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The MoldMaster 12040EE pulp
moulding system is a complete modern semi-automatic system to produce pulp
mouldings such as egg trays from waste paper and cardboard.
It is supplied in two parts; a moulding unit and a batch drying machine.
From the moulding unit the wet egg trays are transferred manually by the
use of a metal supporting tray to the drying machine.
The moulding system has two
moulding machines each with a total usable moulding area of 1200 mm by 400 mm
and each is fitted with three 30-pack egg trays – the two moulding machines
will have a total of six 30-pack egg trays which can be a mix of egg pocket
sizes.
The MoldMaster 12040EE
forming platens fitted with the forming moulds rotate into the stainless steel
moulding tanks and vacuum is applied to mould the egg trays from the pulp mix
– the water which is drawn by vacuum from the pulp mix through the forming
moulds is returned to the stainless steel water storage tank for reuse in the
pulper. The platens then rotate out
of the moulding tanks and the egg trays are automatically transferred by
compressed air from the forming moulds to the transfer moulds.
They are then blown, again automatically by compressed air, onto a hand
held supporting dryer tray for placing by the operator into a dryer truck.
The maximum egg tray
production from the MoldMaster 12040EE is 2100 30-pack egg trays per hour.
The mechanical movements of
the machine are hydraulically powered and controlled to give constant moulding
accuracy. The machine uses
compressed air for transferring the moulded products from the compressor
supplied.
The moulding unit is of
modular construction for ease and speed of building and commissioning on your
site. All pipe work required for
the machine to connect the pumps, valves, tanks, etc is pre-piped at our factory
with stainless steel piping.
Included is a 20 kW
stainless steel pulper with an in-built automatic transfer system to transfer
the pulp from the pulper to the pulp storage tank. The pulper is rated at 130 Kg of pulp per hour at 3%
consistency.
A stainless steel pulp
storage tank with a 1.5 kW agitator is provided and also a stainless steel water
storage tank. Also provided are a
2.5 kW hydraulic pump and a 7 kW vacuum pump.
We also provide a number of pulp and water mixing control pumps and an
automatic water and pulp level control system.
An expandable PLC controls
all the functions of the moulding machine including the pulper and pulp transfer
to the pulp storage tank and allows user access to set up different egg tray
specifications, it also displays the programmed setting and displays any error
messages. The PLC control system
has a 2000 hour battery back-up system to ensure that no ‘memory’ is lost in
the event of an on site power failure.
An automatic mould cleaning
facility is supplied to clean the moulds on each cycle.
This system also automatically switches to a lower pressure to smooth the
outer pulp moulded surface of the trays and to clean the tray edges as the
forming moulds return from the forming tank.
Also provided is one high pressure cleaning gun for periodical high
pressure cleaning of the moulds.
Six 30-pack egg tray moulds
complete with stainless steel meshes are included.
The MoldMaster 12040EE
batch-drying machine has four drying chambers each chamber arranged to hold two
runabout trucks. Sixteen runabout
trucks are provided, eight of the trucks being in the drying machine for the
drying process whilst the other trucks are being unloaded and filled up by the
machine operators with wet egg trays supported on metal dryer trays.
After forming, the 6 wet
egg trays are automatically blown onto metal
support trays held by the operators who then place these metal trays into
runabout trucks. Meanwhile, the
moulding machines are automatically producing the next egg trays.
Each metal tray holds 3 egg trays and each truck holds 88 metal trays and
therefore a capacity of each truck of 264 30-pack egg trays per truck.
With 4 drying chambers, each loaded with two trucks, the holding capacity
of the drying machine is 2112 30-pack egg trays.
The drying time is approximately 40 minutes with an air temperature of
130 ºC. The maximum air
temperature available is 160 ºC. Specially
designed air guides within the drying chambers ensure an even and controlled
drying of the egg trays to give the maximum possible dimensional stability to
the egg trays. 1430 metal dryer
trays measuring 1400 mm by 400 mm and 16 dryer trucks are supplied with the
drying machine.
The drying machine will be
arranged for direct gas or light diesel oil heating and would consume 580,000
kcal per hour and have a total installed electrical power requirement of 61 kW.
An electrical control panel
and temperature control system is also provided. The air within the drying machine is guided over the moulded
egg trays and re-circulated with approximately 10% of the saturated air being
passed through the exhaust system to atmosphere. You the customer would provide the exhaust ducting from the
exhaust connection to atmosphere.
For the 12040EE MoldMaster
pulp moulding system we also include the services of our technicians to build
and commission the drying machine for a twenty day period including their
airfare with you the customer supplying first class hotel accommodation, meals
and transport from your local airport and return. You would also supply our technicians with labouring
assistance.
GENERAL INFORMATION
Full instruction and
maintenance manuals will be provided for the MoldMaster 12040EE system.
The stainless steel
used in the MoldMaster machine is high quality grade 304.
Operating labour - we
recommend 4 unskilled labourers who will be trained on site by our
technicians
A level concrete floor
is required on your site for the moulding system.
The MoldMaster system
would be loaded CIF your local port in four forty-foot containers.
A supply of clean waste
paper should be available on site for our technicians to commission the
machine.
For good quality egg
trays we recommend the use of Hercules Aquapel 210.
We will supply a 1 Kg sample of this with the machine and also
contact details of your local supplier.
We confirm that the
above goods being supplied to this contract are manufactured in the United
Kingdom and are new, containing no second hand parts.
The goods supplied to
the above customer are guaranteed by us for a period of 12 months from the
date of commissioning on site or 18 months from the date of shipment of the
goods from the UK (whichever is the shortest period) against mechanical and
electrical defects. Any part
developing a defect must be notified to us by fax or letter and we will
replace the defective part CIF. The
defective part must be returned to us free of charge.
SERVICES
The following services
will be required on site to be connected to our equipment by the customer:
Electrical supply - 380
to 415 volts 3 phase 50 cycle (if different please advise local supply).
Total requirement 40 kW for the moulding machine and 61 kW for the
drying machine.
Light diesel oil -
please advise calorific value; LP gas – please advise calorific value; or
natural gas at 10.7 k/watts per cubic metre at 255 mm.wg.
Total consumption 580,000 Kcal per hour or 58.44 Kg diesel oil per
hour or 52.36 Kg LPG per hour or 71.50 cubic metres of natural gas per hour.
Water supply -
approximately 330 litres per hour.
Exhaust ducting from
the drying machine to atmosphere.
Electrical connection
to our control panels.