CI Flexo Printing Machine

BRIFE SPECIFICATION

Substrate: PET/BOPP/PE/PAPER
Printing section: 8
Max. paper width：1320mm
Max. printing width：1300mm
Printing repeat：350mm – 810mm
Register Tolerance: ±0.10mm
Max. printing speed：500m/min (Machine running speed will be impacted by but not limited to following factors)

Plate cylinder diameter/ Character of Substrate

Character of ink and additives

Printing Quality Request/ Flexo plate and tape

Smart Operation

Power supply and compressed air

Cooling/conditioning water

Environment requirements for workshop

Job save/recall, save necessary data of job setup, make job repeat more easily
If you do not follow the procedure, the machine will alarm automatically
On-line monitoring of the whole machine status, real-time monitoring
Lack of air pressure, auto alarm
Camera based register-Camera based registration system
Pre-register
Remote control system-Long distance diagnosis

Machine color: DongHang standard （GREY RAL7038 – WHITE RAL 9010）
Plate thickness + tape thickness ： 1.14mm+0.5mm (decided by customer)
Drying system: Electric heating/Gas/Steam/Hot oil
Machine layout: Operator faces to the machine, unwinder in his left-hand direction
Machine size: Please note the attached drawing

Power: 380V 3PH 50HZ
Max. power:
Compressed air:0.6MPa (AIR COMPRESSOR UNINCLUDED)
Compressed air Consumption :2 m3/min

Filtration clarity less than 20 Micron
Min pressure：2 bar
Max pressure：3 bar
Inlet temperature 15C° - 18C°
Hardness (CaCo2) 2.5 - 4mg/lt.
PH 7 – 8.2
Central impression drum conditioning: a closed loop conditioning unit

Relative humidity: 30 -80% (at 20°C).
Temperature: 15°C – 35°C

Flexo Press Description

FLYING SPLICE TURRET UNWINDER. Twin axis, shafted type, unwinder for reels of maximum diameter 800 mm(film). Unwinder for reel mandrel of external diameter 96 mm (3” air shaft mandrel) Frames complete with base for jacking screws and holes for levelling and securing to the floor.

WINDING AXIS CONTROLS Winding axis are center driven by A.C. motors. Tension control of the unwind axis by dancer roller system with pneumatic reaction, and rotary potentiometer. Web detector incorporated in the dancing roller, auto stop when paper broken Hand wheel for axial adjustment, the maximum adjustment amount is 20mm.

SPLICE SYSTEM Splice system composed by a lay on roller to stick the new reel to the substrate in use, and a cross knife to cut the substrate from the expiring reel. Reel change sequence activated by the operator throughout remote controls located near by the unwind section. Minimum external diameter of the reel permitted for the splice is 500 mm

REEL LOADING Electric reel loading

IN-FEED EDGE GUIDING SYSTEM Automatic edge guiding system is mounted before the printing section. The system includes 1 (one) sensor for “left or right guiding”.

IN-FEED NIP ROLLER Nip roller, composed by a steel roller covered with rubber of hardness 65/70 shores, to lay film on the central drum. The roller is mounted on sealed ball bearings, and is pressed laterally through two (2) pneumatic cylinders, one on each side, having independent pressure control manually adjustable.

PRINTING STAND Central impression type, having framework prepared for maximum 8 printing units. Frames of stabilized HT250 cast iron, 120 mm (To be determined). thickness, connected by spacers and tie rods in steel and cast iron. A cast iron base supports all the structure and allows levelling and securing to the floor by jacking screws and holes. The housing of the inking units are obtained on the lateral frames by cuts of rectangular shape with a window design. This system provides extreme rigidity to the structure, reducing drastically vibrations during the printing operations.

CENTRAL IMPRESSION DRUM Chrome plating drum, protect it from external corrosion. The drum is supported laterally by tapered-roller bearings. In order to ensure the necessary eccentricity tolerance, the grinding and super finish process of the external diameter is carried out with the drum already mounted on its bearings and coupling flanges. Centralized manual lubrication of the supporting bearings of the central drum. Closed loop water conditioning system for the drum. The conditioning system integrates heat exchangers for cooling or heating the water. Drum driven by a servo motor directly A braking system, mounted on the main drive, controls deceleration sequences during the machine stop cycle. Pneumatic brake assists the decelerations during normal and emergency stops.

PRINTING SECTION The plate and the anilox roller sleeve mandrel of each section are driven by a separate servo motor The pressure engage/dis-engage of the plate and anilox roller sleeve of each section is driven by a separate servo motor The horizontal adjustment of the plate roller of each section is driven by a servo motor

TYPE OF INKING SYSTEM Inking system by enclosed chambered doctor blade system. With ink circulation inlet and outlet, both sides are sealed. The two sides are sealed with special sealing blocks, which can effectively overcome the shortcomings of traditional rubber and sponge sealing blocks that wear quickly at high speeds. The enclosed doctor blade chamber is constructed a split design, the knife holder part can be easily separated from the main body, and the blade replacement is quicker and lighter The blade clamping adopts a magnetic design, the blade can be directly attached to the tool holder, which is simpler and more convenient to replace. It also ensures the flatness of the blade. The iron filings in the ink can be adsorbed on the inner cavity wall,. Will not cause damage to the anilox roller due to iron filings accumulating on the blade There is a special pressure relief device in the cavity to prevent the blade from deforming due to over pressure in the cavity. Ink circuit is integrated inside the cavity, reducing external ink circuit pipes, neat and beautiful The contact pressure between the doctor blade and the anilox roller is ensured by air pressure. Adjusting the air pressure can adjust the pressure, reduce blade wear, and maintain the pressure unchanged. Each section contains air-pressure ink pump, ink tank A stainless steel ink tray is installed under each section to collect spilled ink during the operation and cleaning of the machine. The ink tray can be quickly replaced. Automatic ink supply and cleaning system for quick replacement and cleaning

SLEEVE ANILOX ROLLERS One set ceramic coated and laser engraved sleeve Steel mandrel, statically and dynamically balanced, to support the anilox sleeve. The mandrel is anchored on the rear side by 2 self-aligning double-row ball bearings laterally sealed, forming a cantilevered system to support the mandrel during sleeve change operation. During the printing operations the mandrel is supported also on the front side of the machine by a needle bearing. Lateral splash guards in aluminium are mounted on the 2 edges of the sleeve.

SLEEVE PLATE ROLLERS One set sleeve to support the plates. Sleeve has a lateral cavity to fit with a pin located on the mandrel, for longitudinal positioning. This device is necessary to use the pre-register system. Steel mandrel, statically and dynamically balanced, to support the plate sleeve. The mandrel is anchored on the rear side by 2 needle bearings, forming a cantilevered system to support the mandrel during sleeve change operation. During the printing operations the mandrel is supported also on the front side of the machine by a needle bearing. The rolling tracks for the supporting bearings needle type, located on the journals of the supporting mandrel, are superficially hardened. Centralized lubrication, timer controlled, of the bearings supporting the sleeve mandrel. Plate roller axis driven by a servo motor, mounted directly on the mandrel axis. The servomotors maintain the peripheral speeds constantly engaged with the speed of the press during the line run. The speed of the motors is manually variable in respect to the line speed, throughout remote controls, thus permitting printing lengths variations up to a maximum of 3% in respect to the nominal printing length.

SUPPORTS AND CHANGE OF THE PRINTING SLEEVES AND MANDRELS Supports of the sleeve mandrels are constructed in steel alloy and move for their positioning operations and for the printing pressures registrations on linear guides (ball guides) pre-stressed. On the rear side of the machine the supports are anchored to the frame by two linear guides, one located on the bottom of the support and one on its top. On the front side of the machine the supports are anchored by one linear guide located on the bottom. This system provides the necessary supporting system when the mandrel is in the cantilevered position for the sleeve change operation and grants an extreme rigidity during the printing operations. Both sleeves, anilox and plate support, are replaced from the operator side (front side of the machine). The printing unit permits to create the necessary space to replace the sleeves on their supporting mandrels very easily, and without the need of any tool or any automation device. Both supports, for the anilox and plate axis, are fulcrate on a sturdy hinged system, and are opened on the operator side just as a door, relaxing a locking lever and pulling a handle which operates an additional security lock. Sleeve change by compressed air, inlet between the sleeve and the supporting mandrel throughout orifices located on the surface of the mandrel. The compressed air between the sleeve and the mandrel, creates a cushion that permit lateral shift of the sleeves on to the mandrel. A rotary pneumatic joint is mounted on the rear journal of the mandrel for the air inlet, permitted by valves remotely controlled by selectors located on each printing unit on the operator side.

PRINTING ADJUSTMENTS AND SETTINGS Longitudinal print registration by remote controls located near by the printing stand and on the rewind area, or near by the monitor of the video-scanner when this unit is supplied. The longitudinal printing registration, is permitted by a difference of rotation speed of the plate sleeve mandrel, operated during the registration period by the motor driving the axis. The registration length is consequently infinite. Side print registration motorized operated through remote controls located near by the printing stand and on the rewind area, or near by the monitor of the video-scanner when this unit is supplied. The side registration is carried out by moving axially the plate sleeve mandrel. Maximum adjustment permitted is 20 mm. on each printing unit. Micrometric printing pressures registrations remote controlled. The registration is carried out via the four servo-motors connected to the ball screws of the inking units positioning system. The remote controls permit two different adjustment steps, one short for the fine adjustments and one long for the quick approach. Sequential printing pressures quick release during machine stop cycles. When machine stop is activated, the pressures of the anilox rollers from the plate cylinders are released immediately in order to stop ink transfer on the plates. The plate rollers pressures against the web, are released later after a pre-selected time to permit complete ink transfer on to the web, to get a clean plate when the machine stops. The throw-off are activated by the four servo-motors used for the decks positioning system and for the printing pressures adjustment. The system ensures the return of the printing rollers in the correct position by a control carried out throughout encoders. The throw-off are activated independently or simultaneously for all the printing units, through remote controls located on the machine main control panel. The simultaneous insertion at machine start up, and the release during machine stop cycle, is automatically activated for all the pre-selected printing units. Electronic lock down of the printing units, via the four servo-motors used for the decks positioning system. The lock down system is always active and is automatically deactivated when positioning system or printing pressures registrations are operated.

AUTOMATIC DECKS POSITIONING SYSTEM Printing decks are moved to their printing position automatically, depending on the repeat lengths selected. Each printing unit is moved throughout two high precision ball screws and driven by four servo-motors. 2 motors control the movement of each plate cylinder supports (1 motor each supporting side), 2 motors control the movement of each anilox cylinder supports (1 motor each supporting side). The position of each support, on each side, is precisely controlled by an encoder mounted on each motor. All printing units selected are moved simultaneously. Operator decks positioning system interface is by the central industrial processor of the machine. Print to print pre-registering system. Registering system used to minimize the distance to length register position of the plate sleeves mounted on the requested printing units, at the start of the machine. This system allows fast set up of the length registration and considerably reduces film scrap during start up procedure. The system requires an accurate positioning of the plates, with a precise circumferential alignment to a reference mark located on the supporting sleeve. A cavity on one edge of the sleeves must be provided to fit on a reference pin located on the supporting mandrels.

The pre-registering system is controlled by the central processor used for the automatic decks positioning which automatically prepares all the sleeve mandrels in phase at machine start up

DRYING SYSTEM The drying fans, the heat supplying units, the final drying tunnel and part of the entire ducting system of the dryers, is mounted on a steel framework located on the top of the machine and connecting the printing stand to the out-feed and chill roll assembly. A walkway, accessible from the ground by a ladder, is integrated in the steel structure assembly for ease of service for the units mounted on this section.

DRYING SYSTEM BETWEEN THE PRINTING UNITS Air box distributors mounted on the printing section, one after each printing unit excluding the last one. The box distributors are constructed in steel, and the air is blown onto the printed film by airstreams transversal to the web running direction. Exhaust cavity integrated for the evacuation of the air soaked of solvents. Edges protected by rubber seals to avoid air flows outside the drying area, and for proper evacuation throughout the exhaust system. One fan to supply the necessary air for drying. One separate fan to exhaust the air soaked of solvents. Maximum capacity of the fans as reported below. Ducting system to connect and distribute the air to all air boxes on the printing section. Manual dampers to regulate the air flow, inlet and exhausted, on each air box individually. Supports of the distributors permit the registration of the distance from the film. Easy clamping system to permit removal of the distributors for inspections and cleaning operations.

HEATING SOURCE The drying air is heated by modular electric resistant heaters, 20 kw. each, with manual insertion through remote controls. The insertion of different numbers of resistant heaters, allows the regulation of the air temperature. Maximum temperature increase (ΔT), 60°C. WIDTH (cm.):100-140 INFEED BLOWER (Nm3/h):7000 OUT FEED BLOWER(Nm3/h):7800 AIR SPEED (m./sec.): 47 POWER (Kw. / Kcal./h.):140/120.000

FINAL DRYING TUNNEL Closed type drying tunnel composed by 3 sections with integrated distributing chambers, mounted after the printing section. The tunnel is constructed in steel, and the air is blown onto the printed film by airstreams transversal to the web running direction. Exhaust cavity integrated for the evacuation of the air soaked of solvents. Edges protected by rubber seals to avoid air flows outside the drying area, and for proper evacuation throughout the exhaust system. One fan to supply the necessary air for drying. One separate fan to exhaust the air soaked of solvents. Maximum capacity of the fans as reported below. Ducting system to connect and distribute the air to final tunnel. Manual dampers to regulate the air flow, inlet and exhausted, on each chamber. Tunnel equipped with a pneumatic opening system to permit inspections and cleaning operations.

OUT-FEED TENSION CONTROL Chill roller driven by a servo motor to maintain a constant tension of the film, through the path coming from the printing section. Dancer roller system, or double load cell system depending on machine and film specifications, for the tension control. Rubber covered nip rollers, on the chill roller, controlled laterally by pneumatic cylinders with independent manual adjustable pressure. The supports also enable independent manual regulation of the pressure of each individual nip roller.

IMAGE INSPECT Remotely controlled automatic mobile platform for video camera movement inspection The video lens is composed of high-resolution chips to observe the printing effect

AUTO PAPER SPLICING REWINDER

TYPE AND STRUCTURE Twin axis, shafted type, unwinder for reels of maximum diameter 800 mm(film). Rewinder reel mandrel external diameter 96 mm (3” air shaft mandrel) Frames complete with base for jacking screws and holes for levelling and securing to the floor. The supporting structure is fixed on the rotating tower to realize the positioning of the material roll The mandrel horizontal support chuck can be opened manually in the axial direction quickly and conveniently. Equipped with a safety system that can automatically lock the chuck to avoid danger

WINDING AXIS CONTROLS Winding axis are centre driven by A.C. motors. Tension control of the unwind axis by dancer roller system with pneumatic reaction, and rotary potentiometer. Hand wheel for axial adjustment, the maximum adjustment amount is 20mm.

REEL LOADING Electric reel loading

OPERATOR INTERFACE AND CONTROLS

MAIN CONTROL PANEL Control panel comprised of a steel cubicle, ergonomically designed in order to supply maximum operative comfort, connected to the machine by electric wires protected by insulation and laid into a proper ducting system. The control panel contains the push buttons, selectors, instruments and all necessary controls, for the main machine controls and set up operations.

COMPUTER OPERATOR INTERFACE Operator interface by industrial processor using Windows software. The system enables future upgrading and expansions. The hard disk permits data recording of each job (see list of parameters recording capability). Equipped with touch screen, mouse and keyboard. Automatic fault detection Remote control

MAIN SPARES ELECTRIC 1WEB GUIDE: ST 3MONITOR:INDUSTRIAL DISPLAY 4SWITCHING POWER SUPPLY:MULL/CARLO/SCHNAIDER 5CONTACTOR:LG 6CONTROL BUTTON:FUJI 7PHOTOELECTRIC SENSORS:LEUZE/TURCK GERMANY 8MAIN DRIVE SERVO MOTOR:REXROTH GERMANY 9UNWINDER/REWINDER/OUTFEED TENSION FLOATING CYLINDER:AIRTAC

ATTENTION: IF THE USER'S LOCAL SAFETY REGULATIONS DIFFER FROM THOSE USED BY THE MANUFACTURER, THE USER NEEDS TO PROVIDE A FULL SET OF INSTRUCTIONS AND BEAR THE COSTS OF MACHINE MODIFICATION. MACHINE MODIFY MAYBE DELAY THE DELIVERY TIME.

DOCUMENTATION

Full sets of description, Includes installation operations and routine maintenance, electrical, pneumatic, and hydraulic diagrams. User must strictly follow the contents of these documents. The manufacturer is not responsible for any results If the user does not operate the device correctly according to the instructions. The user should notify the manufacturer immediately when the machine is abnormal, otherwise the user will bear the results by himself.

THE FOLLOWING CONFIGURATIONS AND SERVICE ARE NOT PROVIDED Lifting device for anilox roller and plate cylinder Anilox roller washing machine Waste gas from drying system exhaust pipe Air compressor, gas pipeline connected by air compressor and pneumatic device Air compressor, containers, Compressed air treatment equipment and related accessories. Power cables and wires input to the machine Fire equipment Any form of land construction All kinds of oil Thermal insulation and sound insulation Solvent volatilization treatment and recovery Others not listed

REMARK

DONGHANG company is qualified to make the necessary design changes without affecting the performance of the machine

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