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The moulding unit has a
total usable moulding area of 1200 mm by 400 mm and is ideal for four 30-pack
egg trays or other pulp moulded products of similar size.
The MoldMaster 12140E
forming platen fitted with the forming moulds rotates into the stainless steel
moulding tank 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 platen then rotates out of the moulding tank 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 12140E is 5.83 transfers per minute, so with four
30-pack egg tray moulds fitted this gives a maximum output of 1400 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 18 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 87 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 5 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.
Four 30-pack egg tray
moulds complete with stainless steel meshes are included.
The MoldMaster 12140E
batch-drying machine has two drying chambers each chamber arranged to hold two
runabout trucks. Eight runabout
trucks are provided, four 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 operator with wet egg trays supported on metal dryer trays.
After forming, the 4 wet
egg trays are automatically blown onto a metal support tray held by the operator
who then places this metal tray into a runabout truck.
Meanwhile, the moulding machine is automatically producing the next egg
trays. Each metal tray holds 4 egg
trays and each truck holds 88 metal trays and therefore a capacity of each truck
of 352 30-pack egg trays per truck. With
2 drying chambers, each loaded with two trucks, the holding capacity of the
drying machine is 1408 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. 720
metal dryer trays measuring 1400 mm by 400 mm and 8 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 350,000
kcal per hour and have a total installed electrical power requirement of 33 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 5 to 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 12140E MoldMaster
pulp moulding system we also include the services of our technician to build and
commission the drying machine for a twenty one day period including his airfare
with you the customer supplying first class hotel accommodation, meals and
transport from your local airport and return. You would also supply our technician with labouring
assistance.
GENERAL INFORMATION
Full instruction and
maintenance manuals will be provided for the MoldMaster 12140E system.
The stainless steel
used in the MoldMaster machine is high quality grade 304.
Operating labour - we
recommend 3 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 two 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 33.5 kW for the moulding machine and 30.5 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 290,000 Kcal per hour or 29.22 Kg diesel oil per
hour or 26.18 Kg LPG per hour or 35.75 cubic metres of natural gas per hour.
Water supply -
approximately 165 litres per hour.
Exhaust ducting from
the drying machine to atmosphere.
Electrical connection
to our control panels.