Used 90" New Era Converting Coating, Laminating and Embossing Line

New Era Coating, Laminating & Embossing Line (2021) — 90 in Web

• — Process materials: Three-ply film/fabric/film laminations from 2.7 - 6.7 oz/yd² woven PET, woven PP, woven fiberglass, nonwoven PET, and woven nylon fabrics combined with 1 - 8 mil PVC and 1 - 3 mil PTFE films; PET up to 10 mil plus PP, urethane, and aluminum provisioned as future materials
• — Web width & speed:
  • — Web width: 61 - 90 inches
  • — Process speed: 4 - 40 yards per minute
  • — Gear-in speed: 45 yards per minute
• — Coating process: Two direct-gravure stations (forward and reverse) for solventless, 98%-solids adhesives at 5,000 - 60,000 cps, applying 0.909 - 1.01 oz/yd² wet laydown at 100% coverage across 60 - 90 inch coating width
• — Coating station components:
  • — Impression roll: 12 inch air-mandrel with 60 - 65 durometer EPDM sleeve
  • — Gravure roll: 12 inch diameter × 96 inch face, duo-flow, temperature-controlled (300°F maximum oil)
  • — Doctor blade: Pneumatically loaded with adjustable wiping angle
  • — Coating pan: Oil-heated stainless steel (250°F maximum)
  • — Nip adjusters: Dual-range with dial indicators
  • — Service mandrel: Provided for off-line sleeve work
  • — Enclosure: Safety-interlocked aluminum frame with exhaust fan
• — Laminating & embossing section: Film/fabric/film joining, preheat, embossing, and cooling with hydraulic nip loading
• — Laminating/embossing components:
  • — Preheat drum: 36 inch double-shell chrome drum
  • — Lay-on rolls: Two 8 inch EPT rubber rolls, 55 durometer
  • — Stripper roll: 5 inch chrome stripper roll
  • — IR heater panel: 14 kW, three-zone
  • — Embossing nip: Heavy-duty, hydraulically loaded with ceramic-coated double-shell embossing roll and 15 inch EPT-covered impression roll (70 - 75 durometer)
  • — Nip pressure: Up to 500 pli with 0 - 0.25 inch manual laminator gap control
  • — Temperature capability: Up to 482°F
  • — Embosser stripper/cooling roll: 8.5 inch roll
  • — Cooling rolls: Three 24 inch double-shell rolls
• — Fabric unwind system: Dual-position turret unwind with automatic edge guiding and accumulator for zero-speed splices
• — Fabric unwind details:
  • — Turret positions: Dual-position with four safety chucks
  • — Airshafts: Two 3 inch OD airshafts
  • — Maximum roll diameter: 30 inches
  • — Maximum roll weight: 2,000 lbs
  • — Core size: 3 inch ID, 4 inch OD cores
  • — Edge guiding: Automatic ±3 inch edge guiding
  • — Accumulator: 90 foot nine-roll accumulator with AC vector tension control and pneumatic web clamp for zero-speed splices
• — Fabric conditioning section: Heated pull roll/conditioning section with 16 inch double-shell, spiral-wrapped chrome roll for fabric pre-shrink before lamination
• — Film unwind systems: Two-position, horizontal side-by-side units with dual-direction unwinding and manual zero-speed splices (designed for future full-line-speed automatic splicing)
• — Film unwind details:
  • — Maximum roll diameter: 24 inches
  • — Maximum roll weight: 1,500 lbs
  • — Core size: 3 inch ID, 4 inch OD cores
  • — Tension control: Force-transducer tension control with ultrasonic diameter sensors
  • — Edge guiding: ±3 inch linear-rail edge guiding
• — Turret winder system: Dual-position turret winder with electro-mechanical web guiding ahead of the winder and zero-speed manual transfer
• — Turret winder details:
  • — Turret positions: Dual-position with four safety chucks
  • — Airshafts: Two 6 inch OD airshafts
  • — Maximum roll diameter: 36 inches
  • — Maximum roll weight: 3,600 lbs
  • — Core size: 6 inch ID, 7 inch OD cores
  • — Winding tension: 60 - 180 lbs
• — Controls & drives: Allen-Bradley safety PLC, AC drives, inverter-duty motors, and operator interfaces for full line control
• — Control system details:
  • — PLC: Allen-Bradley ControlLogix 5580 (L81ES) safety PLC with Point I/O
  • — Drives: PowerFlex 755 DC-bus drives with braking resistor and PowerFlex 527 drives
  • — Motors: Marathon Blue Max inverter-duty encoder motors, 1 - 10 HP
  • — HMIs: PanelView Plus 7, 10 inch main operator panel plus two 7 inch local panels
  • — Local controls: Local I/O panels and pushbutton stations
  • — Safety scanner: Two-zone safety scanner at the winder turret
• — Static control: Ion Systems IQ Power static control with three BPS power modules and six Speed-T neutralizing bars
• — Utilities: 480 V / 3-phase / 60 Hz electrical, 80 PSIG pneumatics, and hot oil up to 390°F
• — Machine construction: Four OSHA-compliant operator platforms, steel superstructure supporting process sections, and dead-shaft hard-coat anodized aluminum idler rolls (6 inch minimum) throughout