sizing and specisizing and speciifying a coifying a co-ex ... · sizing and specisizing and speci...
TRANSCRIPT
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Sizing and SpeciSizing and SpeciFil
VijayVice
Mamata BramptoAhmedabaAhmedaba
ifying a Co ex Blownifying a Co-ex Blown m Line
By y Shankar e Presidenton Engineering Pvt.Ltd.ad Gujarat Indiaad,Gujarat, India.
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FILM
Cast Blo
HM HDPE High Neck PPTQ D dHM-HDPE High Neck Bubble
(Mono / Multi Layer)
PPTQ Downward(Mono / Multi
Layer)
B i FilBarrier Film usPA, EVOH, PV
5-11 Layer
WHAT WE ARE GOING TO TALK ABOUT
own
PE / PP / Barrier Upward
i
PE/PP/ Barrier Downward
sing DC s
Non Barrier Film 2/3 Layer and above Mono Layer
3 layer and
above
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Basic Blown FilmBasic Blown Film
Fi 1
Line Line
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Elements of Blownn Film
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Melt Orientation Th
Fi 3
heory
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Blow Up Ratio (BUR) = B
BUR = 0.637 x La Die Dia
Drawdown Ratio (DDR) = Wid Film
Bubble Diameter Die Diametere a ete
ayflat Widthameter
dth of Die GapThickness x BUR
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Theory Geometry oCollapsing BubbleCollapsing Bubble
of the
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Rotation
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Roll Defects
Gauge BandsNon-Uniform Surface HardnessConvex FaceConvex FaceConcave FaceTapered Through LengthWrinklesCorrugated EndsFuzzy EndsFuzzy EndsTelescopingBlocking, wound with too much tensiCrushed CoresRoll End ColorDamaged Edgesg gScuff MarksCore Ends
ProtrudingBuried
SplicesWeightDiameterRoll-to Roll-UniformityIdentification—missing roll labelsTreated SurfaceW d W Sid O tWound Wrong Side OutIncorrectly IdentifiedNot IdentifiedIncorrect Additive Levels
Film Defects
Low YieldGauge Bands, TDVariable MD GaugeVariable MD GaugeFlatnessCamberWrinklesVariable WidthUneven GussetsUneven GussetsFuzzy Ends
ion BlockingTreatment LevelSplittiness
MD Film StrengthgEdge CreasesDie & Weld LinesScratches
AppearanceGlossClarityColor
ImperfectionsApplesauceGelsA h dArrowheadsAir Ring Chatter
BlockingVery High GlossIncorrect Additive Levels
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How To Configure A BlowWhat You W
The OnlC tCusto
Selection
wn Film Line To Produce Want To Sell?
ly Way Is iz domized
n Criteria…
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A. Macro Level Config
Width Of TWidth Of T
guration (Customer’s requirement)
The LineThe Line
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Co-ex blown film having capabiith li ibl h f iwith negligible chances of pin
the film wider in multiples of any mono layer film line.
More the width more the More the Die size more t
surfacMore the output Lowe
LoweLowescopLow
filmfilm LoweUltim
lity to offer better melt strength h l i h i t bl holes gives us a choice to blow
minimum size required against
Die Size for a given BURthe output due to higher cooling ce in and around the bubbleer the cost of manufacturinger the over all space required
h d der the man power required due to pe of viable automationswer the energy consumed per kg of
er the over all Wastagemate economy of SCALE
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A. Macro Level Config
How Many
guration (Customer’s requirement)
Layers
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Case StudyCase Study
L t U T k ALet Us Take A Films Required Fq
Edibl
C St d OCase Study On For Packaging Of g ge Oil
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Th i i1. They are sensitive to c2. They pick up Moisture
spoiledspoiled.3. There are two type of
1. Hydraulic Rancidity: Faty yto growth of bacteria wthe product
2 Oxidative Rancidity: Fat2. Oxidative Rancidity: Fatform peroxides which g
4. Fats also absorb odor dgoods
liclimate / Oxygen and get
rancidity:-ts absorbs moisture and leads hich splits the fats and spoils
ts absorbs oxygen from Airts absorbs oxygen from Air gives rise to rancidity/ flavors from other
16
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Mustard /Rapeseed
SaturatedProducts
Soybeans
Sunflower
Mustard /Rapeseed
5Palm
2Groundnut
y
6Butter
6Vanaspati
6Ghee
9Coconut
Higher the unsaturation percentage
946
Unsaturated fatty acidsd fatty acids
8416
8812
946
5050
8020
3763
3961
3664
1090
e, fast will be the spoilage
17
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MATERIALS. N.
EVOH F at 0% RH2
PVDC1
HDPE5
PA 64
EVOH at 100% RH3
PP7
OPP6
LDPE (LLDPE)8
Ionomer10
EVA (>12% VA)9
LDPE (LLDPE)8
Oa2: permeability measured as cc.mil/100 in2 day.atm
H2Ob:g.mil/100 in2.day. @ 38 degree C, 90% RH
H2ObOa2
3.80.01
0.05-0.50.08
0.3-0.6530-250
24-262.6
1.15
0.25-0.7150
0.3-0.4110
1 0 1 5250 840
1.3-2.1226-484
3.9515-645
1.0-1.5250-840
m @ 23 degree C.
18
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S N DescriptionsS N Descriptions
1 LL (C4)2 LD 3 m-LL4 HDPE5 Tie Layer Resin 6 Polyamide7 EVOH7 EVOH8 Master Batch
PricePrice
68.0084.0081.0068.00
140.00192.00360 00360.00135.00
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Mono layer Structure:
No. of Layers
Polymer 45%
% Thickness
Total Thickness
Price
1
%LLDPE +10% HDPE+ 10% LDPE +30% m-LLDPE + 5% MB
100%
120 Microns
R 76 85Rs. 76.85
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3 layer Structure:y
No. of Layers 1 (OUTER)
Polymer 70%LLDPE + 10% LDPE+ 20%m-LLDPE
% Thickness 20%% Thickness 20%
Total Thickness
Benefits
Price
•Distinct skin layers – slip on sealant for opestacking•Low COF on inner layers for faster speeds •Chances of least pin holes & hence down gChances of least pin holes & hence down g•Coloured master batch only in middle and/ •Possibilities of using PP, HDPE & PE in desbest of both world benefits against limitationSAVING OF RS 3 82 PER KG AS COMPA•SAVING OF RS.3.82 PER KG AS COMPA
2 3 (INNER)
75%LLDPE75%LLDPE + 10%HDPE+10%
LDPE+5MB
60%LLDPE +10% LDPE + 30%m-LLDPE
60% 20%60% 20%
100 Microns
Rs 73 03Rs. 73.03
en-ability & non slip on surface for printing &
on FFS machinesgauging to save on resin costsgauging to save on resin costsor outer layer to avoid contact with oilsirable blends in different layers available for
ns of mono layers to do soARED TO MONO LAYERARED TO MONO LAYER
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5 layer Structure:
No. of Layers 1o o aye s
Polymer
65%LLDPE(C4) +10%LDPE+
20% TPolymer 20%m-LLDPE +
5%MB
T
% Thickness 35% 7% Thickness 35% 7
Total Thickness
Benefits
Price
e e tsExcellent Gas Barrier Properties in 5 Lain cool dry place)
2 3 4 53 5
Tie Poly Amide Tie60LLDPE(C4)
+ 10% LDPE +Tie Poly Amide Tie + 10% LDPE +30% m-LLDPE
5% 15% 7 5% 35%.5% 15% 7.5% 35%
100 Microns
Rs. 104.67
ayer (Shelf Life up to 6 months if stored
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7 l St t
No. of Layers 1 (O) 2
7 layer Structure:
y ( )
l
70%LLDPE(C4) +10%LDPE+ 20%
85%LLDPEPolymer +10%LDPE+ 20%
m-LLDPE LLDPE0%LDP5%MB
% Thickness 17.5% 17.5%
Total Thickness
Price
BenefitsLower resin cost of the skin layers withSAVING OF RS. 1.11 PER KG IN 7 LA
3 4 5 6 7 (I)( )
+1 Poly
85%LLDPE+10%L
60LLDPE(C4) + 10% +1
PE+ Tie PolyAmide Tie +10%L
DPE+5%MB
LDPE +30% m-LLDPE
7.5% 15% 7.5% 17.5% 17.5%
100 Microns
Rs. 103.56
the same barrier propertiesAYER AS COMPARED TO 5 LAYER
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7 layer Structure (Thicker Nylon L
No. of Layers 1
70%LLDPE(C4)8
Polymer
70%LLDPE(C4) +10%LDPE+ 20%
m-LLDPE
L1+
% Thickness 10% 1
Total ThicknessTotal Thickness
Price
Limitation:To improve on shelf life from 6 months toincreased to 30%.increased to 30%.
Layer):
2 3 4 5 6 7
85% 85%LLDPE+
60LLDPE(C4) + 10%LLDPE+
10%LDPE+5%MB
Tie PolyAmide Tie
LLDPE+10%LDPE+5%
MB
4) + 10% LDPE +30% m-LLDPE
10% 15% 30% 15% 10% 10%
100 Microns100 Microns
Rs. 132.50
o 12 months, PA layer thickness to be
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9 layer Structure with split PA Laye
No of Layers 1 2 3No. of Layers 1 2 3
70%LLDPE(C4) +10%LDPE+ 20%
85%LLDPE
Polymer+10%LDPE+ 20%
m-LLDPE +10%LDPE+5%MB
Tie A
% Thickness 10% 15.5% 7%
Total Thicknessota c ess
Price
As PA has less flex crack resistance - 30% PHence, need to go for 9 layer line by splitting SAVING OF RS.8.27 PER KG COMPARED
ers:
4 5 6 7 8 94 5 6 7 8 9
85%LLDPE+10%LDP
60LLDPE(C4) + 10% LDPE
+PolyAmide Tie Poly
Amide Tie10%LDPE+5%M
B
+30% m-LLDPE
14% 7% 14% 7% 15.5% 10%
100 Microns00 c o s
Rs. 124.23
PA will crack and loose the barrier in long run. PA.7 LAYER FILM WITH 30% NYLON
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9 layer Structure with EVOH:No. of Layers 1 2 3
Polymer
70%LLDPE(C4) +10%LDPE+ 20%
m-LLDPE
87%LLDPE+10%LDPE+3 Tie%MB
% Thickness 10% 31% 3%
Total Thickness
Benefits
Price
e e tsEVOH is introduced as a sandwich layer bproperty at same cost / same barrier propePRICE SAVING DUE TO USE OF EVOH A
4 5 6 7 8 9
60LLDPE(C
PolyAmide EVOH Poly
Amide Tie
87%LLDPE+10%LDPE+3%MB
60LLDPE(C4) + 10% LDPE +30% m-LLDPE %MB
4% 4% 4% 3% 31% 10%
100 Microns
Rs. 101.84
between two PA Layers to increase barrier erty at lower cost.AS SANDWICH LAYER RS. 22.39/KG
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11 layer Structure
No. of Layers 1(I) 2 3 4
70%LLD
Polymer
70%LLDPE(C4)
+10%LDPE+ 20%
m-
88%LLDPE+10%LDPE+2%MB
88%LLDPE+10%LDPE+2%MB
Tie PA
LLDPE %MB B
% Thickness 10% 15.5% 15.5% 3%
Total Thickness
Benefits
Price
BenefitsEngineered the film to see that almost all more than 15.5% of total thickness to havSAVING W.R.T. 9 LAYER FILM RS.0.85 WITH MUCH BETTER FILM IN EVERY A
5 6 7 8 9 10 11(O)
88% 88% 60LLDPE(C4)
Polymide EVOH Poly
Amide Tie
88%LLDPE+10%LDPE
88%LLDPE+10%LDP
E(C4) + 10%
LDPE +30% m-LLDPE+2%
MBE+2%MB
LLDPE
15 5 15 54% 4% 4% 3% 15.5%
15.5% 10%
100 Microns
Rs. 100.99
layers are of similar thickness i.e. No layer ve inbuilt flexibility.
AND W.R.T. ORIGINAL 5 LAYER RS 3.68 ASPECT
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A. Macro Level Config
Automation LeveAutomation Levebe produced
Auto Gauge Control System-Thickness measurement CapacThickness measurement – Capacbased, contact/ non contact Thickness Control – By segmentLip OR By Deflected Die Lip Gap
Auto GSM Control (Gravimetric Simple Hopper Loader with Off LGravimetric Feeding with Off LinM l i C Bl di (CMulti Component Blending (Con
Auto Width Control – For Non IBOthers – ITALYCS (Integrated TeSystem) Easy Change SCADA (System), Easy Change, SCADA (Acquisition) etc. for ease of ope
guration (Customer’s requirement)
el - Based on tolerances of film toel Based on tolerances of film to
citance based/ Nuclear based/ Infra redcitance based/ Nuclear based/ Infra red
ted Air flow/ temperature OR By Heated Die
Feeding) –Line Blending/ Single Component ne Blending
i / B h)ntinuous/ Batch)BC Lines/ IBC Lineemperature & layer Yield Control (Supervisory Control And Data(Supervisory Control And Data eration
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Auto Gauge MeasurementAutomation:
g
Auto Gauge Cog
Di H t d Li TDie Heated Lip Type
Multi Component Gravimetric Dosing SystemGravimetric Dosing System
ontrol Systemy
A t G Ai RiAuto Gauge Air Ring
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A. Macro Level Config
Output – kg/hr of the linOutput kg/hr of the linActual film requirement – 250 Thr/day & 26 days/month workiDie Diameter finally selectedDie Diameter finally selected –maximum film width of 2250 mExtruder Combination to match1:4:1…) – extruder size of 75-11:4:1…) extruder size of 75 1kg/hrCooling Capacity – In excess ofWinder Line Speed – Upto 150 mp pkg/hr for 20 micron film at 150Recipes to run – whether LL/mLmelt strength & less than 500 ksupported recipes (better melt more than 500 kg/hr)Issues of Blocking – Ambient teeffective height tacky materiaeffective height , tacky materialayer
guration (Customer’s requirement)
ne (Example – 500 kg/hr)ne (Example 500 kg/hr)T/ month (450 kg/hr based on 22 ng) 500 mm on 2375 mm Line to produce500 mm on 2375 mm Line to produce
mm (2.86 Blow Up Ratio)h with Layer ratio (1:1:1 or 1:2:1 or 120-75 to pump 180+450+180 = 810120 75 to pump 180+450+180 810
f 1 kg/hr/mm of die Diameterm/min to match the output of 500 / p00 mmLL rich, PP based, Nylon based (lower kg/hr) OR conventional LD/ HD/ MD strength & hence possible to offer
emperatures mainly in summer, plant ls like Primacor Affinity etc in innerls like Primacor, Affinity etc. in inner
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A. Macro Level Config
RETURN ON INVESTRETURN ON INVEST◦ Interest on Plant & machin◦ Manpower Costs◦ Electrical Power Costs◦ Wastages & other costs
B i C f i / K◦ Basic Cost of conversion/ K◦ Value additions by putting
Raw material savings if anyRaw material savings if anyDown gauging possibilitiesProperties enhancements if
l f◦ Real Cost of conversion/ ◦ Pay Back period for the en
guration (Customer’s requirement)
TMENT (ROI)TMENT (ROI)ery Cost
KKg“Right” Blown Film line –
yy if anyf anykkgntire Investment
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OPTION 1 OPTION 2OPTION - 1 OPTION - 2
660 mm 990 mmLine Width 32” 44”
Level of Automation Manual Winders Semi Automatic Winders
Approx Line cost Rs. 3,000,000/- Rs. 8,100,000/-
Land & Building Rs. 5,000,000/- Rs. 7,500,000/-
Approx Project Rs. 8,000,000/- Rs.15,600,000/-pp j , , , ,
Approx Ag. O/p 75 Kg/hr 150 Kg/hr
Investment / Kg Rs.106,667/ KG Rs.104,000/ KG
Fixed Cost / KGFixed Cost / KG
Interest @ 13% Rs. 2.02 Rs. 1.96
Variable Cost / KG
Power cost Rs 3 00 Rs 2 70Power cost(6 Rs/Unit)
Rs. 3.00(0.5 Unit/Kg)
Rs. 2.70(0.45 Unit/Kg)
Manpower cost p. a. Rs. 1,000,000/- Rs. 1,500,000/-
Man Power Cost/kg Rs. 1.94 Rs. 1.45Man Power Cost/kg Rs. 1.94 Rs. 1.45
Total Cost / kg Rs. 6.96 Rs. 6.11
OPTION 3 OPTION 4 OPTION 5OPTION - 3 OPTION - 4 OPTION – 5
1320 mm 1980 mm 2640 mm64” 84” 104”
Fully Automatic Winders with Single Component Gravimetric
Fully Automatic Line with Auto Gauge, GSM & Width Control
Fully Automatic Line with Auto Gauge, GSM & Width Control
Rs. 27,000,000/- Rs. 54,000,000/- Rs. 72,000,000/-
Rs. 10,000,000/- Rs. 15,000,000/- Rs. 15,000,000/-
Rs. 37,000,000/- Rs. 69,000,000/- Rs. 87,000,000/-, , , , , ,
275 Kg/hr 450 kg/hr 575 kg/hr
Rs. 134,545/ KG Rs. 153,333/ KG Rs. 151,304/ KG
Rs. 2.54 Rs. 2.90 Rs. 2.86
Rs 2 52 Rs 2 40 Rs 2 10Rs. 2.52(0.42 Unit/Kg)
Rs. 2.40(0.40 Unit/Kg)
Rs. 2.10(0.35 Unit/Kg)
Rs. 1,800,000/- Rs. 2,000,000/- Rs. 2,000,000/-
Rs. 0.95 Rs. 0.65 Rs. 0.50Rs. 0.95 Rs. 0.65 Rs. 0.50
Rs. 6.01 Rs. 5.95 Rs. 5.46
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A. Macro Level Config
SUCCESS OF THE PSUCCESS OF THE P◦ Supplier of Blown Film Line◦ Raw material suppliers – T◦ Operating Team – The skil
guration (Customer’s requirement)
PROJECTPROJECTe – The experiencehe Knowledgel
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B. Micro Level ConfiguExtruder Design◦ Type of Gear Box, motors & Drives –
Loop/ SensorlessLoop/ Sensorless ◦ Gearless Motors (New Energy Saving ◦ Compression/ Barrier Screws
Smooth Bore/ Grooved Feed Barrels◦ Smooth Bore/ Grooved Feed Barrels◦ L/D ratio◦ Metallurgy of the screw & Barrel – Bim
N d f ddi i l D i S◦ Need of any additional Dosing System◦ Pressure Gauge/ Transducers◦ Melt Temperature Indicators
d f l◦ Need of Temperature Control Units i◦ Need of any additional mechanical sa
discs
uration (M/c supplier’s expertise)
A/c Vector Flux Close
motors)
metallic/ Nitro alloylik Li id PIB D ims like Liquid PIB Dosing
d hn Feed throatafety devices like rupture
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B. Micro Level ConfiguDie Design◦ Spiral mandrel/ Stackable/ ◦ Conical◦ Die Metallurgy – EN8/ EN 24◦ Spiral geometry in line with recipe &◦ layer ratio◦ Machining Accuracy◦ Die Gap as per the recipe
uration (M/c supplier’s expertise)
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Streamlined Co(Single half module SCD)(Single half module SCD)
o-extrusion Die
37
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B. Micro Level Configu
Air Ring & IBC Desig◦ Mono Lip/ Dual Lip/ Duo Cool Air R◦ Screen Type/ pancake Type IBC◦ IBC Control MechanismIBC Control Mechanism◦ IBC Response/ Features to control th◦ IBC an instrument to increase produ
uration (M/c supplier’s expertise)
gning
he width/ change the sizeuctivity
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B. Micro Level Configu
Oscillating Haul Off◦ Horizontal◦ Vertical
uration (M/c supplier’s expertise)
f options
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B. Micro Level Configu
Winder Options ◦ Surface/ Centre /Combina/ /◦ Maximum Line speed◦ Maximum Roll Diameter◦ Maximum Roll Weight◦ Various Features on roll ch
l di / h dli iloading/ handling options
uration (M/c supplier’s experience)
ation
hange over options/ air shaft
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AmbientAmbient◦ Height of the Plant◦ Temperature and humidityp y
Selection of Utilitie◦ Chiller (chilled or cold water)( )◦ Compressed and Dried Air◦ Uninterrupted & Stable Power
A ili iAuxiliaries◦ Dryer for resins◦ Material handling System / Ce◦ Material handling System / Ce◦ Corona Treater◦ Web guide◦ Testing Equipments
es
supply
ntralized loading systemntralized loading system
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BackgroundBackground –A Customer from Western Africanmillion people whose capital DAKAk d DAKAR C ll (Fknown due to DAKAR Car rally (FrIn 2006-7, company was producincomponents and 100+Tonnes of At t t f I j tiAt present, apart from Injection a4 Monolayers, 1 Dolci make 3 layefully loaded line (350 kg/hr) and upgraded by MBE for high outputupgraded by MBE for high output retrofitting Extruders , Die and AiThey also do contract packing & sAfricaNow they they will reach to 1000 installing 300 T/month new fully
Country Senegal with just 12.50 AR is a famous tourist place & well
P i D k 4000 k )rom Paris to Dakar – 4000+ km)ng 200+ Tones of Injection molding Flexible Packaging d bl ldi hi th hnd blow moulding machines, they have
er line (350 kg/hr), 1 MBE make 3 Layer 1 Taiwan make non IBC 3 layer (from 90 kg/hr to 180 kg/hr) by(from 90 kg/hr to 180 kg/hr) by r Ring
selling packaging machines in Western
Tones+ of Flexible Packaging after loaded 3 Layer Line from MBE
43
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Major Requirements of Flexible Pa
Sr. No. Description
1 Milk Powder
2 Detergent
3 Seasoning Powderg
4 Water Pouches
5 Shrink Wrap p
6 Stretch Wrap
7 Biscuit Packaging Bagsg g g
8 Agriculture films
9 Edible Oil Films
ackaging in Senegal
Type of films
Lamination films
Lamination
Lamination
Surface printed Films
Heat Shrinkable Films
Machine Wrap Films
Surface Printed outer bags to replace CartonsUV based Films
Surface Printed Films
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Major Requirements of Flexible Pa
Sr. No. Description
10 Cereals
11 Sugar
12 Coffee
13 Tarpaulin
14 Bleach packagingp g g
15 Lidding Films
16 Cosmetics
17 Fish Packaging
18 General Purpose Films18 General Purpose Films
ackaging in Senegal
Type of films
Lamination films
Surface Printed Films
Lamination
Films
Surface Printed Films
Lamination Films
Lamination Films
Fish/ lamination Films
LaminationLamination
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Aft h i 2 3 lAfter having 2 no. 3 layline from Taiwan, they wexpansion in 2007 Theexpansion in 2007. Themachine capable to runstructures as a supplierstructures as a supplierSTRUCTURS:◦ 100% MLLDPE (Outer) : 10100% MLLDPE (Outer) : 10
Primacore (Inner)◦ 100% MLLDPE (Outer) : 10
Affi i (I )Affinity (Inner)These structures were tnon refined African Oilnon refined African Oil seal through contamina
li f D l i d 1yer lines from Dolci and 1 were looking for ey were looking forey were looking for following specific
r selection criterion.r selection criterion.
00% PP (Middle) : 100%00% PP (Middle) : 100%
00% HDPE (Middle) : 100%
to be used to mainly pack packing to have betterpacking to have better
ation.
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For first time they werIndian supplier to run raw material structureh hthese structures in the
To build their confideconsultant visited Indimachine running in InThey were very impresVariation performanceGauge Control Systemthe performance of md id d f MBdecided to go for a MB
re interacting with any such stringent specific
es (they could not run l )eir existing lines)
nce, their technical ia to see one of our dia. ssed with the Gauge e even without Auto
m and convinced with achine and hence BE 3 L liBE 3 Layer line
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BUR 1.5Good
LFW 20002.52 52.5
Better3.18Out of Range
Sr. No. Application tubeFilm Width(mm)
Thickne(mic )pp
1 Surface Print 680 sheet 702 Surface Print 680 sheet 803 Surface Print 680 sheet 904 Lamination 760 sheet 40
(mm) (mic.)
5 Lamination 760 sheet 356 Lamination 880 sheet 1007 Lamination 910 sheet 408 Lamination 940 tube 409 Lamination 1000 tube 809 Lamination 1000 tube 80
10 Lamination 1000 tube 2511 Lamination 1000 tube 3012 Lamination 1040 sheet 4013 Lamination 1040 sheet 3014 L i ti 1040 h t 2514 Lamination 1040 sheet 2515 Lamination 1060 sheet 5016 Lamination 1060 sheet 3517 Lamination 1140 sheet 60
2000 2000 2000 2000 2000Max. width BUR BUR BUR BUR BUR
2000 375 400 425 450 475ess
1360 2.31 2.17 2.04 1.92 1.821360 2.31 2.17 2.04 1.92 1.821360 2.31 2.17 2.04 1.92 1.821520 2.58 2.42 2.28 2.15 2.041520 2.58 2.42 2.28 2.15 2.041760 2.99 2.8 2.64 2.49 2.361820 3.09 2.9 2.73 2.58 2.44940 1.6 1.5 1.41 1.33 1.26
1000 1 7 1 59 1 5 1 42 1 341000 1.7 1.59 1.5 1.42 1.341000 1.7 1.59 1.5 1.42 1.341000 1.7 1.59 1.5 1.42 1.341040 1.77 1.66 1.56 1.47 1.391040 1.77 1.66 1.56 1.47 1.391040 1 77 1 66 1 56 1 47 1 391040 1.77 1.66 1.56 1.47 1.391060 1.8 1.69 1.59 1.5 1.421060 1.8 1.69 1.59 1.5 1.421140 1.94 1.82 1.71 1.61 1.53
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After successful instalcustomer requested tomake 3 Layer Line in o
d f l land film quality.After having detailed slayer Taiwanese line, tnos. 50 mm extruderslEliminator Air Ring wa
in 2008. The line is ped bl h idouble the output wit
lation of first machine o upgrade their Taiwan order to improve output
study of their existing 3 to increase the output 3 s with 225 mm Die &
f d h las retrofitted to the line erforming with almost h b lh better gauge controls.
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During the meeting atDusseldorf GermanyDusseldorf, Germany, desire to go for 4th linserve specific marketserve specific market Processed Meat and FiAs the market potentiAs the market potentilimited to 100 TPM onapplications as mentioapplications as mentiogot major market sharHence they ultimatelyHence, they ultimatelylayer blown film line won the cost of converson the cost of convers
t K-2010 show in the customer put histhe customer put his e as a 5 layer Line to like Edible Oillike Edible Oil, ish packing Industry.al for barrier film wasal for barrier film was
nly and three layer oned above had alreadyoned above had already re out of this 100 TPM. y decided to go for 3y decided to go for 3 with focus on reduction sion.sion.
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BUR 1.5Good
LFW 272.52.52.5
Better3.18Out of Range
Sr No Application tubeFilm Width ThickSr. No. Application tube
1 Surface Print 680 sheet 72 Surface Print 680 sheet 83 Surface Print 680 sheet 94 Lamination 760 sheet 4
(mm) (mi
4 Lamination 760 sheet 45 Lamination 760 sheet 36 Lamination 880 sheet 107 Lamination 910 sheet 48 Lamination 940 sheet 49 Lamination 1000 sheet 89 Lamination 1000 sheet 8
10 Lamination 1000 sheet 211 Lamination 1000 sheet 312 Lamination 1040 sheet 413 Lamination 1040 sheet 314 Lamination 1040 sheet 215 Lamination 1060 sheet 516 Lamination 1060 sheet 317 Lamination 1140 sheet 6
750
2750 2750 2750 2750Max. width BUR BUR BUR BUR
2750 525 550 575 600kness 2750 525 550 575 600
70 2720 3.3 3.15 3.01 2.8980 2720 3.3 3.15 3.01 2.8990 2720 3.3 3.15 3.01 2.8940 2280 2.77 2.64 2.53 2.42
ic.)
40 2280 2.77 2.64 2.53 2.4235 2280 2.77 2.64 2.53 2.4200 2640 3.2 3.06 2.92 2.840 2730 3.31 3.16 3.02 2.940 1880 2.28 2.18 2.08 280 2000 2 43 2 32 2 22 2 1280 2000 2.43 2.32 2.22 2.1225 2000 2.43 2.32 2.22 2.1230 2000 2.43 2.32 2.22 2.1240 2080 2.52 2.41 2.3 2.2130 2080 2.52 2.41 2.3 2.2125 2080 2.52 2.41 2.3 2.2150 2120 2.57 2.46 2.35 2.2535 2120 2.57 2.46 2.35 2.2560 2280 2.77 2.64 2.53 2.42
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Extruder 75 m
M Th h (K /h ) 225Max. Throughput (Kg/hr) 22533.3 : 33.3 : 33.3 % 18030 : 40 : 30% 18025 : 50 : 25% 15020 : 60 : 20% 10030 : 30 : 40% 13530 : 30 : 40% 13570 : 20 : 10% (PE : Tie : Surlyn) 210
mm 90 mm 75 mm Throughput(Kg/Hr.)
5 360 225 8105 360 225 8100 180 180 5400 240 180 6000 300 150 6000 300 100 5005 135 180 4505 135 180 4500 60 30 300
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The plant is equipped Gravimetric Dozing SyGravimetric Dozing Sysingle component supAuto Gauge Control SyAuto Gauge Control Syair ring as against disklineline.Auto Width control syssecond linesecond line.SCADA system upgradoperate the machine toperate the machine tmodem.
with 1+3 Components ystem compared toystem compared to pplied in first line.ystem is with completeystem is with complete k type supplied in first
stem added in the
ded with navigator to thru’ internet againstthru internet against
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A Lebanese owner with French a very small country dared to wM i l li lik D DMaterial suppliers like Dow, Duand hiring technical experts frofrom India to expand their busi1000 TPM (2011) within 4 yearsright Blown Film Lines to produWith a mix business of InjectionWith a mix business of Injectionflexible packaging customer coto expand in flexible packagingbusiness of Injection Mouldingbusiness of Injection Moulding flexible packaging mainly due treducing cost of Raw Material MB d bBased on above success customin other west African countries
citizenship with a small unit in work with best available Raw
E M bil S bipont, Exxon Mobile, Sabic etc. om France / UK and expatriates ness from 100 TPM (2007) to s by selecting / configuring
uce what he wanted to sell. n Moulding and blown filmn Moulding and blown film
ould derive that it is far better g rather than his earlier core due to better profit margins indue to better profit margins in
to value additions and scope of Man Power and Power cost.
i i i il imer is going to put similar units s like Ivory coast / Angola.
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Brampton EngineeringWorld Leader In Blown Film
20082005BE2000
BE Milestones
History of blown film
1995of blown film
innovation
1990
1985197519751970
m TechnologyTenth AquaFrost® lineFirst 11-layer SCD lineI-Flex Family of Gauge ControlsFirst AquaFrost® lineFirst AquaFrost® line4+1 IBCEliminator Air RingFirst 10-layer SCD lineISOth SCDISOtherm SCD AntiBlock IBCBlown Film Technology CenterFirst 9-layer SCD lineyAutogauge Air RingFirst 8-layer SCD lineFirst 7-layer SCD lineFirst 5 layer SCD lineFirst 5-layer SCD line First 7-layer pilot lineFirst linear lay-on winderFirst ITALYCS control systemFirst Airfoil IBCFirst computerized controlsFirst computerized rheology modelFirst spiral dieFirst spiral dieFirst dual lip air ring
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MBE Milestones 2010 ● 1st MBE w
Installed Installed.
2008 ● 50th MBE● 1st MBE 3
2007 ● 1st MBE 3
2006 ● 1st MBE w Installed
History of Joint Venture
2005 ● 25th MBE
2004 ● 1st MBE 3
2003 ● 1st ever 72003 ● 1st ever 7● 1st MBE
2002 ● 10th MBE
2001 ● Introducti for Indust
2000 ● 1st ever 5 in India
1998 ● 1st Line o
1997 ● 50:50 Join1997 ● 50:50 Join Mamata M
wider width 2895 mm higher output 800 kg/hr 3 Layer Line
E Line Supplied3 Layer line supplied to Australia
3 Layer Line to Europe
wider width 2375 mm higher output 500 kg/hr 3 Layer Line
E Line Supplied
3 Layer line export to Far East & Middle East
7 Layer Line installed in India7 Layer Line installed in India3 Layer Line export to West Africa and Russia.
E Vegaflex concept line sold within one year of launch.
ion of Vegaflex concept line - A new standard of excellence try to follow
5 Layer SCD Line Manufactured & Installed successfully
of the Joint Venture
nt Venture between Brampton Engineering Canada &nt Venture between Brampton Engineering, Canada & Machinery Pvt. Ltd.
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THE MAMATA GROUPTHE MAMATA GROUP
The Flagship comThe Flagship com
AA jointjoint ventureventureENGINEERINGENGINEERING IIfilmfilm lineslines andand systsyst
AA jointjoint VentuVentuFlexopackFlexopack toto mamaformedformed PouchesPouches fofoformedformed PouchesPouches fofo
AA GreenGreen fieldfield PPforfor PurposePurpose ofof CooCooforfor PurposePurpose ofof CooCoo
AA JointJoint ventventAA JointJoint ventventKLöCKNERKLöCKNER DESDESmouldingmoulding machinmachin
mpany of the groupmpany of the group
ee:: MAMATAMAMATA MACHINERYMACHINERY && BRAMPTONBRAMPTONINCINC.. CANADACANADA toto makemake MultiMulti layerlayer BlownBlowntemtem elementselements includingincluding fullfull CNCCNC controlscontrols..
rere b/wb/w MamataMamata MachineryMachinery && SpanSpanakeake SpoutSpout FixingFixing lineslines andand FillingFilling lineslines forfor PrePre--oror PackagingPackaging IndustryIndustryoror PackagingPackaging IndustryIndustry..
rojectroject toto propagatepropagate UsageUsage ofof SolarSolar EnergyEnergyolingoling && HeatingHeating applicationsapplicationsolingoling && HeatingHeating applicationsapplications..
tureture :: MAMATAMAMATA MACHINERYMACHINERY andandtureture :: MAMATAMAMATA MACHINERYMACHINERY andandSMA,SMA, Germany,Germany, toto makemake RubberRubber InjectionInjectionnesnes andand ShoeShoe SolingSoling machinesmachines inin IndiaIndia..
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THE MAMATA GROUPTHE MAMATA GROUP
AA JointJoint ventureventureHOLSTEINHOLSTEIN SEITSEIThighhigh--techtech statestate--ooplantsplants comprisingcomprisingplantsplants comprisingcomprisingSealers,Sealers, LabellingLabelling
A subsidiary oA subsidiary oA subsidiary oA subsidiary oproviding Hiproviding Hi--tectechardware solutihardware solutiand Novell.and Novell.
InIn--house Travelhouse Travelthe group companthe group compan
ee :: MAMATAMAMATA MACHINERYMACHINERY && KLöCKNERKLöCKNERTZTZ MACHINEN,MACHINEN, GERMANYGERMANY.. ToTo manufacturemanufactureofof--artart highhigh speedspeed BottlingBottling lineline // packagingpackaginggg ofof BottleBottle WashersWashers FiltersFilters PrePre--mixersmixers CapCapgg ofof BottleBottle Washers,Washers, FiltersFilters PrePre mixers,mixers, CapCap
MachinesMachines etcetc......
of MAMATA MACHINERYof MAMATA MACHINERYof MAMATA MACHINERYof MAMATA MACHINERYch computer software and ch computer software and ions. Authorized suppliers of IBM ions. Authorized suppliers of IBM
l Agencyl Agency providing all travel related services to providing all travel related services to nies.nies.
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Thankk You!