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The MoldMaster E44 pulp
moulding system is a complete modern automatic pulp moulding machine to produce
egg trays from waste paper and cardboard.
It is supplied as two (2)
pulp moulding and drying lines with one stainless steel pulp preparation system
with stainless steel pulper and stainless steel pulp and water storage tanks.
Each of the two stainless
steel moulding units has two stainless steel forming platens each fitted with
four (4) 30-pack egg tray moulds of your choice – a total of four (4) platens
and sixteen (16) moulds.
On each moulding unit of
the MoldMaster E44 one of the forming platens fitted with the forming moulds
rotates into the stainless steel moulding tank and vacuum is applied to form the
egg trays from the pulp mix – the water which is drawn by vacuum from the pulp
mix through the forming moulds returns to the stainless steel water storage tank
for reuse in the stainless steel pulper. This platen then rotates out of the stainless steel moulding
tank and the egg trays are automatically transferred by compressed air from the
forming moulds to the transfer moulds. They
are then gently blown, again automatically by compressed air, onto the conveyor
of one of the drying machines. Whilst
these trays are being transferred, the second forming platen, which is at 180 °
to the first forming platen, is forming the next four egg trays in each moulding
unit.
The maximum egg tray
production from the Moldmaster E44 is 5.835 transfers per minute.
The MoldMaster E44 has four
(4) stainless steel forming platens each fitted with four (4) forming moulds
therefore the maximum output from the MoldMaster E44 is 5600 egg trays per hour.
Each of the MoldMaster E44
moulding units has one stainless steel transfer platen which is fitted with four
transfer moulds – a total of eight transfer moulds in the system.
The mechanical movements of
the moulding machine are hydraulically powered and controlled to give constant
moulding accuracy. The machine uses
compressed air for transferring the moulded products, which is taken 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 with the moulding
unit is a 45 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 360 Kg of pulp per hour at 3% consistency.
The pulper also has an automatic feed for adding the chemicals to the
pulp.
The MoldMaster E44 has a
stainless steel pulp storage tank with a 1.5 kW agitator and also a stainless
steel water storage tank. Also
provided are a 7.5 kW hydraulic pump and a 10 kW vacuum pump. We also provide a number of pulp and water mixing control
pumps and an automatic water and pulp level control system.
The E44 moulding machine is
fitted with an expandable PLC which 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 systems have a 2000 hour battery back-up system to ensure
that no ‘memory’ is lost in the event of an on site power failure.
Automatic mould cleaning
facilities are fitted to the machine 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 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.
Sixteen (16) 30-pack egg
tray forming moulds and eight (8) matching transfer moulds complete with
stainless steel meshes are included. The
standard sizes are 15˝lb, 17 lb and 20 lb.
GENERAL
From the moulding machines
the trays are automatically transferred to the conveyor of a drying machine.
After drying the product is removed from the dryer manually.
Each dryer will consist of
three high velocity nozzle drying sections.
A slatted band conveyor would pass through the drying sections having an
effective conveying width of 1.45 metres. The
conveyor belts would be extended beyond the drying machine enclosure at both the
feed and delivery end for automatic loading and manual off-loading.
Each drying section has an air circulating fan, oil or gas burner system
and temperature control. The
conveyors are fitted with variable speed drive units.
Exhaust fans are mounted on the roof of the machines to extract moisture
laden air from the interior of the machine.
The overall length of each
drying machine is 13.0 metres, effective over nozzles.
FRAMEWORK
For each dryer a steel
framework fabricated from hollow sections and rolled sections would be provided
to support the conveyor and internal air system. The framework will be of welded and bolted construction.
CIRCULATING FANS
Each dryer has six (6) fans
in each dryer and they will be of the centrifugal pattern being mounted in the
lower position of the machines suitable for a maximum operating temperature of
200 °C. Each fan will be driven
directly from 18.0 kW TEFV motors mounted on the outside of the machines.
The starters will be mounted in the control panel.
Each fan motor is fitted with an inverter to allow adjustment to the
airflow within the dryers.
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 trays or cartons 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 above 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 and maintenance and fitted
with robust lockable mechanisms. Adjustable
end seals are fitted at the conveyor entry and exit slots.
DRYER FUEL
The drying machines will be
arranged for either direct gas or light diesel oil heating.
Details of the customer’s fuel to be confirmed.
EXPLOSION RELIEF
If the drying machines are
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
Each drying machine has six
(6) indicating electronic temperature control instruments would be provided on
the control panel. The instruments
would control the temperature in each machine as well as indicating the
temperature of the circulating air. The
temperature probes would be mounted in the main air circulating ducting inside
each section of the machines. The
machines would be designed for a maximum operating temperature of 200 °C.
SAFETY FEATURES
The machines will be fitted
with air pressure switches with interlocks on the air circulation systems and
exhaust systems to prove that these are operating prior to ignition of the
burner. An air purge from within
the machines also takes place prior to burner ignition. All main access doors on the machines are fitted with
lockable mechanisms. Guarding of
drives, etcetera will comply with BS5304-1988.
Explosion relief panels are fitted in the rooves of the machines as
recommended in Health and Safety Booklet No 16 - evaporating and other ovens.
High limit temperature safety thermostats are provided to shut down the
burners in event of failure of the temperature controls.
EXHAUST FAN
Two centrifugal fans would
be mounted on the roof of each machine to extract moisture laden air from the
body of the machine. This would
create a negative pressure inside the machines to induce air to enter the
machines through the fresh air inlets. 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
Each drying machine 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
starters for the air circulating fans and exhaust fans 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 E44 for a six (6) week
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 E44
system.
The stainless
steel used in the MoldMaster machine is high quality grade 304.
Operating
labour - we recommend six (6) 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 eight (8) 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 Hercules Aquapel 210 is recommended.
We will supply 1 Kg of this for commissioning purposes.
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 140 kW
for the moulding machine and 230 kW for the drying machine.
Light diesel
oil - please advise calorific value; LP gas – please advise calorific value;
or natural gas at 14.2 k/watts per cubic metre at 255 mm.wg.
Total consumption 1,160,000 Kcal per hour or 168 Kg diesel oil per hour
or 140 cubic metres of natural gas per hour.
Water supply -
approximately 880 litres per hour.
Exhaust
ducting from the drying machines to atmosphere.