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The Moldmaster P41 pulp
moulding system is designed to produce a wide range of pulp packaging for
industrial, commercial and supermarket use, etc up to an overall height of 180
mm.
It is a complete, modern,
fully automatic pulp moulding system to produce pulp packaging from waste paper
and cardboard. It is supplied with
its own stainless steel pulp preparation system, stainless steel moulding unit
and high efficiency single conveyor drying machine.
The moulding unit has a
moulding platen with a total usable area of 1400 mm by 400 mm for products up to
180 mm overall height. The moulding
platen can be fitted with a variety of moulds using the full usable area of the
platen. The maximum pulp packaging
production from the Moldmaster P41 is 5.83 transfers per minute with products up
to 1.5mm thick – thicker products will of course take slightly longer to
mould.
The Moldmaster P41 forming
platen fitted with the forming moulds rotates into the stainless steel moulding
tank and vacuum is applied to mould the pulp packaging 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 pulp packagings
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 pulp packaging
production from the Moldmaster P41 is 5.83 transfers per minute with packaging
up to 1.5 mm thick.
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 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 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 90 Kg of pulp per hour at 3% consistency.
The pulper also has an automatic feed for adding the chemicals to the
pulp. The chemicals are aluminium
sulphate which is used to bond very small fibres together to avoid mould
blockage and soluble wax which may be required if water proofing of the
packaging is required. The amounts
of chemicals are relatively small, approximately 1.5% by total volume of pulp of
aluminium sulphate and 0.75% again by total volume of pulp of soluble wax.
The Moldmaster P41 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 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.
The P41 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 pulp packaging specifications (including
wall thickness), 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 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
complete with stainless steel meshes are provided with the system, these moulds
being designed to suit the customer’s requirements.
GENERAL
From the moulding machine
the pulp packagings are automatically transferred to the conveyor of the drying
machine. After drying the products
are removed from the dryer manually.
The 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 belt 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
conveyor is fitted with a variable speed drive unit.
Exhaust fans are 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 13.0 metres, effective over nozzles.
FRAMEWORK
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
There will be three (3)
fans in the dryer and they will be of the centrifugal pattern being mounted in
the lower position of the machine suitable for a maximum operating temperature
of 200 °C. Each fan will be driven
directly from 22.0 kW TEFV motors mounted on the outside of the machine.
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 dryer.
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 mouldings 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 machine will be
arranged for heating by natural gas. Details
of the calorific value to be confirmed.
TEMPERATURE CONTROL
Three indicating electronic
temperature control instruments would be provided on the control panel for the
dryer. 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 drying 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 systems and
exhaust systems 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 rooves of the machine 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
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 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
The 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 mounting
near the drying machine. We include
for site wiring between the panel and the machine but we do not include for
bringing your electrical supply to our panel.
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.
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 P41 for a three (3) 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 P41
system.
The stainless
steel used in the MoldMaster machine is high quality grade 304.
Operating
labour – we recommend three (3) unskilled labourers to operate the machine and
our technicians will train them on site.
A level
concrete floor is required on your site for the moulding system.
The Moldmaster
system would be loaded CIF your local port in three (3) forty-foot containers.
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 60 cycle (if different please advise local
supply). Total requirement 42 kW
for the moulding machine and 60 kW for the drying machine.
Natural
gas - please advise calorific value. Total
consumption 290,000 Kcal per hour which equates to 1,166,667 BTU’s per hour.
Total gas consumption 35 cubic metres per hour.
Water supply -
approximately 300 litres per hour depending on product chosen.
Exhaust
ducting from the drying machines to atmosphere.
Electrical connection to our control panels.