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The Moldmaster 8060PC pulp
moulding system is a complete semi-automatic system to produce pulp mouldings
from waste paper and cardboard and is supplied in two self contained units; a
moulding unit and a continuous conveyor drying machine linked together by a
transfer conveyor. From the
moulding unit the wet mouldings are automatically transferred by the use of a
metal supporting tray to the drying conveyor, this metal tray is manually fed
into the moulding machine.
The moulding unit has a
total usable moulding area of 800 mm by 600 mm and is ideal for a wide range of
pulp moulded products up to a maximum product depth of 180 mm.
Products with different overall depths can be produced at the same time.
The Moldmaster 8060PC
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 a
product supporting dryer tray which has been fed into the machine by the
operator. This tray is then automatically transferred to the conveyor
of the drying machine.
The maximum product
production from the Moldmaster 8060PC 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. 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 15 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 43.5 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 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 product 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 high
quality moulds is included.
GENERAL
From the moulding machine
the dryer trays carrying the wet product are automatically transferred to the
conveyor of the drying machine. After
drying the product is removed from the dryer trays and the dryer trays are
returned to the moulding machine by the tray return conveyor.
The dryer will consist of
three high velocity nozzle drying sections.
A cross-rod type conveyor would pass through the drying sections having
an effective conveying width of 1.00 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 machine size is based
on the following:
Pallet Size:
850 mm x 650 mm
Maximum Product Size:
800 mm x 600 mm x 180 mm
Drying time:
5.0 minutes
Cycle
time:
10.30
seconds
Conveyor:
Carrying one dryer tray across
Conveyor
speed:
1.95
metres per minute
Machine length:
18.4 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 27.0 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 and would consume 200,000 k
cal per hour and have a total installed electrical power requirement of 30 kW.
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
Three indicating electronic
temperature control instruments would be provided on the control panel.
The instruments would control the machine temperature in each drying
section 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
instruments 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 cross-rod type 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.
RETURN CONVEYOR
A conveyor is provided to
return the dryer trays to the feed end of the machine.
DRYER TRAYS
50 dryer trays are
provided.
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.
For the Moldmaster pulp
moulding system we also include the services of our technician to build and
commission the 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 8060PC
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 – 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 30 kW
for the moulding machine and 27 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 200,000 Kcal per hour or 20.16 Kg diesel oil per hour
or 18.06 Kg LPG per hour or 24.66 cubic metres of natural gas per hour.
Water supply -
approximately 110 litres per hour.
Exhaust ducting
from the drying machine to atmosphere.