Frame Structure
Distinctively designed and precisely machined, strong and sturdy, steel frame structure completely machined on CNC-VMC, maintainsaccuracy over long dependable life and ensures less vibration even with optimum line speed. The structure enhances illumination of the working area.
The precise mechanical construction of each component, which undergoes extensive tests, ensures optimum performance and longer equipment life.
Control system
All the printing units, unwinder, rewinder, in-feed and out-feed are individually driven by servo motors-drives and controlled and supervised by the high performance PLC/PPC having its own intelligent software.
‘Fiber optic bus system’ used for maintaining tight synchronization between all the drives by providing fast, reliable and jitter-free communication.
Operator interface
Master operator control panel mainly consists of full colored touch screen operator interface located at rewind side and remote operator control panel located at unwind side, facilitates easy operation.
Unwind group
Turret type unwinder with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC.
The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller and cutting blade assembly etc.
Pneumatically expanded shafts and safety chucks to hold the reels.
Unwind web tension control by using latest generation AC servo motor and AC drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motors and drives, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back.
Electro-electric edge guiding system with Ultrasonic edge sensor.
Operating method ISO integrated with 'SAP' ERP operating system Spread in 19,000 (sqm) with build up area of 10,000+ (sqm)
In-feed system (Draw unit)
The system maintains set tension between in-feed and first printing unit precisely and isolates the printing unit from tension disturbance of the unwinding zone. The system mainly composed of matt chromium plated steel roller, AC servo motor and drive, load cell and rubber covered nip roller with pneumatically adjustable pressure.
Print unit control panel
Each print unit control panel consists pneumatic controls for drying hood, doctor blade and impression rubber roller & electrical controls for manual length and side-lay registration setting, blower control, temperature display for drying chamber and emergency stop.
Trolley system
For quick change of engraved cylinder & the whole inking group facilitates fast and easy job changes. Trolley consists of hollow type cylinder mounting shaft assembly with quick locking check nut, double ink basin and speed variable air motorized Ink pump.
Idle rollers
Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness
Chill rollers Low friction design chill rollers, made of Aluminum alloy with stain steel inner sleeves for effective web cooling.
Sleeve type Impression assembly
The sleeve system, consists of an air mandrel with a rubber covered fiberglass sleeve, provides functional flexibility.Sleeve type rubber covered impression roller raising lowering on precision linear bearings ensure smooth and precise displacement. Pneumatic working impression controls with independent pressure adjustment for both the sides. Sleeve made of fiberglass or fiberglass and carbon. Hardness: between 70 and 85 shore A
Transmission
The printing cylinder shaft is directly connected to the drive motor without gears, which eliminates mechanical backlash, ensures consistent operation over time and offers true direct drive solution.
Viscosity Controllers (optional)
An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.
Doctor blade group
Designed to ensure a straight profile of the blade resulting in lesser blade pressure, better printing quality and longer cylinder life. The blade locking by eccentric rod without tools. The group allows horizontal, vertical and angular adjustment for the doctor blade position on engraved cylinder. Pneumatic doctoring pressure with adjustment possibility from the unit control panel.
Automatic register control system
Automatic length and side-lay register control system with full colored touch screen operator interface facilitates automatic mark centering and recognition. Automatic selection of different control parameters during machine speed changes and control parameters individually configurable to different materials for easy operator selection.
Drying system
Ink drying is obtained by blowing hot air on the web through air nozzles. The optimized airflow minimizes heat consumption and avoids solvent retention in the printed substrate. The system mainly composed of single hood drying chambers, ventilation modules, connection ducts, central exhaust system and thermic fluid heating system.
Single Hood Drying Chamber Opening-closing by means of pneumatic piston, horizontally sliding on the rails, to allow easy access for web threading and cleaning.
Ventilation Module suitable to send and re-circulate the process air. The module composed of AC frequency drive controlled centrifugal fan, thermal oil heat exchanger and necessary controls and feedback device for temperature.
Central Exhaust System Composed of AC frequency drive controlled heavy-duty centrifugal fan to collect solvent contaminated air from all the printing units through central duct. The ducts fitted with manual adjustable dampers.
Out-feed system
The system maintains set tension between last printing unit and out-feed precisely and isolates the printing units from tension disturbance of the rewinding zone. The system mainly composed of matt chromium plated steel roller AC servo drive, AC servo motor, load cells and rubber covered nip roller with pneumatically adjustable pressure.
Web Video Inspection System
Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).
Rewind Group
Turret type rewinder with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC/PPC. The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller, and cutting blade assembly etc. Pneumatically expanded shafts and safety chucks are provided to hold the reels.
Rewind Web Tension Control By using latest generation AC servo motor and AC drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and AC drive, pneumatically loaded low friction dancing roller assembly and load cells for tension feed-back.
Lay–on Roller Assembly Pneumatically operated lay on roller assembly complete with pressure gauge and regulator for control of the pressure on the rewind reel.
Viscosity Controllers (Optional)
Rewind Web Tension Control An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.
Automatic Defect Detection System (Optional) Automatic defect detection system detects printing defects before they are seen by the human eye. The moment any of the defect like Color variations, Doctor Blade Streaks, Mis-registration, Spots, Splashes etc. are detected, the relevant Image of the printed area is displayed on the screen and the red alert switches on. All defects are marked and classified.
