Home » Technical development » Blown film production » In-Line winder
The winder built onto the film blowing machine gets consumer demands come to the front against the requirements determined by the winders.
The biggest advantage of the in-line winder is therefore the introduction of the consumer-oriented production technology. In the conventional technologies the physical parameters of the jumbo rolls (adhering capacity, flexibility, breaking elongation) have been adjusted according to the requirements of the winder machines for the purpose of rewinding finished products in the easiest way at the highest speed possible. This method usually deteriorated physical parameters that were necessary for best application. With the in-line winder, there is no need for rewinding, the optimal formulation can be set up preliminary with the in-line production of the finished product. And what’s more important, consumer demands can be supplied on a wide range with individual formulas.
The new, narrow winder was developed specially for the winding of cut and spreaded filmstripes. The stripes of the cut hose are winded on more narrow winders. Each stripe is cut into half on the winder. The advantage of the smaller, narrow winder is that much bigger jumbo rolls can be produced. In case there are 5 or 6 separated rolls next to each other on a long pneumatic axle, the axle bends after a certain size (weight) and the rolls touch each other. On the smaller winders there are only 2 rolls next to each other, the pneumatic axle is much shorter and this way, even in case of same sized rolls, its load capacity is multiple. The winders are designed to produce jumbo rolls with a diameter of 1 meter. It is not only geometrically capable to produce big jumbo rolls, but also the tighteness of the winding is adjustable in order to assure the unwinding. The big jumbo roll has an importance in course of the economical operation of the automatic rewinder machines.
On the equipment being built presently the stripes will be 600 mm wide and each will be cut into two 300 mm pieces. These jumbo rolls, in contrast to the 8-10,000 m ones, have a lenght of about 100,000 meters. In other systems the jumbo rolls are rewinded on a separate unit having a theoritical line speed of 1,000 m/min. The rewinding of a jumbo roll lasted about 10 minutes and was followed by a 2-minute roll changing process. This way the actual real winding speed, considering the side-time, is reduced to approximately to 800 m/min. The new technology results in a significant decrease in the side-time, because the winding time increases by 10 times with the same side-time. With the above it is possible to reach, with a good approximation, a production speed of 1,000 m/min.
With the in-line type end-product manufacturing, we furnish the winder with a revolver unit, winding the end-product directly to a length of 300, 100 or 50 meters. These revolver type winders are of rather simple construction, because their line speed is only a portion of an automatic rewinder’s. The line speed of the film is 1,000 m/min. In case we consider the fact that there are 6 revolver winders in work and on each of them there are two rolls produced, this way the actual output speed is increased to 1,200 m/min. As there are no side-times deriving from roll changes, the real production speed does not decrease.
Flexiblity=optimal utilization. The combination of the two types of winding methods makes the equipment incredibly flexible. We can exploit the enormous production capacity of the equipment according to actual demands. It is possible to produce jumbo rolls and end-products simultaneously depending on the lane adjusments.