Pp Tape Fabrilating Plant

By Author: AKI
Total Articles: 17
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PP fabrilated tape is made where we need both strength and flexibility. It strong
because it is made from PP material and we use fabrilation where we tear the pp
tape to different amount as per our requirement of softness and flexibility. Here
we will understand the pp tape fabrilating prosecc step by step.
1)EXTRUSION PROCESS:- This is the first step in this process. This includes
screw&barrel , screen changer, melt pump, die. here the mixed and dryed pp
granuels are inserted in the barrel zone. Barrel is heated at high temperature so
the granuels are melted properly. There is a screw rotating in the barrel which is
hardened by different process like gas nitration, bimetallic. This screw makes a
good mixture of melted granuals and pushes the melted granuels towards the
die. We set the speed of screw in such range that the granues are not remaining
half melted and they are properly mixed. We use screen changer to filter the
melted material. If there is any kind of unwanted material then it will be filtered.
We use melt pump whenever required. Melt ...
... pump is used to maintain the
pressure in the die. If there are any sudden changes in the speed of extrusion
then denier of yarn can change because of change in pressure. But if we use the
melt pump then it will maintain the pressure in every situation so the denier of
yarn don’t change. After this the melted and filtered material will come to die. We
use T-die in this process. Whole pp sheet will be coming out of the die which will
be slitted as per our denier requirement.
Difference between gas nitrated & bimetallic screw &barrel:-
a) Nitriding is a case hardening process for steel material.Gas nitriding is a surface
hardening process, where nitrogen is added to the surface of steel parts using
dissociated ammonia as the source. Gas nitriding develops a very hard case in a
component at relatively low temperature, without the need for quenching.
b) In bimetallic product two metals are fixed together, and not mixed together.
Mixing of two (or more) metal is called alloy. Bimetallic screw barrel are made of
two metals or two alloys of metals and mostly coated with extra layer of carbides
and other commercial coating material.
2) SLITTING :- This process contains slitting tower. First the pp sheet coming out
of the die is cooled by passing through the cold water tank(we need to maintain
the temperature of the water in the water tank because constantly coming hot
sheet of pp material can raise the temperature and make it hard to operate. We
have to take care of temperature in such way that it doesn’t get too cold also,
because it can harm the pp material to some extent by making it hard). Then the
sheet is stretched and slitted by sliter as per our denier requirement and it
becomes tape form after that. We can change the denier range as we want by
adjusting the slitting blade’s range.
3) ELONGATION & FIBRILATION :- After slitting tape goes into the godet-1which
are made of MS Plate & Heavy Duty Structure, where process of elongation starts.
Both of godets contains rollers which are cotted with hard chrome layer to
prevent it from rusting and provides good operating surface for pp tape. The
tapes are passed from godet -1 rollers and then they go into oven.(We use rubber
rollers with Pneumatic System on both side of the godets for the grip, so that the
tape is properly fitted in godet). We use ejecto cerculatioin type blower. In this
oven we use heaters and blowers to blow hot air on the tape from both sides.
Which gives the shine to tape. It vaporizes all moisture from the tape by blowing
hot air and this hot air makes it possible to stretch the tape to its maximum
capacity. After this the tape goes in to second godet which will be operating at
very high speed compared to the first godet. Because of this difference in speed
the tape is stretched. We have to set the stretch ratio between two godets for the
maximum elongation & maximum denier of tape. (we use gear godets instead of
chain or timing belts . These gear godets are made of steel material which are
made in our in house production unit with CNC & VMC machines which makes the
life of this godets upto 40 years). At the starting of the second godet there is
fibrilation unit which contains a roller full of spikes(of stain less stell material) on
it. Which fibrillates the tape or we can say it tores the pp tape as per your
requirement. This roller is operated pneumatically. This fibrillation unit makes the
pp tape soft and flexile.
4) WINDING UNIT:- In winding unit we wind the pp fibrilated tape in different
ways as per our requirement. There are different types of winders like bobbin
winder, ring winder, cheese winder etc.. if we want to wind the material in MS
bobbin for further use in rope making machines then we will use bobbin winder.
Magnetic type bobbin lock is given for easy fitting & remove without any
difficulty. Individual On/Off Switch provided for each Stations so you don’t have
to stop whole winder for operating on one spindle. Take Up Capacity is 20 Kg with
Bobbin (Gross).
If we want to wind the bobbin in ABS or nylon bobbin then we use ring winder.
Ring of the winder made by hardening the high quality material metal. ring holder
is made with Presser Die Casting with both side oil lubrication points. Ring winder
has the snail hook on every spindle to hold the yarn which is being winded. ring
winder has Yarn guide traverse hook & Foot Type Switch for start & stop which
makes it easy to operate. Synthetic Endlace type belt is used for better
performance.
If we want to make baler twines the then we use cheese winder which makes
cheese packages. Each winder is driven by a high efficiency 3-phase AC motor
controlled by individual 3 phase frequency inverter. Use of timing belt for power
transmission for traverse mechanism ensures lowest maintenance and noise.
Winding ratios can be easily changed by replacing timing pullies and belts.
Pressure roller assembly with adjustable bracket pressure is provided to get
constant pressure of the traverse mechanism which in turn gives high quality
packages.