Enter the Main Moldmaster Site
Moldmaster Text Only
Site Index
The Moldmaster 12060PCR pulp moulding system
is a complete modern automatic system to produce a wide range of pulp mouldings
from waste paper and cardboard. It is supplied as a complete line including the moulding unit
and drying machine.
The moulding unit has a
total usable moulding area of 1200 mm by 600 mm and is ideal for pulp moulded
products up to a maximum height of 180mm.
The Moldmaster 12060PCR
forming platen fitted with the forming moulds rotates into the stainless steel
moulding tank and vacuum is applied to mould the products 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 platen then rotates out of the moulding tank and the products are
automatically transferred by compressed air from the forming moulds to the
transfer moulds. They are then blown, again automatically by compressed air,
onto the conveyor of the drying machine.
The maximum product
production from the Moldmaster 12060PCR is 5.83 transfers per minute with a
product having a wall thickness of up to 1.5 mm (thicker products will take
slightly longer to form). The whole
platen area can be used without restriction.
The mechanical movements of
the machine are hydraulically powered and controlled to give constant moulding
accuracy and the top transfer platen is accurately guided to connect with the
bottom moulding platen by a series of accurately aligned guides and again a
hydraulic cylinder.
The machine uses compressed
air for transferring the moulded products from the bottom moulding platen and
also to automatically and gently blow the mouldings onto the conveyor of the
drying machine. The compressed air
is 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 70 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 is a 2.5 kW
hydraulic pump.
A 6.5 kW vacuum pump and
vacuum water separator tank are provided – this system draws the pulp mix in
the moulding station over the moulding dies and the water is then returned via
the separator to the water storage tank.
We also provide all
necessary pulp and water mixing control pumps, valves 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 product
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 products and to clean the 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.
One complete set of moulds
for the full platen area with stainless steel meshes are included.
GENERAL
From the moulding machine
the products are automatically transferred to the conveyor of the drying
machine. After drying the product
is removed from the dryer manually.
The dryer will consist of
four high velocity nozzle drying sections.
A slatted band conveyor would pass through the drying sections having an
effective conveying width of 1.83 metres. The
conveyor belt would be extended beyond the drying machine enclosure at both the
feed and delivery end for loading and off-loading.
Each drying section has an air circulating fan, oil or gas burner system
and temperature control. The
conveyor is fitted with a variable speed drive unit.
An exhaust fan is mounted on the roof of the machine to extract moisture
laden air from the interior of the machine.
The overall length of the
drying machine is 20.0 metres, effective over nozzles.
FRAMEWORK
A steel framework
fabricated from hollow sections and rolled sections and would support the
conveyor and internal air system. The
framework will be of weld and bolted construction.
CIRCULATING FAN
This will be of the
centrifugal pattern being mounted in the lower position of the machine suitable
for a maximum operating temperature of 200 °C.
The fan will be driven directly from a 18.0 kW TEFV motor mounted on the
outside of the machine. The starter
will be mounted in the control panel.
AIR CIRCULATING SYSTEM
Each drying section will
employ a closed type re-circulating high velocity nozzle type drying system with
upper and lower discharge nozzles. The
circulating air is discharged from the fan into a cross duct which feeds air
into a side distribution box. The
distribution box has a series of specially designed air discharge nozzles which
are arranged above and below the line of the conveyor.
The discharge air impinges directly on to both the top and bottom surface
of the product and then returns back over the burner unit to the fan inlet for
re-circulation. The air nozzles are spaced at 150 mm pitch along the length
of the machine and below the conveyor.
MACHINE ENCLOSURE
This would be constructed
from insulation panels from two folded steel trays with interior filled with
high density mineral fibre. Nominal
panel thickness 75 mm. The panels
would be held together by special locking sections.
Certain panels would be hinged for cleaning/maintenance fitted with
robust lockable mechanisms. Adjustable
end seals are fitted at the conveyor entry and exit slots.
DRYER FUEL
The drying machine will be
arranged for direct gas or light diesel oil heating.
EXPLOSION RELIEF
If the drying machine is
heated by direct gas then certain of the roof panels would be of explosion
relief type arranged to disintegrate in the event of an explosion.
They will be manufactured with outer surface having a soft friable
material.
TEMPERATURE CONTROL
Four indicating electronic
temperature control instruments would be provided on the control panel.
The instruments would control the machine temperature as well as
indicating the temperature of the circulating air.
The temperature probes would be mounted in the main air circulating
ducting inside the machine. The instrument would be mounted in the control panel.
The machine would be designed for a maximum operating temperature of 200
°C.
SAFETY FEATURES
The machine will be fitted
with air pressure switches with interlocks on the air circulation system and
exhaust system to prove that these are operating prior to ignition of the
burner. An air purge from within
the machine also takes place prior to burner ignition. All main access doors on the machine are fitted with lockable
mechanisms. Guarding of drives,
etcetera will comply with BS5304-1988. Explosion
relief panels are fitted in the roof of the machine as recommended in Health and
Safety Booklet No 16 - evaporating and other ovens.
A high limit temperature safety thermostat is provided to shut down the
burner in event of failure of the temperature control.
EXHAUST FAN
A centrifugal fan would be
mounted on the roof of the machine to extract moisture laden air from the body
of the machine. This would create a
negative pressure inside the machine to induce air to enter the machine through
the fresh air inlet. An adjustable
damper is provided on the exhaust connections so that the correct amount of
exhaust can be set during commissioning of the equipment. We do not include for exhaust ducting from the exhaust fans
to outside atmosphere.
CONVEYOR
The drying system would be
fitted with a slatted band conveyor, with side chains running on toothed wheels
at the feed and delivery end. The
chains would be supported on angle supports along the top and return pass.
The conveyor would be driven at the delivery end with a variable speed
drive unit giving a dwell range of 2-8 minutes.
Guards would be provided over all moving parts.
CONTROL PANEL
A folded sheet steel
control panel will be provided with the equipment being suitable for wall
mounting. The panel would house the
starter for the air circulating fan and exhaust fan and purge timers.
The instrument and push buttons would be mounted on the front face of the
panel. The panel would be fully
pre-wired internally complete with circuit breakers, etcetera.
A lockable main isolator would be provided on the panel.
We do not include for the
site wiring between the panel and the machine as this depends upon the final
siting of the panel.
FINISH/MATERIAL
Insulation Panels:
Outer and inner skins aluminised steel sheet.
Insulation 75 mm thick mineral fibre.
Inside Ducting and Nozzles:
Aluminised sheet steel.
Circulating Fan:
Mild steel with special insulating panel and cooling disc. High temperature paint finish.
Exhaust Fan:
Mild steel with high temperature protection and cooling disc.
High temperature paint finish.
Guards and Access Panels:
Aluminised steel sheet. Powder
coat finish.
Burner Tube:
Stainless steel.
Framework:
Mild steel hollow section and rolled section.
High temperature aluminium paint finish.
We include the services of
our technicians to build and commission the
Moldmaster 12060PCR for a twenty one 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 12060PCR system.
The stainless steel
used in the MoldMaster machine is high quality grade 304.
Operating labour - we
recommend 2 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 FOB UK port in two forty-foot containers – one for the
moulding machine and one for the drying machine.
A supply of clean waste
paper should be available on site for our technicians to commission the
machine.
For good quality
products 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 60 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 384,000 Kcal per hour or 38 Kg diesel oil per hour
or 46 cubic metres of natural gas per hour.
Water supply -
approximately 200 litres per hour.
Exhaust ducting from
the drying machine to atmosphere.
Electrical connection
to our control panels.