentic entry-level in-line extrusion system. These machines process LDPE pellets to produce a wide range of excellent-quality air bubble films at moderate outputs. With its simplified structure and no-frills finishing, the POLYBOLL is the most suitable solution for medium-to-small market necessities. The POLYBOLL production process is completely automatic and fully controllable by a single, un-skilled operator. This machine allows a new bracket of customers (e.g. air bubble film distributors and converters) to enter and learn the production market while substantially containing their up-front investment costs.

The POLYBOLL system is also ideal for air bubble film manufacturers intending to relocate production facilities directly in distant, but profitable, new markets, while drastically reducing transport costs and writing off, in the short-term, the initial investment. The POLYBOLL system’s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc…

POLYBOLL™

in-line mono-extrusion, medium/low production speeds and outputs










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALLDPE pellets

THERMOFORMING PROCESSWith cast extruder






CAST DIEone die with double delivery




Diameter of screw extruderØ 95 mm L/D=30


38 39

MAC BUBBLE is a traditional off-line system which processes LDPE rolls for high-output air bubble film production. A thermoform process laminates two individual films using Teflon-coated cylinders heated by a diathermic oil-circuit connected to electric heating units.

The result is high-speed air bubble film production with superior lamination quality, even for films of larger widths. In some cases, the production speeds achieved by MAC BUBBLE machines are much higher than those of an extrusion-based machine, even when starting from very high thickness films.

The MAC BUBBLE system also has an on-board network connection which allows machine function to be remotely monitored via Internet and the system’s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc…

MACBUBBLE™

high-speed/high-output, off-line processing










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALRolls of LDPE pellets and coated materials

THERMOFORMING PROCESSBy diathermic oil cylinders

WEB WIDTHSFrom 1,25 to 3 m









AIR BASIC is Torninova’s patented off-line system which processes LDPE rolls to produce air bubble film of various bubble sizes for technical packaging and reflective insulation. A thermoform process laminates two individual films using a special heating bar to blow hot-air over the films. Compared to traditional off-line systems, this process significantly reduces energy consumption and provides maximum production-plan flexibility with its “stop-on-phase” procedure. Such special features serve to significantly reduce inventory, transportation and energy costs.Because the AIR BASIC system is so versatile and easy to use, a single, un-skilled operator can quickly perform production changeovers without wasting material at restart. The on-board network connection allows remote monitoring of machine function via Internet and the system’s modular configuration lends itself to many useful upgrades such as a 3rd layer lamination unit, perforation unit, etc. The AIR BASIC series is still one of the most purchased lines for production of air bubble film for technical packaging and reflective insulation.

AIR BASIC™

medium output/medium speed, off-line processing










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALRolls of LDPE and coated materials

THERMOFORMING PROCESSBy hot air *(or by hot air + diathermic oil cylinders)



MAX. PRODUCTION SPEED35 m/min *(65 m/min)




Standard production size190 kg/h (75 g/m2) * 360 kg/h (75 g/m2 )

Standard production size3.350 m2/h (40 g/m2) * 6.250 m2/h (40 g/m2)

Average power consumption50 kW-h* 65 kW-h

40 41

TWIN BUBBLE is a patented in-line system with an extrusion line specifically developed to produce reflective bubble foil insulation for construction applications. The TWIN BUBBLE series uses LDPE pellets to produce multi-layer compound (sandwich) bubble foil, PE-foam and aluminium foil, all in a single process.

The system basically consists of two “twin” bubble lines producing two bubble foils (laminated with coated aluminium film) in opposite directions; in the middle there is a lamination station that welds the components together. The final multilayer product is then collected on the winder at the end of the line.

The TWIN BUBBLE system can even produce flame-retardant materials certifiable for all different Worldwide Standards.

TWINBUBBLE™

in-line processing for reflective insulation materials with double bubble layers


reflective bubble foil insulation - air bubble film lamina-

ted with coated aluminium foil - air bubble film laminated

with MPET film - air bubble film packaging - bubble solar

pool cover - air bubble film laminated with PE-foam - air

bubble film laminated with LDPE film - air bubble film

laminated with HDPE film - air bubble film laminated with

coated kraft paper - air bubble film laminated with printed

film - air bubble film laminated with non-woven - etc...

OPTIONAL EQUIPMENT

- DUPLEX PLUS winder- VIR winder- Lamination unit by hot air- Forming cylinders- Chiller unit

TECHNICAL DATA

RAW MATERIALLDPE pellets, flame retardand addivitive, coated aluminium rolls

THERMOFORMING PROCESSWith cast extruders


FINISHED AIR BUBBLE FOIL WEIGHTmin. 80 g/m2 - max. 625 g/m2 (double bubble)




CAST DIESTwo dies with double delivery+ one with single delivery

REFERENCE Machine1,6 m / five layers double bubble



Diameter of screw extruderstwo (Ø 80 mm L/D=30)+ one (Ø 55 mm L/D=30)


OPTIONAL EQUIPMENT

for Air Bubble Film and PE-Foam Machinery

TRIPLEX™WINDER

fully automatic winder with very short cycle time

Torninova’s patented TRIPLEX winder is the fastest automated tapeless and glueless winder for air bubble film and PE-foam machines. This turret winder is based on a three-cantilever-shaft configuration that allows extremely fast cycle changes (< 40s). The automatic loading of new cardboard cores (whole or split) and extraction of finished rolls is synchronized with a roller-table at the final collection station. The new transversal cutting system allows film to be wound without glue or adhesive tape on the core. Thanks to its advanced technology, the TRIPLEX winds various types and thicknesses of air bubble film and PE-foam, into very short roll lengths, at a speed of over 100 m/min. The TRIPLEX can also be installed on existing production lines.

TECHNICAL DATA


MAX. WORKING SPEED100 m/min

REFERENCE50 m length roll at 70 m/min of working speed

MAX. WINDING DIAMETER1.100 mm

Bubbles on inside or outside

TRIPLEX™ CAN WORK WITH:

air bubble film - reflective bubble foil insulation -

bubble solar pool cover - air bubble film laminated with

PE-foam - air bubble film laminated with LDPE film - air

bubble film laminated with HDPE film - air bubble film la-

minated with coated kraft paper - air bubble film laminated

with coated aluminium foil - air bubble film laminated with

MPET film - air bubble film laminated with printed film - air

bubble film laminated with non-woven - PE-foam packaging

- reflective PE-foam insulation - etc...

DUPLEX PLUS™WINDER

flexible automatic winder

The DUPLEX PLUS is Torninova’s traditional, highly reliable tapeless and glueless turret winder consisting of two cantilever air expansion shafts with automatic inflation/deflation. Extremely reliable and powerful, the DUPLEX PLUS winds perfect quality rolls to extremely accurate lengths and widths, even when divided in-line into sub-formats. The DUPLEX PLUS can be configured to wind external bubble, internal bubble or double-system films. The DUPLEX PLUS is available with an automatic FAST LOADING system for finished roll extraction, core loading and hot-melt application (both for initial core gluing and roll closure). The DUPLEX PLUS can wind air bubble film and PE-foam of any type and thickness and can also be installed on existing production lines.

TECHNICAL DATA



REFERENCE50 m length roll at 40 m/min of working speed


Bubbles on inside or outside or booth

DUPLEX PLUS™ CAN WORK WITH:










VIR™WINDER

contact winder for jumbo rolls

The VIR is an in-line contact winder for assembly on air bubble film and PE-foam machines. With its guaranteed speed performance and finished roll quality, the VIR produces rolls up to two meters in diameter and is thus recommended for all customers converting air bubble film or PE-foam through a second manipulation phase (bags, envelopes, formats, sheets, etc.). The larger diameter rolls (longer) are automatically unloaded onto the floor to reduce finished roll replacement times during the conversion process. The VIR can also be installed on existing production lines.

TECHNICAL DATA




Bubbles on inside

VIR™ CAN WORK WITH:










CORELESS READY (patented)

CORELESS READY (patented)

THIRD LAYEREXTRUSIONLAMINATION UNIT

This lamination module can be retrofitted to any new or old extrusion-based machine for the production of air bubble film or PE-foam in net widths of up to 3 meters. It laminates, in-line, a 3rd film of LDPE or HDPE over the bubble layer. The melted film from the single flat die adheres directly to the heads of the bubbles which are rapidly cooled. The result is a surprisingly low-cost, three-layer LDPE air bubble film.Additionally, the same melted film can be used as an adhesive layer for perfectly smooth, high-speed lamination to other rolled materials (PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc). The finished product is an air bubble film with two flat faces, one of which can be optionally characterized by a different material.

TECHNICAL DATA



STACK UNWIND WITH AUTOMATIC ROLL CHANGEmax. Ø 1.200 mm

CAN WORK WITH:









PE-foam packaging - reflective PE-foam insulation - etc...

THIRD LAYER DIATHERMIC OIL LAMINATION UNIT

This fast and powerful in-line lamination module is easily retrofitted to any new or old machine for high-speed production of air bubble film or PE-foam in net widths of up to 3 meters. The 3rd film layer to be laminated is supplied from the unit’s double-station film unwinder (with no-stop changeover). Teflon-coated cylinders heated by a diathermic oil circuit connected to electric heating units, laminate the 3rd film layer over the bubble layer. This lamination process guarantees the highest production speeds of any main line and ensures best-quality lamination with all kinds of material (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc.). The main advantage of this lamination unit is its ability to laminate film directly on top of the air bubble film with no additional adhesive layer.

TECHNICAL DATA




CAN WORK WITH:









PE-foam packaging - reflective PE-foam insulation - etc..

THIRD LAYER HOT-AIR LAMINATION UNIT

This in-line, hot-air lamination system is easily retrofitted to any new or old machine for air bubble film or PE-foam production in net widths of up to 1,6 meters. The 3rd film layer is supplied from rolls on the unit’s double-station film unwinder (with no-stop changeover) and is laminated over the bubble layer using hot air. Thanks to this air-based heating system, the unit is especially suitable for lamination of delicate materials such as PE-foam, coated aluminium foil, printed film, etc. This unit is further distinguished by its “stop-on-phase” procedure and very low energy consumption.

TECHNICAL DATA




CAN WORK WITH:









PE-foam packaging - reflective PE-foam insulation - etc...

FOURTH LAYER UNWINDER

This unit laminates a 4th layer film (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc.) to the base of the air bubble film, improving or varying the finished film’s aesthetic and/or mechanical characteristics. It consists of a double-station unwinder equipped with two air expansion shafts for loading the 4th layer film rolls. While a roll is unwinding on one station, a new roll can be prepared in stand-by on the other for a no-stop changeover. This modular unit is easily retrofitted to any new or existing in-line air bubble film machine.

TECHNICAL DATA




CAN WORK WITH:









etc...

PERFORATIONUNIT

This useful independent module is easy retrofitted in-line to any air bubble film machine and can possibly be used in other types of machines producing similar films (PE-foam, blow film, etc). It makes a preliminary cut on the film at desired intervals (max. 400 strokes/min) before winding, resulting in a finished film roll prepared in pre-cut sections that are quickly and easily torn-off when needed. A brushless motor with encoder drives the double-blade pre-cutting device and ensures exact, consistent sheet sizes. The module is available with an optional trim-cutting unit and suction group.

TECHNICAL DATA



CYCLE TIMEmax. 400 stroke/min

MIN. PERFORATION LENGTH110 mm (45 m/min)

CAN WORK WITH:

air bubble film packaging - bubble solar pool cover

- air bubble film laminated with PE-foam - air bubble film

laminated with LDPE film - air bubble film laminated with

HDPE film - air bubble film laminated with coated kraft pa-

per - air bubble film laminated with MPET film - air bubble

film laminated with printed film - air bubble film laminated

with non-woven - PE-foam packaging - etc...

FORMING CYLINDERS

These chromed cylinders for bubble moulding are the most distinguishing element of Torninova’s technical know-how. A monolithic steel cylinder, with a special internal water circuit provides perfectly homogenous thermoregulation, guaranteeing the highest production performance and maximum stability with material of any thickness. The sector vacuum system used for bubble thermoforming increases efficiency and conserves power. The push-to-connect design allows for fast cylinder changes. The cylinders can be manufactured to custom bubble shapes and dimensions and are available for all types of air bubble film machinery.

TECHNICAL DATA


MOULDER ROLLER DIAMETERSFrom 270 to 500 mm

BUBBLE SHAPESSpherical, square and other shapes

STANDARD BUBBLE SIZESØ3 - Ø6 - Ø10 - Ø15 - Ø25 - Ø30 mm and other diameters

CAN WORK WITH:


insulation - bubble solar pool cover

48 49

ConvertingMachines

for Air Bubble Filmand PE-Foam

50 51

The MAX ONE machine produces various sizes and types of envelopes, bags, sheets, formats, tubulars and sleeves, starting from rolls of air bubble film and PE-foam.

This All-in-One system ensures ease of use for even the unskilled operator. Moreover, through its various automatic devices, a single operator can manage up to two systems simultaneously.

The entire process is controlled by the main touch screen where hundreds of recipes can be saved and/or loaded. The needles are mounted on a pneumatic unit which collects and stacks envelopes or formats into bundles.

Once completed, the bundles are transported to the collection conveyor. The palletizing system can stack several bundles at the same time, thus eliminating the need for operators to perform this task, a feature that is especially convenient when producing envelopes or large-dimension formats.

This process is completely automatic. After pre-cutting, bags can be wound into rolls on a downstream winder.

MAXONE™

bag-making and sheeter machine with needle staking

Can convert:

air bubble film - PE-foam - air bubble film laminated with






bubble film laminated with non-woven - etc...

TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films

WEB WIDTHSFrom 1,6 to 2 m

MAX. STARTING ROLL DIAMETER1.200 mm (max. weight of 75 kg) on 3-inch cores

FILM FEED SPEEDmax. 120 m/min

NUMBER OF LONGITUDINAL BARS1, 3 or 5

NUMBER OF TRANSVERSE BARS2

NUMBER OF LONGITUDINAL KNIVES6 or more

ENVELOPE AND FORMAT FEED STEPSmin. 100 mm / max. 1.300 mm in automatic mode; for larger sizes the machine can also run in semi-automatic mode


The SHEETEX machine is the best solution for effortless cutting of plastic materials (such as PE-foam and air bubble film) into sheets of pre-set length.

Sheets (or multiple sheets) are cut and divided by self-sharpening blades which require no adjusting even when material thickness or the number of layers to be cut varies.

A needle stacker collects the sheets and stacks them on a table with pivot rotation to facilitate extraction.

SHEETEX™

sheeter machine with needle staking

Can convert:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films


MAX. STARTING ROLL DIAMETER1.000 mm (max. weight of 50 kg) on 3-inch cores

MAX. THICKNESS OF MATERIALS TO BE CUT16 mm

MAX. NUMBER OF FILMS TO BE CUT SIMULTANEOUSLY4 (e.g. 4 rolls of air bubble film with 4 mm bubble height)

FEEDING LENGTHmin. 100 mm / max. 1.000 mm or more

PRODUCTION SPEEDsheet length cycles/min150 mm 23 300 mm 21 500 mm 18 1.000 mm 15

AVERAGE POWER CONSUMPTION1,5 kW-h

52 53

The RP machine is a fully automatic rewinder that produces coreless, small-diameter rolls (mini-rolls, max. diameter Ø 350 mm) of plastic film (air bubble film, PE-foam, EPS, corrugated paper, etc.)

Once the starting roll is inserted, the RP rewinder automatically begins producing the small diameter rolls. The operator does nothing more than simply change the starting roll and replace the collecting box once it is full. The machine can also split the starting jumbo reel to produce 2 or more narrower rolls at the same time.

The RP rewinder is the perfect choice for entering retail markets (hardware stores, superstores, DIY, etc.) where air bubble film rolls are not sold in standard sizes, but rather, in shorter lengths of 3 to 30 meters.

Avoiding the use of an internal cardboard core is crucial in this specific market, as its cost is excessively high in relation to the end product being sold, a compelling reason to choose the RP Coreless Rewinder.

RP™

corelessrewinder

Can rewind:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films; corrugated paper


PRODUCTION LENGTHSFrom 3 to 40 m (max. Ø 350 mm)

PRODUCTION SPEEDapprox. 180 rolls/h (length 5 m)approx. 120 rolls/h (length 10 m)approx. 90 rolls/h (length 15 m)approx. 70 rolls/h (length 20 m)

MAX. STARTING ROLL DIAMETER2.000 mm


In addition to producing the same short length rolls as the RP Coreless Rewinder, the RP PLUS is capable of rewinding coreless mini-rolls up to a diameter of Ø 600 mm (containing 100 meters of air bubble film).

As the diameter of the roll in production grows, automatic support devices are engaged to handle the extra weight.

This off-line rewinder can produce coreless rolls in standard sizes (50 and 100 meters) for increased savings of cost and space.

RP PLUS™

coreless rewinder

Can rewind:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films; corrugated paper


PRODUCTION LENGTHSFrom 3 to 100 m (max. Ø 600 mm)

PRODUCTION SPEEDapprox. 175 rolls/h (length 5 m)approx. 115 rolls/h (length 10 m)approx. 85 rolls/h (length 15 m)approx. 65 rolls/h (length 20 m)


AVERAGE POWER CONSUMPTION4,5 kW-h

54 55

The LAM machine is a hot-air lamination system which laminates the entire surface of two or more rolls of plastic materials (two or three layer air bubble film, PE coated materials, LDPE and HDPE films and PE-foam) for value-added improvement of complex, final products used in various applications.

Alternatively, by adding electrically-heated sealing wheels, the extremities of two rolls of bubble foil can be coupled with aluminium on the external side (like a “tube”).

Such coupling may also include an additional internal material (PE-foam or other). The LAM machine is therefore recommended for plastic film lamination and/or production of complex materials specific to the reflective insulation market.

LAM™

lamination machine

Can produce:

reflective bubble foil insulation - air bubble film lamina-

ted with coated aluminium foil - air bubble film laminated

with MPET film - reflective PE-foam insulation - air bubble

film laminated with PE-foam - air bubble film laminated

with LDPE film - air bubble film laminated with HDPE film

- air bubble film laminated with coated kraft paper - air

bubble film laminated with printed film - air bubble film

laminated with non-woven - all lamination with air bubble

film and PE-foam.

TECHNICAL DATA

HEATING SYSTEM Lamination with hot air or infra-red lamps; longitudinal welding with circular electric resistances


PRODUCTION SPEEDLamination from 10 to 35 m/min longitudinal welding from 5 to 15 m/min


MAX. FINISHED ROLL DIAMETER800 mm

LONGITUDINAL WELD WIDTHFrom 10 to 40 mm

LAMINATION LAYERSFrom 2 to 4

NUMBER OF LONGITUDINAL WELD LAYERSFrom 2 to 5


56 57

Blown Film

Machinery

58 59

BLOWN FILM MACHINERY

Blown film is the technology which allows the production of majority of the plastic films used in the flexible packaging industry as such or printed and laminated with other products in order to achieve the necessary properties of the package itself.

This technology is relatively new to Torninova as the Company has been active in the plastic processing market for over two decades building its own experience and technology that is nowadays applied to the whole of the production , from ten layers bubble film machines to multilayers high speed stretch film cast lines.

The know-how generated and produced by Torninova is in part a resource coming from its own experience but it has also been implemented recently with the addition of the experience of staff and engineers being active in this particular field for over 40 years.It is in fact the case that the specific knowledge

required for the production of the head and air ring as well as the nip and the winder is now at Torninova thanks to the addition of a number of engineers proceeding from this specific industry. These engineers, along with Torninova’s managed to reach a extremely high level of quality and neatness of design by merging different experiences in the plastic processing field.

The aim of producing blown film machines, amongst the other technologies is purely dictated by specific requests made by customers who feel satisfied with the technology and the service provided by Torninova and would like to have the same level of quality and service with the blown film lines, so they specifically requested the production of these machines.

It is obvious that these extruders do produce 24/7 and nobody but an experienced and fully responsible organization can cope with the

required reaction speed, this is the reason why Torninova turned up to be such a successful Company and achieved the position of market leader in bubble film machines.

The dedication and the knowledge as well as the skillness of the engineers are the resources of Torninova which is one of the few Companies that can boast long term engineers experience in this particular field.

Torninova produces blown film machines in mono and coextrusion configuration up to 5 layers, covering a vast range of polymers and widths from 1000 mm to 3500 mm with outputs in excess of 1000 kgs per hour.

60 61

Three layers coextrusion is the base of the plastic film nowadays and has substituted monolayer films in many cases. The reasons for this success are due to the easiness of production of this technology and the improvement of properties on the film that can be achieved by producing a film made with different properies’ layers. Coextrusion technology in fact consists of hot lamination of different types of polymers before they actually exit the die avoiding a offline lamination and saving in glues or additives that allow diffenet materials to stick together.

The first applications of coextrusion were created for the simple necessity of producing a film for milk packaging that was white outside so to be printed nicely and create an attractive package, and black inside so to prevent contact of the product with light which is accelerating degradation of the contained product . Since then coextrusion has been widely used to match and combine different products and polymers in order to improve the properties of the final product or with the simple necessity to produce a good quality film with a reduced price using reclaimed or cheaper materials for example.

Torninova produces different sizes of machines to match all the market requirements from 1000 mm to 3500 mm wide film. All the machines are complete with fixed dies provided with Internal Bubble Cooling and fully oscillating nip unit , gravimetric units up to 6 components for each extruder that allow a severe control on the percentages and give a average even thickness. We do offer as option the automatic thickness control and optimization unit that controls by a capacitive sensor the actual film thickness and reduces the peaks up to 70 %.

To cope with the quality produced and the demand of the different products Torninova has designed a series of winders with a fully

automatic configuration that thanks to tension and speed controls permit the production of the best geometrical quality of the produced rolls. Between the others, winders are supplied optionally with non-contact winding for thin films , weighting units before the roll is actually unloaded , semi automatic and fully automatic handling units for the shafts, 3” and 6” diameter and many other options in order to have complete and accurate control of the film in all its path from the die to the winder.

FEATURES

• Automatic thickness control units• Gap winding • Oscillating nip unit with variable angle and

speed• Deep gussets• Aluminium and wood exchangeable

rollers/slats• Carbon fiber rollers• 3“ and 6” air shafts • Touch screen controlled (though PLC)• Fully automatic handling of the air shafts • Fully automatic handling of the finished

rolls• Weighing and labeling of the rolls• Remote controlled machines• Gravimetric units for full process control• Torque motors

COEX BLOWN (3)™

High efficiency,high production, cost saving


high quality lamination films, high quality

printing films, flexible packaging films, high

resistance films, heavy duty bags, pallets

hoods, shrink hoods, shrink films, stretch films,

recycled films, different layers properties,

Polypropylene layer for high stiffness

Extruder Die Range Kg/h max Dimensions Weight

2x55 mm1x65 mm 175/350 mm 300 4.992x2.200 mm 7.500 kg

2x55 mm1x80 mm 220/550 mm 350 5.692x2.200 mm 8.200 kg

2x65 mm1x80 mm 220/550 mm 400 5.850x2.250 mm 8.500 kg

2x65 mm1x100 mm 220/550 mm 550 6.517x2.250 mm 9.500 kg

LDPEHDPEEVAMLLDPEPPLLDPEMDPEPARECLAIM

62 63

Five layers coextruded film focuses on the food industry where a specific barrier to oxygen and grease is required. Air is a strong oxidation agent and if foods such as meat and cheese are not properly packed they soon get attacked by oxygen which permits diffusion of bacteria and start loss of properties and decomposition. Polyethylene as such is not a good barrier to oxygen therefore it cannot be used alone to prevent oxidation. In this case a layer of Polyammide or EVOH is required in order to prevent degradation of the product by oxygen contamination.

Nowadays though the five layers technology is also more and more used for different applications which differ from the food industry packaging, such as for example shrink film, stretch film and more rarely for standard packaging .Torninova is one of the few companies in the world which can claim a full and complete knowledge of barrier films as it is also widely used in the stretch film and more frequently in the production of bubble film where PA prevents air to escape from the bubbles flattening the film and making it useless.

The experience in five layers bubble film with PA helped a lot Torninova in order to produce its die heads and extruders. It is in fact vital in bubble film (a very light product where transport costs impact a lot in the final selling price) that the amount of the PA and the thickness of this layer are very accurate as PA is very expensive. Over 15 years of experience have been used to design the best dies, the best screws able to target the most accurate control of this very expensive and important layer.

All the five layers coextrusion machines are fitted with gravimetric units and can be completed with automatic thickness control. The winders accept both 3” and 6” shafts and can wind film either in contact with the

rubber covered drum roller or by a gap, with a motorized shaft unit applied to the same winder.

As it is the case of the other machines produced by Torninova , in this case also a wide range of extras and options are available in order to have a specifically designed and complete machine for the necessities of each and every single customer.

COEX BLOWN (5)™

High efficiency five layers coextrusion machines

FEATURES

• Smooth feeding sections water cooled• Different screw diameters designed for the

specific application• Dedicated screws for PA and EVOH layers • Automatic thickness controlled machines • Gravimetric units for full process control • Oscillating nip unit with variable angle and

speed• Touch screen controlled (though PLC)• Gap winding • 3“ and 6” air shafts• Fully automatic handling of the air shafts • Fully automatic handling of the finished

rolls• Weighing and labeling of the rolls• Stabilizing water cooled rollers and water

bath• Remote controlled machines• Torque motors


high barrier properties films for food application,

film for vacuum use, oil and grease barrier pro-

perties, typical food and high resistance grades,

EVOH layer, PA layer, double PA layer, thickness

controlled and optimized film, yield control and

average control of the barrier layer, fully auto-

matic and remote controlled machines

Head Zones Dies Ø mm Kw installed

20 K5F 5 180/330 30 kw

30 K5F 6 200/380 35 kw

20 K5F IBC 5 180/330 49,3 kw

30 K5F IBC 6 250/380 57,3 kw

LDPETIEPALLDPEPPPEEVOHMLLDPE

64 65

COMPONENTS EXTRUDERS

The extruders we do produce are all designed with grooved feeding sections to allow a higher material feeding and a higher production. All the extruders are fitted with ceramic heater bands and water cooled feeding section in order to optimize the output. In the case of a three layers coextrusion the three extruders are accommodated on a single platform that includes all the wiring, the piping and the necessary electronics that allow a full control of the unit.

The extruders are mounted on a special unit that allows expansion of the barrel without damaging the same. All the extruders are designed to accommodate gravimetric unit and the die head. Dimensions are designed in such way that they fit into a container or a trailer.

DIE HEADS

All our die heads are designed with dedicated computer aided programs that allow a perfect distribution of the flow and avoid raw material to stop in the die.

All the dies are provided with fittings able to accommodate automatic thickness control.

The inner spirals are designed in such way to avoid material stop and build up in the die.

WINDERS

The winders we do produce are fully automatic with change over sequence controlled by a auto sequence through a PLC unit.

All the winders are complete with floor positioning of the finished roll as well as programmable meter counter. The winders do have a unit that is able to recognize automatically the size of the air shaft and the positioning of the same during the sequence.

Winders can be completed with fully automatic labelling and weighing units of the roll as well as recognition of the shaft diameter and fully handling of the finished rool.

HAULOFF

We do produce fixed and oscillating haul off units. Both the items can be fitted with gussets units made of wood slats or carbon fiber rolls or combination of the two.

All the oscillating units are complete with plc unit that allows control of the oscillating speed and angle as well as a full control of the same.

Nips can be fitted with secondary cooling section or water tank to avoid curling on PA rich films.

SPECIALCOMPONENTS

All our machines can be retrofitted with automatic thickness control unit, IBC systems, full remote control and machine management, links to a existing machine supervision program and a full remote feed back and printing.

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FlexographicPrinting

Machine

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The Mencarelli family engaged in theproduction of flexographic presses in the1969, and has always followed the developments of this industry with great interest.

The Torninova Corporation core business became top-level cast lines for the production of bubble wrap, stretch film, extrusion line for masterbatch & compound and blown film, because of the complexity and state of the art technology that these machines require.

Given the past experience manufacturing flexopresses and the opportunity to cooperate with some of the most competent and expert professionals in the market, who introduced unmatched technological innovations in this industry, Torninova Corp. has engaged in the creation of the Torninova flexographic printing machine project, combining specialized teams of highly experienced and committed engineers and technicians with a proven capability of designing and producing a wide-range of reel-to-reel flexo printing presses according to every Client’s specific need.

In addition to state-of-the-art and leading edgetechnology, business continuity is of the utmostimportance at Torninova Corp., where great importance is given to maintaining key people within the organization to dominate the present and strengthen the future.

The Torninova flexographic printing machinedivision offers central drum and stack lines,gearless or conventionally driven, all equippedwith state of the art components and technologies available in the market to guarantee quality, reliability, constant performance, extremeoperator safety and easy remote maintenanceprocesses reduce machine down time to thevery minimum.

The modular criteria used for the Torninova Corp. presses enable the reproduction of the same solutions on the different machine types, ensuring thus the same quality level and technology regardless of the number of colors and the requested speed and print repeat.

A new family of machines, an exciting chapterof Torninova’s 40 year professional journey, butthe value and engagements are just the same:at Torninova Corp. everybody has the same level of attention, care for the details and customer-oriented attitude on every project, for every single Client, before, during and after every project.

FLEXOGRAPHIC PRINTING MACHINE

UNIDRUM™

flexographic printingmachine

Can produce:

- printed materials on plastic, paper and board

TECHNICAL DATA

PRINT SECTIONCentral impression drum

NUMBER OF STATIONS4, 6, 8 and 10

PRINTING WIDTHUp to 2.000 mm (80”)

REPEAT RANGE REGULAR430-1.000 mm (17”-40”)

REPEAT RANGE EXTENDED480-1.300 mm (18.9”-51.1”)

DRIVE TO PRINT CYLINDER AND ANILOX ROLLERGearless

PRINT CYLINDER CONFIGURATIONSleeve

ANILOX ROLLER CONFIGURATIONSleeve

SLEEVE CHANGE OVER PROCEDUREFully automatic, programmable

CYLINDERS’ FRONT / BACK MOVEMENTServo motors

DOCTOR BLADEAluminum or carbon fibre

PRE SET AND PRE REGISTERIncluded in all versions

PRINT SECTION FRAMEWindow type

MACHINE LAYOUT REGULARFront print

MACHINE LAYOUT SPECIAL PROJECTUp/down stream equipment

MACHINE MANAGEMENTPC, PLC communication system

REMOTE SERVICEComplete remote control, all function

INK AUTOWASHFully automatic, programmable

PRODUCTION SPEED400 m/min (1300 – 2000 ft/min)

DRYING SYSTEMAt customer’s choice

INK TYPESolvent, water based

SPECIAL INKSUV

WEB SUBSTRATES REGULARFilm, laminates, paper, board

WEB SUBSTRATES OTHERSLiner pre-print for corrugated board

MARKET COMPONENTS AND ACCESSORIESOn request

Unidrum is a completely automatic, high-performance flexo-printing press, designed to guarantee versatility and flexibility along with a top-level printing quality with easily accessible control process.

70 71

POLYSTACK™

flexographic printingmachine

Can produce:

- printed materials on plastic, paper and board

TECHNICAL DATA

PRINT SECTIONStack

NUMBER OF STATIONS2, 4, 6, 8 and 10

PRINTING WIDTHUp to 2.000 mm (80”)

REPEAT RANGE REGULAR430-1.000 mm (17”-40”)

REPEAT RANGE EXTENDED480-1.300/1.500 mm (18.9”-51.1” / 59”)

DRIVE TO PRINT CYLINDER AND ANILOX ROLLERGeared option gearless mechanical transmission

DRIVE TO IMPRESSION ROLLERGeared, option gearless

PRINT CYLINDER CONFIGURATIONIntegral option sleeve

ANILOX ROLLER CONFIGURATIONIntegral option sleeve

SLEEVE CHANGE OVER PROCEDUREFully automatic, programmable

CYLINDERS’ FRONT / BACK MOVEMENTManual, single motor, 4 step motors

DOCTOR BLADEAluminum or carbon fibre

PRE SET AND PRE REGISTEROption

PRINT SECTION FRAMEBracket type

MACHINE LAYOUT REGULARFront print

MACHINE LAYOUT SPECIAL PROJECTUp/down stream equipment

MACHINE MANAGEMENTPLC communication system

REMOTE SERVICEOption

INK AUTOWASHFully automatic, programmable

PRODUCTION SPEED300 m/min (830-1000 ft/min)

DRYING SYSTEMAt customer’s choice

INK TYPESolvent, water based

SPECIAL INKSUV

WEB SUBSTRATES REGULARFilm, laminates, paper, board

WEB SUBSTRATES OTHERSLiner pre-print for corrugated board

MARKET COMPONENTS AND ACCESSORIESOn request

Polystack stands as a splendid example of stack technology applied to the flexo-printing industry: the wide printing width and repitition, along with its powerful drive and the outstanding mechanical pre-cision make it ideal for every Client’s printing need.

Torninova S.r.l.via dell’Artigianato 1806083 Bastia Umbra (Perugia)Italy

tel. +39.075.8000655fax. [email protected]

www.torninova.com

TNV_

0913

_K

masterbatch & compound cast stretch film bubble wrap blown ... · flexographic printing blown...

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