RIGID FILM EXTRUSION LINES

RIGID FILM EXTRUSION LINES

The origins of a solid forward thinking company Ever since its establishment in 1947 by Luigi Bandera, it has proved to be a dynamic company focussed on innovation – the perfect ingredients to be the pioneer of the extrusion line sector, in Italy and worldwide.

Today, Bandera designs and manufactures a complete range of extrusion lines based on two major applications: sheet and foil through flat die technology and blown film.

Bandera Brand Value

CONTROL AND ORGANISATION

EXPERIENCE & INNOVATION

A family business, managed by skilled managers

R&D – ongoing investments

IN-DEPTH KNOWLEDGE OF EXTRUSION PROCESS

RELIABILITY

Sturdy and heavy-duty equipment

Over 65 years of in-house production and design expertise

TOP PERFORMANCE

Enhanced productivity and tolerances

TOP DESIGN FLEXIBILITY

Turnkey customised complete extrusion lines

CUSTOMER ORIENTED

A customer service oriented company

COMPETITIVENESS AND COST EFFECTIVENESS

Consolidated standard production processes

2

PROVEN PERFORMANCES

Over the years Bandera has earned a sound reputation worldwide thanks to its reliability and top quality standards

Fully-fledged proven technologies

APPLIED INNOVATION

Preferred supplier in the long term

Bandera – Excellence in Extrusion Bandera’s mission is to become the major European centre for excellence in extrusion.

Focussed on manufacturing cutting-edge technological lines for plastics processing in blown film and sheet & foil, Bandera is pursuing to confirm its leading position for the future.

Willing to enhance its international market position, Bandera’s corporate strategy concentrates on converging innovative extrusion line designing, engineering, manufacturing and commissioning in its Italian headquarters, together with its customer service centre.

BANDERA IS FOCUSSED ON ESSENTIAL HIGH-TECH ASPECTS:

Ensure minimised power consumption.

Design safe and reliable top performing extrusion lines compliant with the strictest safety standards.

Manufacture extrusion lines dedicated to finished products from the latest innovative thermoplastics, thus favouring the processing of recycled and/or biodegradable materials.

Promote technologies and processes aimed at consistent packaging weight reduction.

3

Rigid PET Film Extrusion Line High Output and maximum quality Process materials:

PET, A-PET, C-PET, PET-G

Standard thickness range:

120µm ÷ 1,50mm

Foil width:

up to 2000mm max

Foil layer structure:

single-layer, coextruded

Hourly output:

up to 2700kg/h

Other process materials:

PP, PS, PLA

Available option: foil production with PE film lamination (barrier or not) Available option: composite foil production with in-line coating system Available option: semi-foamed foil production by physical and chemical process Alfa Food series PET foil extrusion lines stand out for high output and top quality of processed products.

Building on its expertise – mainly gained since the end of 1990s when the demand for thermoformed PET trays recorded an exponential growth – and its proactive collaboration with its own Customers, Bandera has reached a level of specialisation and innovation that is much appreciated and requested by the reference market.

Among Bandera referrals, top world food and non-food packaging manufacturers can be listed.

4

Bandera PET foil extrusion lines include the following equipment: Co-rotating twin-screw extruders with high efficiency high vacuum venting system, ensuring maximised process cost efficiency and final product quality.

Continuous automatic melt filtering system with screenplate selfcleaning (purging).

High-precision flat dies with automatic thickness adjustment (option available on request).

Sturdy calenders for foil calibration and polishing, offering a wide reliable thickness range (actually, the widest range available on the reference market). Calenders can feature a horizontal, inclined or vertical configuration.

Bandera winders are manually, semi-automatically or fully automatically operated and accurately designed to ensure operator’s safety and ease overall extrusion line management and control.

5

Co-rotating Twin-Screw Extruders – The Benefits The use of co-rotating twin-screw extruders in foil extrusion lines is growing, based on strengths such as great flexibility and versatility applied to the whole extrusion line.

As far as the production of rigid packaging film is concerned, co-rotating twin-screw extruders offer the following benefits:

Excellent blending and self-cleaning Maximised melt purification Enhanced versatility and flexibility processing different materials High power savings Processing of 100% PET flakes and/or reground PET User-friendly management and control of feeding and dosing system No thermal and hydrolytic degradation of the co-rotating screws ensured by special screw profile

6

Rigid PET/PP/PS film extrusion lines equipped with flexible film lamination systems Positive market trends and growing demand – basically due to polymer characteristics and recyclability – have significantly widened the use of PET for applications other than classic thermoforming into trays.

Based on the need to combine flexible barrier film with PET, PP foil/ sheet, Bandera has developed the following equipment: In-line polyolefin film lamination by contact, with support roller In-line polyolefin film lamination by hot method

IN-LINE LAMINATION WITH EVOH BARRIER FILM PE ADHESIVE RESINS EVOH ADHESIVE RESINS VIRGIN MATERIAL 100% RECYCLED PET VIRGIN MATERIAL

PE ADHESIVE RESINS VIRGIN MATERIAL 100% RECYCLED PET VIRGIN MATERIAL

Hot lamination

Cold lamination

7

Rigid PET/PP/PS film extrusion lines equipped with in-line coating systems As far as process raw materials selection and management, in-line coating systems offer unrivalled flexibility. In its standard A-B-A structure, PET/PP/PS foil is slightly pre-heated and subsequently laminated with barrier (EVOH and adhesive resin) and/or PE layers.

Resins are processed by small-size single-screw extruders arranged on a dedicated support frame.

Coating is carried out by automated flat die and chill-roll, specifically designed for the purpose.

PET and PE layer bonding rate is extremely high.

PE Bandera expertise has optimised the coating system, which can be RESINE ADESIVE integrated on existing extrusion lines.

EVOH RESINE ADESIVE

It is worth highlighting that the system can process several materials, MATERIALE VERGINE among which are PP and PS. 100% PET RICILATO MATERIALE VERGINE

IN-LINE LAMINATION WITH PET/PE PE RESINE ADESIVE MATERIALE VERGINE 100% PET RICILATO MATERIALE VERGINE

IN-LINE LAMINATION WITH PET FILM BARRIERA PE ADHESIVE RESINS EVOH ADHESIVE RESINS VIRGIN MATERIAL 100% RECYCLED PET VIRGIN MATERIAL

PE ADHESIVE RESINS VIRGIN MATERIAL 100% RECYCLED PET VIRGIN MATERIAL

Ø

100

CORSA 100

Ø 100 CORSA 100

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Rigid Film Extrusion Lines – the “Light Duty Line” Series A Cost-Effective Investment for Average Production Ranges Standard process materials:

PET, PS, PP, C-PET, PET-G, PLA

Foil width:

up to 1100mm max

Foil layer structure:

single-layer or coextruded

Hourly output:

500kg/h and 700kg/h

“Light Duty Line” foil extrusion lines have been designed by Bandera to comply with the most recent market requirements from rigid food and non-food packaging field.

“Light Duty Line” series can be equipped with single-screw and /or co-rotating twin-screw to offer high flexibility in processing different materials (PET, PS, PP, C-PET, PET-G, and PLA) and excellent production efficiency.

Outputs from the two available versions are detailed below.

LIGHT DUTY LINE 1/500

The “Light Duty Line” series stands out for cost-effectiveness.

PET (ABA)

500kg/h ± 5%

Sturdy and accurate calender design offers the option to process raw materials in a wide thickness.

PP (ABA)

350kg/h ± 5%

PS (BA)

380kg/h ± 5%

Foil Thickness Range

PLA (ABA)

360kg/h ± 5%

180µm ÷ 1200µm

PET foil

320µm ÷ 1800µm

PP foil

180µm ÷ 1800µm

PS foil

280µm ÷ 800µm

PLA foil

“In-line” extrusion system production is in collaboration with major thermoforming machine producers.

LIGHT DUTY LINE 2/700 PET (ABA)

700kg/h ± 5%

PP (ABA)

470kg/h ± 5%

PS (BA)

620kg/h ± 5%

PLA (ABA)

520kg/h ± 5%

BENEFITS Maximum flexibility with raw materials Thanks to its modular construction, the Light Duty Line can be timed for quick delivery The extrusion line arrangement is aimed at minimising overall line dimensions and ensuring a fast installation.

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Compact Rigid Film Extrusion Lines The “Agility Line” Series – a Synonym for Unrivalled Flexibility Outputs from the two available versions are detailed below.

AGILITY LINE 870MM_600KGH_2C70-65 PET (ABA)

600Kg/h ± 5%

PP (ABA)

420Kg/h ± 5%

PS (BA)

460Kg/h ± 5%

PLA (ABA)

430Kg/h ± 5%

450Kg/h ± 5%

PP (ABA)

350Kg/h ± 5%

PS (BA)

400Kg/h ± 5%

PLA (ABA)

360Kg/h ± 5%

PET, PS, PP, C-PET, PET-G, PLA

Foil width:

up to 870mm max

Foil layer structure:

single-layer or coextruded

Hourly output:

450kg/h and 600kg/h

The “Agility Line” series is a synonym for Bandera’s exceptional technical know-how and innovative technology.

The design accuracy applied by Bandera Engineering Department has led to a line concept aimed at meeting production requirements from both extrusion newcomers – customers looking for operation friendly machinery – and major producers looking for production agility and flexibility.

AGILITY LINE 620MM_450KGH_2C55-65 PET (ABA)

Standard process materials:

The “Agility Line” series is mainly intended for FFS (Form-Fill-Seal) – a high growth market – and thermoforming sectors (food and nonfood rigid packaging).

“Agility Line” series characteristics are detailed below: Low and average outputs with high flexibility in raw materials (PET, PP, PS, PLA), accompanied by user-friendly line control.

Smaller overall dimensions (85sqm approx.), with modular construction (suitable for relocation in different sites) and accurate/ compact installation to reduce costs.

Reduced power consumption High cleaning and safety level thanks to its specific plant engineering Fume exhaust hood and hoist for disassembly of extrusion screws and barrels, flat die and calender rolls

ADD

ALARMS

HLD MIX ALM DMP ADD COL NAT REG

R A C

0 0 0

COLOR

NAT COL

0 0 0 0 0 0

% OF NATURAL % OF NATURAL

REG HOLD DUMP

ADDITIVE

9

LOCKED OUT

3 6 CE

TOTAL WEIGHT - GRAMS

WEIGH SCALE BLENDER

MAGUIRE PRODUCTS, INC. MEDIA, PA COLOR

5 AMP

1/2 AMP

FUSE

FUSE ON-OFF

120 VOLTS

3 AMP

PIPE-POMPA MELT

8 0

PIPE-POMPA MELT

TAG 2

10

GRUPPO ASPIRAZIONE

5

TERMOREGOLAZIONE

ESTRUSORE BIVITE

*

CONTROLLO SPESSORE

1

TERMOREGOLAZIONE

7

3 2

4

4 1

SET OPER TIME VER CAL

% OF MIX

VIEW RCP BTCH REPT EXIT PARA ZERO FULL MIX ALRM

ESTRUSORE MONOVITE

MAGUIRE

REGRIND

Fully automated winding unit

SUPPORTO UCFC206 GDB

SNODO SIKAC 10 SKF

Automatic foil and lamination film thread-in

32 100

Integrated raw material feeding and control systems

Rigid PP-PS Film extrusion line The “Beta” Series Medium output and maximum flexibility Standard process materials:

PP (HoPP, CoPP), PS (HIPS, PSK)

PP foil thickness range:

320µm ÷ 2.20mm

PS foil thickness range:

190µm ÷ 2.20mm

Foil width:

up to 1600mm max

Foil layer structure:

single-layer or coextruded

Hourly output:

(up to 7 layers, barrier layer included) up to 1200kg/h

Optional mineral fillers:

(Talc, Calcium Carbonate, etc.)

Available option: foil production with PE film lamination (barrier and not) Available option: composite foil production with in-line coating system Available option: semi-foamed foil production by physical and chemical process

“Beta” lines can be equipped with single-screw and /or co-rotating twin-screw to offer high flexibility in processing different materials and excellent production efficiency.

As far as polypropylene foil is concerned, Beta calenders – either inclined or vertical – are equipped with 5 or more calibrating and cooling rolls (3 main ones and 2 - or more – additional ones, which can be assembled subsequently).

A technical solution aimed at obtaining a second foil thermoregulation stage. It results in polymer chain relaxation, with consequent increase of mechanical properties and enhanced foil thermoformability.

Calender – as well as extruder – dimensioning depends on output requirements.

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High Output Rigid PP-PS Film Extrusion Lines Standard process materials:

PP (HoPP, CoPP), PS (HIPS, PSK)

Thickness range (PP foil extrusion by calendering):

280µm ÷ 2,20mm

Thickness range (PS foil extrusion by air blade):

120µm ÷ 2,20mm

Thickness range (PS foil extrusion):

150µm ÷ 2,20mm

Foil width:

up to 2000mm max

Foil layer structure:

Single-layer or coextruded (up to 7 layers, barrier layer included)

Hourly output:

up to 2800kg/h

Optional mineral fillers:

(Talc, Calcium Carbonate, etc.)

Available option: foil production with film lamination (barrier and not) Available option: semi-foamed foil production by physical and chemical process Alfa PP-PS extrusion line technical and technological asset is highly appreciated by Customers.

Being equipped with special calenders, extrusion lines are specifically suited for foil processing in a wide range of thicknesses. Lines are complete with air blade system, (variable frequency drive controlled double-effect vacuum box) to obtain PP foil with 120µm min thickness.

Alfa PP-PS extrusion lines can be equipped with single-screw and /or co-rotating twin-screw to offer high flexibility in processing different materials and excellent efficiency.

Alfa PP-PS extrusion lines are predominantly intended for the production of PS and PP thermoformed items

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Special design non-standard Rigid Film / Foil Extrusion Lines LINE FEATURING LONGITUDINAL STRIPS CO-EXTRUSION Standard process materials:

PP (HoPP, CoPP), PS (HIPS, PSK)

Thickness range (PP foil extrusion by calendering):

280µm ÷ 2.20mm

Thickness range (PS foil extrusion by air blade):

120µm ÷ 2.20mm

Thickness range (PS foil extrusion):

150µm ÷ 2.20mm

Foil width:

up to 1100mm max

Foil layer structure:

coextruded (up to 4 layers with 5 extruders)

Hourly output:

up to 600kg/h

Optional mineral fillers:

Talc, Calcium Carbonate, etc.

TR 30

TR 50

TR 50

TR 100 2"

2"

TR 50

N°1 STEP

Special DESIGN lines for the production of TOP aesthetical quality printed foil These lines are conceived for high performance: minimised tolerances and unrivalled machine construction accuracy in processing PET, PC and PMMA.

LENTICULAR PET FOIL LAYER

STANDARD PET FOIL PRINTED SURFACE

The final product is a lenticular foil with outstanding aesthetic characteristics – due to the embossing on the still unprinted surface, it is capable of conferring motion-simulation properties with the illusion of depth to the printed image.

A sophisticated three-dimensional effect can be conferred to the final product.

13

Special design Foil Extrusion Lines for Semi-Foamed Products Any new Bandera product development is focussed on matching cost effectiveness and environment protection. Bandera commitment is based on transforming plastic materials into light-weight eco packaging.

In order to obtain top quality foamed PET foil, Bandera has developed equipment aimed at maximizing the whole extrusion process.

Use of post-consumer PET flakes Lighter weight combined with unchanged mechanical properties Savings in terms of virgin raw material Re-processable scraps Possible change from PS to foamed PET

Foamed PET to replace traditional PS (serving trays)

Bandera technology is setting the pace in packaging weight minimisation, besides being a synonym for unrivalled flexibility.

Bandera R & D team has patented the works carried out on the physical expansion by low-pressure injection of gas of the most commonly employed polymers in the field of rigid food packaging.

For the elevated volumes required and the recycled material availability (post-consumer bottle flakes), the PET market is presently offering wide-potential applications.

Cutting-edge 3-layer structural foam PET (yogurt pots)

Bandera has focussed on employing of latest-generation co-rotating twin screw extruders (L/D ratio 52:1), whose technology had already been patented for the production of PET foil.

By the addition of a suitable low-pressure gas injection system and a few devices, a standard Bandera extrusion line for rigid foil can be easily dedicated to the production of semi expanded foil – high tech ensured with the highest versatility.

Weight reduction up to 30% (fruit trays)

Such lines offer innovative products which are very “natural” looking, cost effective, and eco-sustainable due to the reduced quantity of raw materials required.

Dedicated extrusion equipment, aimed at whole process optimisation, can be supplied to produce top quality semi-foamed foil.

Weight reduction ratio is strictly depending on the final application required.

Fully recyclable (meat trays)

Once again even in this field Bandera has given clear evidence of its pioneering attitude and openness in facing innovation, combining experimentation of new ideas and solutions to maximise technology enhancement, minimise costs while caring for environmental issues.

Bandera’s goal is to transform plastic materials into top quality and unrivalled performance eco-compatible packaging, featuring minimised weight.

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Special Multilayer Film Extrusion Lines Standard process materials:

PP, PE, PET, PA, EVOH, adhesive resins

Thickness range:

15µm ÷ 2.20mm

Film width:

up to 2500mm max

Film layer structure:

coextruded (up to 13 layers)

Hourly output:

up to 2500kg/h

Bandera special lines based on the cast method technology are always customer-oriented; they are “tailor-made” lines, accurately customised on the converter technical requirements.

Due to its distinctive capacities and proven skills, Bandera stands out for the manufacture of fully “customized” lines, highly complex and sophisticated, specifically intended for special coextruded film (up to 13 layers with thickness up to 35µm), for superior-quality food packaging and pharmaceutical applications.

The highly-performing final product required involves basic excellence in machinery design and manufacture.

Production quality and reliability are ensured by the following equipment: Flat die internal design (as a standard, automatic control of internal expansion bolts for flexible lip control) according to polymer rheological properties in order to obtain full control of material flows.

Chill-roll sturdiness and modularity; chill-roll is equipped with dedicated equipment according to finished product requirements.

Winding accuracy and speed; winders are fully automated to ensure unrivalled safety of operators and high production efficiency.

High-tech lines for cast film are fully automated, to minimise margin of errors and optimise production efficiency.

N.6 M12x50

N°4 M16x60

ø MAX 1000

15

Bandera Equipment for Cutting-Edge Extrusion Lines Co-rotating Twin-Screw Extruders Foil extrusion lines are increasingly equipped with co-rotating twinscrew extruders; a choice due to their offering excellent flexibility and versatility.

Co-rotating twin-screw extruders are thoroughly designed and manufactured by Bandera. Extrusion screws are made of high performance wear resistant nitrided steel, and extrusion barrels are made of nitrided steel and/or bimetal alloy (screws and barrels are made of independent sections, accurately assembled).

Bandera co-rotating twin-screw extruder range is detailed in the table below.

Corotating Twin-Screw Extruder 2C 55mm 2C 70mm 2C 85mm 2C 105mm 2C 135mm 2C 170mm

L:D Ratio 42:1 42:1 42:1 42:1 42:1

------

52:1 52:1 52:1 52:1 52:1

42:1 -- 52:1

Single-Screw Extruders Single-screw extruders currently play an important role in foil extrusion line manufacturing.

Today, Bandera is able to offer its customers a wide range of extruders to comply with market needs in terms of productivity, efficiency and quality.

Bandera foil extrusion line production range is mainly divided into 2 categories: Single-screw extruders for polyolefins and polyamides (PE, PP, PA, …) with no venting system (non-hygroscopic process materials) Single-screw extruders for styrene and acrylic polymers (PS, ABS, PC, PMMA, …) with venting system (hygroscopic process materials) Single-screw extruders for styrene and acrylic polymers (PS, ABS, PC, PMMA, …)

Single-screw extruder From TR 50mm to TR 200 mm

L:D Ratio from 32 to 35:1

Single-screw extruders for polyolefins and polyamide (PE, PP, PA, …)

Single-screw extruder From TR 35mm to TR 330mm

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L:D Ratio from 20 to 38:1

Process Material Dosing Systems Proper material loading and dosing into the extruder is undoubtedly a key factor to be taken into account – dosing is considered in fact the first process variable.

Single- and twin-screw extruders are equipped with different dosing systems: Gravimetric dosing unit, continuous loss-in-weight feeder for co-rotating twin-screw extruders (the so-called starve-fed extruders) Volumetric dosing system for single-screw

Gravimetric dosing unit, batch type (with weighers) for single-screw extruders

800x600

KSW125

300/300

Melt Filtering Systems Melt filtering is a key part of extrusion process to ensure final product quality standard compliance. Besides, it is important to safeguard the gear pump, extrusion flat head and calender roll integrity, especially in case of recycled materials.

Standard filtering systems are hydraulic and equipped with filtering screens (2, 4, 8, ‌) to provide for filter screen changing with uninterrupted production and altering of foil / sheet quality.

800x600

KSW125

300/300

Melt Gear Pump Melt gear pump function is to ensure constant melt flow (i.e. under precise and constant pressure and output conditions) from the extrusion die.

800x600

KSW125

300/300

17

Co-extrusion Feedblocks Provided the very wide range of products required by the rigid film sector (raw materials, structures, thickness and width ranges, output, ‌), Bandera flat dies are specifically designed and manufactured for each extrusion line. Besides, as a standard, they are equipped with a feedblock whenever foil structure is multi-layer.

The feedblock comprises a tempered and stabilised stainless steel case: inner melt flow channels are super refined and/or chrome plated.

Layer distribution is managed by interchangeable selector plugs and apposite melt flow and orientation control valves.

Material flow channels are designed and constructed on the basis of process material rheological characteristics and each layer output: these features are of core importance for the utmost precise distribution of foil layers.

Bandera feedblocks can be equipped with flow adjustment valves (for each layer) and flow distribution valves (aimed at controlling the stratified melt before it enters the flat die).

18

Flat Die Heads Single- and multi-channel dies are manufactured in tempered and stabilised stainless steel; inner melt flow channels are super refined and/or chrome plated.

Melt flow channels design and construction are executed according to raw material rheological characteristics and overall machine output.

Thermoregulation system accuracy is unrivalled and enhanced by highefficiency special-design cartridge resistance heaters.

Bandera flat dies can be equipped with several items of equipment, depending on production requirements: Internal and/or external deckles for quick and easy foil width adjustment Distribution bar to evenly distribute the melt flow over the whole foil width Air blade and (single and double effect) vacuum box systems, accurately controlled by AC inverter for thin foil.

In this section, a selection of pictures are provided to show singlechannel flat die manufacturing and use for the production of PET, PP, PS and PLA foil.

It is well worth highlighting that, in case of production of multi-layer foil from raw materials featuring different rheological characteristics, die heads with separate melt channels are a key factor in terms of finished product quality.

Multi-channel die head construction is more complex and requires independent control of thermoregulation and melt flow.

Furthermore, Bandera has developed automatic extrusion dies equipped with thermal bolts to offer an enhanced foil profile control.

The strong interaction between Bandera automatic extrusion dies and thermal bolt software offers an easy thickness control.

19

Film Cooling and Polishing Calenders In foil extrusion and co-extrusion lines, the calender is the actual process core, where material is calibrated and cooled at the extrusion die outlet.

Calenders differentiate characteristics, e.g.:

for

several

design

and

construction

Roll configuration: horizontal, (15째, 30째, 45째, 60째) inclined and vertical Roll opening/closing: hydraulic, pneumatic and mechanical Roll gap adjustment: mechanical - manual, mechanical - motorised, pneumatic with special-design valves Roll construction: cooling through spiral grooves or through transversal holes Roll cooling/thermoregulation: water or oil Roll surface finishing: mirror polished, glazed, embossed On demand, calenders are often equipped with calender roll automatic cleaning systems.

20

Special Design Calenders Pushing on its expertise gained by manufacturing calenders and by proactively collaborating with its own Customers, today Bandera can meet any Customer requirements.

Bandera calenders can be equipped with several different items of equipment: Physical masking: barrier and non-barrier lamination film by satellite pressure roller and by hot melt lamination solution.

Manual or motorised cross-axis system, required to ensure perfect foil calibration in processing very thin thicknesses.

High-precision reducers to eliminate foil optical and surface defects Satellite positioning system for the 3rd calender roll to select contact time between foil and cooling rolls and, in the event of glazed or embossed foil, to maximise finished product surface quality Roll cooling tables for materials requiring a long cooling time.

Calender with pivoting barrel - Stage 1

Stage 2

21

Manual Winding Systems Bandera offers a wide range of winding systems to meet the largest production requirements: Bandera range includes manual, semiautomatic and fully automatic winding systems.

All Bandera winding systems feature the following: Manual foil cutting and threading on the winding shaft in stand-by position Foil storage (accumulation) system synchronised with line speed to allow full-safety cut and thread-in interventions in full safety Haul-off system arranged above the winding stations to ensure a correct adjustment of foil tensioning and top quality finished reels Possible winding of up to 3 reels by equipping the winding unit with 6 stations Possible winding on Ø3”, Ø6” e Ø8” expanding shafts

MANUAL CANTILEVER WINDING UNIT

MANUAL TROLLEY WINDING UNIT

Cantilever winding shafts, motor driven (AC motor),

Winding trolleys, motor driven (AC motor), pro-

equipped with safety devices to ensure operator’s

perly sized to support heavy reels, and equipped

full safety

with cardan joint and safety devices to ensure ope-

Reel diameter: up to 1000mm max

rator’s full safety.

Foil width: up to 1200mm max

Reel diameter: up to 1800mm max Foil width: up to 1600mm max

22

Automatic Winding Systems The automation level offered by Bandera automatic winding systems is definitely high. High automation is aimed at minimising manual interventions by operators, thus enhancing finished reel accuracy and quality.

Bandera automatic winding systems stand out for: Automatic foil transversal cutting and threading on the winding shaft in stand-by position Foil storage (accumulation) system synchronised with line speed Additional haul-off system arranged above the winding stations to ensure a correct adjustment of foil tensioning and top quality finished reels (especially in case of multi-reel winding) Possible multi-reel winding (up to 4 reels on the same shaft) by specialdesign pneumatic expansion shafts

SEMI-AUTOMATIC CANTILEVER WINDING UNITS Bandera semi-automatic cantilever winding system stands out for its versatility and compact dimensions.

Thanks to its mandrel “double support” (tailstock arranged on the cradle for reel removal), Bandera semi-automatic cantilever winding system is a top solution for winding large reels (diameter: 1200mm max, width: 1650mm max) reels with unrivalled accuracy.

Cradle for reel removal is equipped with a rotation system, which can be operated from outside the work area only, to ease finished product management.

Up to 3 reels can be processed on the same shaft thanks to special-design pneumatic expanding shafts.

Transversal cutting is operator controlled; foil threading on the winding shaft in stand-by position is manual.

Foil storage (accumulation) ensures full safety of cutting and threading.

AUTOMATIC TURRET-REVOLVING WINDING UNIT Bandera automatic turret-revolving winging units are much appreciated by Customers who need high speed reel change (quick changeover cycle – shorter than 4 minutes – intended for small diameter reels) and high product quality.

Foil width: 1900mm max Reel diameter: 1200mm max Reel changeover cycle duration: 3.5min approx.

Cradle for reel removal is equipped with a rotation system, which can be operated from outside the work area only, to ease finished product management.

TROLLEY AUTOMATIC WINDING UNIT Jumbo reel winding units are specifically required by Customers with high production capacity as well as from the thermoforming sector.

Trolley automatic winding units feature minimised overall dimensions and accurate safety devices.

Each winding unit is equipped with two motorised trolleys with a dedicated system to easily download finished reels from work area.

Foil width: 2000mm max Reel diameter: 1600mm max

23

Downstream Equipment Downstream equipment – ancillary to extrusion line – is used for further processing of semi-finished products:

BLADE GRANULATORS

THICKNESS MEASUREMENT AND CONTROL SYSTEM

Intended for grinding foil edge trims; in-line systems for ground material direct re-conveying into the extruder dosing equipment are available, or, as an alternative, big-bag storage.

The system features a properly sized blower for ground material conveyance and a cyclone for dust abatement.

The granulator can be supplied enclosed inside a sound-proof box – cutting chamber cooling available by water circulated inside an external sleeve.

Quick and easy screen plate replacement.

The thickness measurement and control equipment is available in different options: by air sensor or radioactive source (e.g. Beta rays).

Suitable for rigid, flexible, transparent and coloured materials.

It can be employed with extrusion dies featuring expansion bolts for automatic lip control and adjustment.

Complete with suitable supporting frame, and dedicated PC with printer for process parameter report generating and printing.

Furthermore: Idle and/or motor-driven roll table featuring independent thermoregulation for top quality foil calibration and cooling Foil ennoblement (lacquering, surface treatments, …)

In-line lamination systems (with pressure roller and/or by hot-melt lamination) for the production of composite foil 24

Ancillary Equipment

LONGITUDINAL CUTTING ASSEMBLIES In-line slitter systems for foil longitudinal cut, by the rotary or fixed blade type, to produce multiple reels (on the same shaft, case of automatic winders).

Cutting systems are complete with independently-driven counter blade.

Highly-automated machinery – cutting system displacement can be power driven with digital control of the position. Extreme attention is given to operator safety – a key design attribute of Bandera Engineering Department.

ROLL CLEANING SYSTEMS Calender cleaning is produced by means of a power-driven cart, movable on a transversal bar, onto which are arranged a pneumatic swab made in no-scratch cloth (merinos wool, cotton, etc.) and a sprayer delivering the cleaning solution onto the roll surface.

The operator controls the cleaning operations from a remote control panel – the cleaning system is suitable for already existing extrusion lines.

Cleaning of calender rolls by power-driven brush with interchangeable sections

In addition: Manual, semi-automatic or fully automatic stacking units In-line foil quality control by video cameras and/or polarised lights

25

Extrusion Line Control Centralised Control The centralised control of all extrusion line parameters has proved to be a key factor in production management.

Markets have increasingly become sensitive about labour costs, quality control, product traceability systems and connection to company network (or remote connection) for production line software check and inspection.

To meet its customers’ – and prospects’ – needs, BANDERA has designed a specific control architecture. The control system is based on an industrial workstation for Windows operating system, whose line master PLC interface is connected to an auxiliary system and single unit remote I/O module PLCs via field bus. Thanks to the design architecture, all line parameters are available for any remote connections aimed at production control, process material management or remote assistance

by Bandera technicians.

User interface has been designed with special care – from hardware, with a large colour monitor to software, with intuitive synoptic graphics, from which the operator interacts via HMI touch screen.

EWon Company/Factory LAN

Machine LAN

PSTN, ISDN PLC

26

A Brand New R&D Area A new Research & Development area is going to be fully operating by 2014 to test complete extrusion lines

Comin

g

Facts & figures: latest turnovers

27

Soon

briefinglab.com

PLASTICS MACHINERY EXTRUSION TECHNOLOGY SINCE 1947

For further details about Bandera technology, visit us at luigibandera.it

BLOWN FILM

EXTRUDERS

PIPE COATING EXTRUDERS

GRANULATION

Costruzioni Meccaniche Luigi Bandera SpA Corso Sempione, 120 - I-21052 Busto Arsizio (VA) Italy t +39 0331 398111 - f +39 0331 680206 lbandera@lbandera.com - luigibandera.com Brochure download available at Bandera website for environmental care.

Discover our unrivalled strengths at http://www.luigibandera.net/bandera/en/prodotti/foil-a-sheet.html

Technical details provided for illustrative purpose only.

Subject to modifications without notice.

REV3/FOGLIA/EN/09/13

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