flexographic printing bubble wrap cast stretch film

Transcription

MASTERBATCH
& COMPOUND
CAST
STRETCH FILM
BUBBLE WRAP
FLEXOGRAPHIC
PRINTING
PLASTIC MACHINERY?
TORNINOVA DOES IT BETTER!
2
Masterbatch
& Compound
Machinery
Cast Stretch
Film
Machinery
Air Bubble
Film
Machinery
Flexographic
Printing
Machinery
pag. 14
pag. 22
pag. 30
pag. 55
3
Milestones
Plastic, Passion and Technology, together.
1925
The experience of the
Mencarelli family in
the mechanical field
begins.
4
1969
Birth of Torninova
“Costruzioni
Meccaniche”
1993
Our First
Air Bubble Film
Machine
2005
We go Global
with Torninova
Corporation
2010
Over 250 working
machines on over
five continents
Today
Our new
Headquarters
5
The experience of the Mencarelli family in the
mechanical field began early in the last century,
in 1925. At the time of its foundation in 1969,
Torninova’s experience had already developed,
leading the company to specialize in technical
support for flexographic printing machines and
extrusion lines.
Later, in 1993, Torninova started designing and
manufacturing air bubble film machines.
The company has always been highly involved
in research and development in order to offer
its customers versatile and flexible systems that
combine the most innovative electronic
and mechanical technologies.
A commitment to meeting the highest possible
standards has led the Torninova Corporation
to design its complete range of air bubble film
machines, stretch film machines, flexographic
printing machines, masterbatch & compound
machines, blown film machines and to acquire
top know-how in the field, now available to its
customers.
About Us
Global Markets
Market Leaders for nearly 40 years Torninova Corporation provides technology
that expands the possibilities of your company and your life.
8
Conferences
& Fairs
K
PLAST
INTERPACK
Dusseldorf / Germany
Milan / Italy
IPACK IMA
STRETCH AND
SHRINK FILM
DRUPA
Milan / Italy
Europe
9
Production
Torninova Corporation provides technology that expands
the possibilities of your company and your life.
New Plant
January 2013: Torninova Corp. begins
production at its new hi-technology
13.000 m2 Plant in Bastia Umbra.
The Plant provides 746 kWp
from its own solar power system.
10
Torninova Corporation - located in Bastia Umbra
(Perugia) in Italy - is a company which
specializes in designing, developing and manufacturing machines for air bubble film, stretch
film, masterbatch & compound, blown film and
flexographic printing production as well as
converting machines for each market.
Thanks to our patented systems and our
technicians with over 40 years of experience,
Torninova Corp. provides the best solutions in a
demanding market and guarantees a high-tech
end product.
Continuous technological advancement and
ever increasing commitment enables Torninova
Corp. to operate all over the World-efficiently,
professionally and more importantly, effectively.
Supported by its young, dynamic yet experienced staff, the company is able to produce
machines tailored to customer needs, paying
particular attention to production versatility.
Innovative design ideas, manufacturing
precision, highly reliable components and the
constant support of our technicians, ensure our
customers receive a solid, long-term service.
These features mean that our company has
become a market leader, with hi-tech
machines all over the World.
Italy, Qatar, Spain, India, United States, Japan,
United Kingdom, Germany, Canada, Russia,
France, Argentina, Australia, Saudi Arabia,
China, Indonesia, South Africa, Mexico,Turkey,
South Korea, Brazil.
11
Technical
Assistance
12
CALL CENTER
Torninova Corp.’s integrated use of pioneering mechanics, electronics and information
technology is the company’s real strength and
guarantees efficient after-sales service.
The diagnostic software and display panels on
the machines ensure the operators mantain
high levels of efficiency.
Open during working hours (8 am - 12 pm and 2
pm - 6 pm GMT+1, Monday to Friday), the call
center offers immediate assistance and provides guidance throughout the process always
putting you in direct contact with a qualified
engineer able to resolve your particular issue.
TELESERVICE
SCHEDULED MAINTENANCE
With the development of new technologies and
its skilled staff, Torninova Corp. can provide
its customers with a remote, internet-based
supervisory support system which carries out
machine diagnostics and any necessary
software modifications.
Our technicians perform scheduled
maintenance on our machines.
ON SITE SERVICE
SPARE PARTS
The company is constantly attentive to customer needs, so specialized technicians are
available to provide assistance at the machine
installation site. Torninova Corp. is able to
ensure rapid intervention.
Torninova Corp. guarantees its customers rapid
supply of spare parts that may be needed
during a machines’s entire life-cycle.
13
Masterbatch &
Compound
Machinery
14
15
MASTERBATCH &
COMPOUND MACHINERY
Torninova Corporation has a strong history of
innovation and development of technologically
advanced solutions modelled on customer
needs; the twin-screw corotating extruder, like
all Torninova Corp. installations, is based on an
attentive and specific design and guarantees
reliability, user-friendliness, low maintenance
costs, high performance rates and energy
saving. The Torninova Corp. range includes:
A) Extrusion line for colored masterbatches,
for additives and multifunctional types.
B) Extrusion line for compounds of
technopolymers and polymeric alloys.
The Torninova Corp. installations are completed
by all accessories and components necessary to
carry out the compound and masterbatches production, such as the degassing groups, the side
feeders of polymer mixes or additive charges
and the dosing units for the additives and the
pigment powders.
16
COROTATING TWIN-SCREW EXTRUDERS
The Torninova Corp. twin-screw corotating
extruders offer advanced and versatile solutions
for the production of tecnopolymer compounds,
polymeric alloys and colored masterbatches, for
additives and multifunctional types.
Screws
The screws are entirely modular according to
the needs and the work type; the geometric
configuration of the screw is featured with selfcleaning elements mounted on splined shafts
even HT (high torque).
All components of the Torninova Corp. extruders
are treated in every design and technological
detail to increase their efficiency and durability,
enabling an immediate major benefit in terms of
energy savings.
The modular elements used for the geometric
composition of the screw, either used for
transport, kneading blocks, mixing or special,
are bilobed or trilobed mounted along with the
bilobes and can be realized with high OD/ID
ratio.
The Torninova Corp. corotating twin screw
extruders have screw diameters available from
30 mm to 92 mm and process lengths reaching
up to 42D. Larger diameters are also achievable
on request.
The screw’s geometry
The screw’s geometry is designed to blend and
uniform the compound or masterbatch viscosity
in order to reduce the thermal and mechanical
stress which may deteriorate the product quality, but also to ensure a maximum dispersion
and distribution of additives and pigments in
the polymeric matrix.
Cylinders
The cylinders are featured with modular
elements, providing the possibility to have an
internal insert in special steel or bi-metallic
alloys which increases its resistance to wear,
to abrasion and corrosion.
The rectangular shape of the cylinder elements
ensure that the temperature distribution inside
the chamber is constant and homogenous.
Cooling and thermo-regulation
The cooling system of the barrels composing
the extruder cylinder is specifically conceived
and designed by Torninova Corp. to achieve
a better control of the temperature on both
screws, along with a high energetic efficiency.
The integration of the cooling system of the
barrels with the double-intervention thermal
regulation and integration device guarantees
the same process temperature on both screws,
ensuring the optimization of the extrusion process, especially for those compounds that are
thermo-sensitive to the temperature.
Construction
The transmission group, composed of the
electric motor, the joint limiting the torque and
above all the gearbox, are highly-technological
components used by Torninova Corp. and
feature twin-screw extruders because they
guarantee a precise transmission and distribution of the power needed for the compounds
and masterbatches. The transmission group and
the extruder cylinder are fixed to a frame on a
thermo-welded base; the cylinder can be supported by two saddle supports (three for special
applications). The electric motor is an AC type,
with a high electric and mechanical efficiency,
but it is possible to use new technologies on
request as well (e.g. new motor-reducers).
The electric panel is fitted with a control unit
with MMI-interface and with the possibility to
connect the production data logger by means of
an Ethernet input.
Production process completely controlled
through a simple and user-friendly interface
with the possibility of remote assistance and
data logger through Internet or Ethernet.
The double intervention thermoregulation is
integrated in the main control system with a
preheating automatic system start production
and it permits to obtain ∆t of 1/ 2°C in
comparison to the desired set-point.
A solution with independent thermoregulators
is available as an alternative.
17
DETAILS
.1
.1
.2
.3
.3
.4
.5
.6
1. BUSH INSERT
2. SELF-CLEANING SCREW ELEMENTS
3. RECTANGULAR BARRELS
4. EXTRUDER SCREW
5. CONTROL PANEL
6. EXTRUSION HEAD FOR MASTERBATCH
7. HIGH TORQUE GEARBOX
8. SIDE FEEDER
18
.7
.8
TECHNICAL DATA
& ACCESSORIES
The Torninova Corporation installations are complimented by accessories and components,
necessary for the extrusion process of technical compounds and masterbatches, such as:
LATERAL
FEEDER
LATERAL TWIN-SCREWED
EXTRUDERS
DOSING
SYSTEMS
Lateral feeders for mineral charges and
polymers in general, both in powder and in
granules.
Lateral twin-screwed extruders for the
plasticization of mixtures of additives
and polymers.
Dosing systems for the gravimetric and
volumetric feeding of mixtures of additives
in plastic powder or granules.
PUMP TO INJECT
HIGH-PRESSURE LIQUIDS
DEGASSING
GROUP
VENT PORT
STUFFER
Pump to inject high-pressure liquids for
plasticizing oils (e.g. pharmacopoeia, cosmetics and special applications) or denaturalized
paraffin oils for non-food use.
Degassing group of volatile substances, monomer residuals and humidity by means of single
units or custom-designed systems.
Vent port stuffer for a timely and accurate
extraction of volatile substances.
THE RV™ MACHINES
The RV™ machines can be equipped with screw shafts mod. High Torque for other specific torques.
MB stands for masterbatch production and CP stands for compound.
RV 40
RV 50
RV 58
RV 70
RV 83
RV 92
Extruder ø (mm)
Power (kW)
Machine
RPM
MP
CP
MB
CP
MB
CP
MB
CP
MB
CP
MB
CP
300
40
50
60
100
100
160
130
235
250
450
355
500
600
60
80
80
150
170
300
250
380
320
580
480
830
RV™
19
EXTRUSION MACHINE
FOR MASTERBATCH
The Torninova Corporation twin-screwed corotating extruders for the production of colored masterbatches, additives and multifunction types are treated
in every design and technological detail and ensure:
A) A high energetic efficiency, allowing an immediate benefit in terms of energy saving.
B) Optimisation and timely control of the screws/cylinder system temperature allows reduction in thermal stress, especially for those pigments,
additives and polymers that are thermo-sensitive to temperature.
C) A maximum dispersion and distribution of additives and pigments in the polymeric distribution.
B
C
D
A
E
G
L
F
A) RV twin screw corotating extruder
B) Gravimetric feeder for polymers
20
C) Gravimetric feeder for additives
D) Gravimetric feeder for fillers
H
F
E) Gravimetric feeder for fibers
F) Side feeders
G) Venting system
H) Cooling bath
I
I) Air dryer
L) Strand cutter
EXTRUSION MACHINE
FOR COMPOUND
The Torninova Corporation twin-screwed corotating extruders for the production of techno-polymer compound and polymer alloys ensure:
A) a high quality of the extruded product along with a high energy efficiency.
B) through the timely and constant optimization of the temperature of the extrusion process it is possible to reduce the degradation for those polymers
and additives that are sensitive to thermal and mechanical stress, ensuring at the same time their maximum dispersion and distribution.
B
C
D
A
F
I
G
E
D) Gravimetric feeder for fibers
B
E) Side feeders
F) Venting system
G) Cooling bath
H) Air dryer
H
I) Strand cutter
C
D
A
D
F
G
E
D) Gravimetric feeder for fillers
E
E) Side feeders
F) Venting system
G) Cutting System
21
22
Stretch
Film
Machinery
23
PERFECTLY INTEGRATED,
HIGHLY FLEXIBLE SYSTEM
Torninova Corporation brings to market the
very best in stretch film production technology
thanks to its thorough research and development in collaboration with Italian and American University professors, renowned European
manufacturers of extruder components and
experienced figures from the field of extruded
stretch film.
The SWIFTCOOL™ chill-roll unit’s dual cooling
rollers guarantee total material stabilisation.
A dual-chamber vacuum box with automatic
die adjustment and an integrated x-ray device
to measure material thickness (guaranteeing
accuracy even with coloured stretch film) offers
the finest and fastest control features for the
film extrusion process.
Some of our Client partners (Italian and
foreign) have also supported our research and
development phases by purchasing prototype
systems to scientifically test and continuously
monitor each single component and process.
Customers can choose from three different
winding systems:
During such tests, appropriate adjustments
were made in response to real time controls
under actual production conditions.
The result is a perfectly integrated system of
cutting edge components, calibrated and arranged into a compact, high performance cast line
that provides maximum flexibility with minimum
energy consumption.
Consider some hallmark components of the
COMPACT STRETCH™ system:
The LLPOWEREX™ extruder series with
screw profiles (AC motors and infrared heaters
ensure limited maintenance and low energy
consumption) have been specifically developed
to guarantee perfect LLDPE extrusion.
24
The fast and reliable QUICKSILVER-4S™
winder (rewind cycle time of 10 seconds)
directly rewinds stretch film into rolls on 2-inch
or 3-inch cores (suitable for hand and machine
use), in formats ranging from 100 mm to 250
mm, 450 mm and 500 mm.
The QUICKSTANDARD-2S™ winder is the
best solution for production of machine and
jumbo rolls up to a maximum diameter of 500
mm, on 3-inch cores.
The QUICKGOLD-4S™ is Torninova’s patented, universal, all-in-one evolution of hand and
machine roll winders. Maintaining the same
characteristics, it can also produce jumbo rolls
up to a maximum diameter of 420 mm. The winding cycle still remains extremely fast (around
15 seconds) without compromising the production of hand rolls, even at very high speed.
Optional roll handling features can be integrated into each winder to assure steady, highspeed cast stretch film production. For instance,
the automated packaging system packs hand
rolls in a 6-unit cardboard box.
Another component which sets the machine
apart from others is the FULLFEED™ trimming
system with a force-feed device specifically
designed for the type and quantity of trimming
required by a stretch film machine. A suction device completely recovers all chopped
trimmings for re-use by the main extruder line,
thus preventing variations in pressure and film
thickness even in the event of frequent changes
in production and operating speed.
The FULLFEED system eliminates potential nonuniformities in film thickness, including those in
longitudinal sections.
On request, instead of the flake re-feeding
system, it is possible to equip the COMPACT
STRETCH with a recycling machine that completely re-granulates edge and bleed trims.
INTEGRATED
SOLUTIONS
FAST
AND RELIABLE
SOLUTIONS
AUTOMATED
SOLUTIONS
The new COMPACT STRETCH series is not a
simple combination of standard components
from various processes but, on the contrary, is a
well-developed, well-tested, made-to-measure
integrated system affording maximum simplicity
and flexibility in the production of high-quality
rolls of co-extruded cast stretch film.
Everyday, producers of stretch film have to face
the increasing cost of raw materials, labour and
energy. Producers thus find themselves in an
increasingly competitive market in which prices
are constantly driven down.
All machines are equipped with a PLC-managed
control system which runs touch-screen operated supervisory software for programming and
managing the entire system.
In these circumstances, profitable production
is only attainable with a system that guarantees elevated and continuous production, 24
hours a day. Torninova Corp. has focused all
of its attention on this aspect, developing and
designing affordable systems for high-output
production. The result has been an increase in
sales and satisfied Clients in a very competitive
market.
The operator can use customized formulas to
manage production according to the required
percentage of co-extrusion and the needed
production speed.
Via Internet, the machine can be remotely
diagnosed to provide immediate customer
assistance.
25
COMPACT
STRETCH 2.000™
The COMPACT STRETCH 2.000 series,
characterised by an incredibly compact design,
is a powerful cast co-extrusion line for the production of excellent, multi-layer PE stretch film.
Cast stretch
film machinery.
Various co-extrusion configurations and production outputs can be chosen according to specific
customer needs (3, 5, 7-layer and multi/nano
layer configurations). An auto-adjusting flat
die, a double chill-roll system with inner axial
“torque”motors, an integrated thickness measuring device and super compact gear motors on
the extruders are only a few of this machine’s
special features.
For the production of:
- hand wrap film - machine wrap film
- jumbo wrap film - cling film
The COMPACT STRETCH 2.000 is an “integrated-system” developed to ensure maximum
production reliability, minimum energy consumption, a user-friendly automation interface
and extensive control of the winding process.
The results are excellent rolls of stretch film (including “down-gauged” film) in hand, machine
and jumbo formats.
26
OPTIONAL EQUIPMENT
QUICKSILVER-4S winder
hand and machine rolls
QUICKSTANDARD-2S winder
machine and jumbo rolls
AUTOMATIC HAND-ROLL packaging system
TECHNICAL DATA
RAW MATERIALS
LLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend
and PP pellets
WEB WIDTHS
2.000 mm (production of rolls in widths: 125,
250, 450, 500 and 1.000 mm)
NET OUTPUT
Up to 1600 kg/h
MECHANICAL SPEED
Max. 800 m/min
LAYER CONFIGURATIONS
3, 5, 7 and multi/nano layer
FILM THICKNESS RANGE
7 - 50 µm
ACTUAL POWER CONSUMPTION
< 0,40 kW/kg
RAW MATERIALS HANDLING
By pneumatic loaders or gravimetric dosing
system of up to 6 ingredients for each extruder
EXTRUDERS
Diameters: 55, 70, 100, 120 and 160 mm
L/D ratio: 32 D
Barrel:
- standard grooves
- helical grooves for high extruder output
(+30%)
Drive:
Gearbox and AC motor or internally cooled gear
motor with a compact layout of either 2 or 4
three-phase, asynchronous motors for each
gear motor
EDGE TRIMMING
Double-blade, in-line cutting of edge and bleed
trims. Granulator and extruder force-feed
recycling or dedicated regranulation unit.
WINDER
Shafted double-turret systems for 2-inch or
3-inch cores
- QUICKSILVER-4S for hand and machine rolls
- QUICKSTANDARD-2S for machine and jumbo
rolls
Automatic loading of cores and automatic
unloading of finished rolls with balanced weight
control; automatic packaging system for hand
rolls available on request.
AUTOMATION
SIMATIC WinCC;
Three user-friendly touch screens.
CHILL-ROLLS GROUP
1.200 mm diameter, matted or polished chromed-surface primary chill-roll; 450 mm diameter
chrome-surfaced secondary chill-roll.
27
COMPACT
STRETCH 1.000™
Cast stretch
film machinery
- hand wrap film - machine wrap film
- jumbo wrap film - cling film
TECHNICAL DATA
RAW MATERIALS
LLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend
and PP pellets
WEB WIDTHS
2.000 mm (production of rolls in widths: 125,
250, 450, 500 and 1.000 mm)
NET OUTPUT
Up to 850 kg/h
MECHANICAL SPEED
max. 800 m/min
LAYER CONFIGURATIONS
3, 5, 7 and multilayer
FILM THICKNESS RANGE
7 - 50 µm
The COMPACT STRETCH 1.000 series is the
World’s smallest and most reliable 1-meter
stretch film machine. All components of this
extremely compact, cast co-extrusion system
(occupying less than 75 m2) have been specifically developed to enhance the flexibility
offered by the machine’s specific dimensions
as well as to ensure production of the highest
quality stretch film with the utmost reliability
and energy efficiency.
The COMPACT STRETCH 1.000 produces rolls
of stretch film in hand, machine and jumbo
formats at surprisingly high outputs (850 kg/h),
all without compromising product quality
(available in 3, 5, 7-layer and multi/nano layer
co-extrusion configurations). An auto-adjusting
flat die, a double chill-roll system with inner
axial “torque” motors, an integrated thickness
measuring device and super compact gear
motors on the extruders, are only a few of this
machine’s special features.
28
ACTUAL POWER CONSUMPTION
< 0,45 kW/kg
RAW MATERIALS HANDLING
By pneumatic loaders or gravimetric dosing
system of up to 6 ingredients for each extruder
EXTRUDERS
Diameters: 55, 70, 100, 120 and 160 mm
L/D ratio: 32 D
Barrel:
- standard grooves
- helical grooves for high extruder output
(+30%)
Drive:
Gearbox and AC motor or internally cooled gear
motor with a compact layout of either 2 or 4
three-phase, asynchronous motors for each
gear motor
CHILL-ROLLS GROUP
1.200 mm diameter, matted or polished
chromed-surface primary chill-roll; 450 mm
diameter chrome-surfaced secondary chill-roll.
EDGE TRIMMING
Double-blade, in-line cutting of edge and bleed
trims. Granulator and extruder force-feed
recycling or dedicated regranulation unit.
WINDER
Shafted double-turret systems for 2-inch or
3-inch cores
- QUICKSILVER-4S for hand and machine rolls
- QUICKSTANDARD-2S for machine and jumbo
rolls
- QUICKGOLD-4S for hand, machine and jumbo
rolls
Automatic loading of cores and automatic
unloading of finished rolls with balanced weight
control; automatic packaging system for hand
rolls available on request.
AUTOMATION
SIMATIC WinCC;
Three user-friendly touch screens.
OPTIONAL EQUIPMENT
QUICKSILVER-4S winder
hand and machine rolls
QUICKSTANDARD-2S winder
machine and jumbo rolls
QUICKGOLD-4S winder
hand, machine and jumbo rolls
AUTOMATIC HAND-ROLL packaging system
OPTIONAL
OPTIONAL
OPTIONAL
QUICKSILVER-4S™
QUICKGOLD-4S™
Hand and machine
roll winder
Hand, machine and jumbo
roll winder
AUTOMATIC
HAND-ROLL
PACKAGING SYSTEM
The genuine, completely automatic Quicksilver4S winder is the fastest stretch film turret winder capable of winding both hand and machine
roll formats (2 and 3-inch cores).
The patented Quickgold-4S winder is the most
advanced turret winder for cast stretch film
machines.
The automatic packaging system is the ultimate
downstream accessory for stretch film machines.
This single-module universal winder includes all
the characteristics of the Quicksilver-4S but is
capable of producing rolls of stretch film in all 3
possible formats: hand, machine and jumbo (2
and 3-inch cores).
With the addition of this packing station, any
stretch film machine can achieve fully automatic (no operator), “granules-to-box” production
of stretch film hand rolls.
The specially developed automatic system
for core loading and roll extraction ensures a
very short cycle time (10 seconds) and perfectquality film rolls. Very sophisticated electronic
controls and algorithms, customised mechanical
components and unique materials used on the
contact and satellite rolls, allow winding of very
thin film onto very thin cores-with flat edges
and no wrinkles or entrapped air.
This winder is suitable for widths of up to 3
meters and can be installed on any new or
existing stretch film machine another valueadded upgrade.
A precision scale also checks the production
weight of each roll. The result is high-output of
perfect, ready-for-sale rolls, even for the most
demanding markets.
The automatic procedure builds the cardboard
box, fills it with 6 finished rolls, and lastly, tapes
the package shut.
The closed box is then delivered to the end of
the line for stock handling. This system can
be implemented in any size machine and can
manage rolls coming from 2 or more lines
simultaneously.
This winder is suitable for widths of up to 3
meters and can be installed on any new or existing stretch film machine a truly value-added
upgrade.
TECHNICAL DATA
TECHNICAL DATA
TECHNICAL DATA
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Web widths: from 1 to 3 m
Mechanical speed: 800 m/min
Film thickness range: 7 - 50 µm
Core diameters: 2 and 3 inch
Min. winding tension: 30 N
Min. cycle time: 14 s
Automatic core loading and
extraction of finished rolls
Web widths: 1 and 1,5 m
Mechanical speed: 800 m/min
Film thickness range: 7 - 50 µm
Core diameters: 2 and 3 inch
Min. winding tension: 30 N
Min. cycle time: 17 s
Automatic core loading and
extraction of finished rolls
• Max. diameter for jumbo rolls:
420 mm (50 kg/each)
Output: approx. 8 boxes/min
Carton storage capacity: 100 pcs.
Adjustable carton magazine
Boxes opend and moved by vacuum
Automatic box filling station with
interchangeable groups
• Quick production changes with minimum adjustment
• Box closure by means of self-adhesive
taping group
29
30
Air Bubble
Film
Machinery
31
HI-TECH AIR BUBBLE FILM
MACHINERY
Today Torninova Corporation is synonymous for
Hi-Tech bubble wrap machinery all around the
World.
For over 20 years Torninova Corp. has been engaging in the production of top-level equipment,
presenting state-of-the art technology applied
to air bubble film production lines: all of this
has been possible and realized thanks to the
Company’s constant engagement in finding
innovative, better performing and cost-saving
processes and solutions.
Torninova’s know-how is also based on the
willingness to listen to reccomendations and
suggestions provided by our clients, who have
been helping us to enhance and adapt every
single installation, making them suitable for
each project’s specific necessity and technical
requirements.
32
Completely focused on this specific line of
equipment, Torninova Corp. strives to take the
best possible advantage of market feedback
and requirements, updating its equipment to
comply with the newest regulations each of our
lines components are homogeneous and perfectly connected to their counterparts, resulting
in a perfectly integrated vanguard installation
for the production of air bubble film.
All machines are modular and for this reason
the whole Torninova Corp. system is easy to
upgrade, based on each Client’s specific needs,
and applicable on existing machines even if
supplied by other companies.
Amongst Torninova’s outstanding specialized
bubble foil production equipment the following
lines deserve mention for their very special
features:
The COEX BUBBLE (10)™, an authentic
masterpiece, represents the most advanced
available technology for the production of
high-performance air bubble film. In fact, the
special co-extrusion configuration allows
the production of a symmetrically structured
(ABCBA+ABCBA), multilayer air bubble film
containing an integrated air retention barrier
of Nylon-PA6 (layer C). The result is the production of an ultra-light bubble foil with enhanced
cushioning and protective properties, far superior to the same-weight mono-extruded bubble
wrap film. In practice, better results are ensured
with less material and this means an unbeatable competitive edge in the film market.
The AIR BASIC™ belongs to the family of
the off-line process plants, and is a patented
system based on the hot-air thermoforming
process, which processes LDPE rolls to produce
air bubble film both for technical packaging and
reflective insulation. The specialty of this line,
compared to traditional off-line systems, is that
it significantly reduces energy consumption and
provides maximum production-plan flexibility
with its “stop-on-phase” procedure. The AIR
BASIC series is still one of the most purchased
lines for the production of air bubble film for
technical packaging and reflective insulation.
The TWIN BUBBLE™ is the answer to a new
profitable sector which produces air bubble
film for use as thermo reflective insulation in
costruction applications. Requests from
Customers involved in such specific markets
have moved Torninova Corp. to design and
produce a new patented extrusion system,
called TWIN BUBBLE.
This machine allows the production of multilayer compound (sandwich) bubble foil, PE-foam
and aluminum foil, all in one-single process.
The TWIN BUBBLE system can even produce
flame-retardant materials certifiable for all
different Worldwide Standards.
A solid technical base, constant focus,
continuous development and customised
solutions, make Torninova Corp. the reliable
partner in air bubble film production, ensuring
the most effective and worthy results.
Further, the POWER BUBBLE™, POLYBOLL™
and MAC BUBBLE™ air bubble film production lines complete the Torninova Corp. range.
All Torninova Corp. equipment lines offer highly
developed electronics, mechanical parts
especially designed and created in the
Company workshop and 24/7 teleservice
assistance.
Torninova Corp., a journey of quality and
tradition in plastic machinery which continues
through generations and stands as a guarantee
for Clients Worldwide.
33
COEX
BUBBLE (10)™
high-speed/high-output,
in-line co-extrusion.
The World’s largest packing corporations use
the COEX BUBBLE (10) as it represents the most
advanced technology for in-line production of
air bubble films containing an integrated air
retention barrier.
The COEX BUBBLE (10) is a cast co-extrusion
system with three extruders. It processes
LDPE, TIE and Nylon-PA6 pellets to produce
high-performance, symmetrically structured
(ABCBA+ABCBA), multilayer air bubble film.
air bubble film packaging - reflective bubble foil
insulation - bubble solar pool cover - air bubble film
laminated with PE-foam - air bubble film laminated with
LDPE film - air bubble film laminated with HDPE film - air
bubble film laminated with coated kraft paper - air bubble
film laminated with coated aluminium foil - air bubble film
laminated with MPET film - air bubble film laminated with
printed film - air bubble film laminated with non-woven bubble wrap - etc...
The 10-layer structure allows for integration
of an air-tight, Nylon-PA6 barrier for longer
bubble-air-retention, thus improving the film’s
cushioning and protective properties, even at
reduced thicknesses.
For example, a 35 g/m2 of coex film has the
same resistance of a 60 g/m2 mono film- a
definite competitive advantage!
Especially suitable for technical packaging and
envelopes, the COEX BUBBLE (10) series is fully
automatic and includes touch screen controls
for custom configuration of production recipes.
Thanks to an on-board network connection,
machine function can be remotely monitored via
Internet.
The modular configuration of COEX BUBBLE (10)
lends itself to many useful upgrades, such as
a 3rd layer lamination unit, a perforation unit,
etc...
34
TECHNICAL DATA
RAW MATERIAL
LDPE, TIE and Nylon-PA6 pellets
THERMOFORMING PROCESS
With three cast extruders
WEB WIDTHS
From 1,25 to 3,5 m
FINISHED AIR BUBBLE FILM WEIGHT
min. 25 g/m2 - max. 600 g/m2
MAX. PRODUCTION SPEED
100 m/min
FORMING ROLLER DIAMETER
Ø 450 mm
STANDARD BUBBLE SIZE
Ø 10 x 3 mm spherical
CAST DIE
Two separate dies with feed-block for variable
geometry co-extrusion
CO-EXTRUSION GEOMETRY
base (ABCBA) + bubbles (ABCBA)
REFERENCE Machine
2,5 m - two layers
STANDARD PRODUCTION SIZE
700 kg/h (75 g/m2)
WHY COEX BUBBLE (10)?
Better film performance ensured with less material means an unbeatable
competitive edge in the film market!
STANDARD PRODUCTION SIZE
15.000 m2/h (35 g/m2)
DIAMETER OF SCREW EXTRUDERS:
A= Ø 130 mm L/D=30 (LDPE)
B= Ø 45 mm L/D=30 (TIE)
C= Ø 45 mm L/D=30 (Nylon-PA6)
CO-EXTRUSION AIR BUBBLE FILM
MONO-EXTRUSION AIR BUBBLE FILM
Polyethylene
Tie
AVERAGE POWER CONSUMPTION
170 kW-h
OPTIONAL EQUIPMENT
- TRIPLEX winder
- DUPLEX PLUS winder
- VIR winder
- Third layer extrusion lamination unit
- Third layer diathermic oil lamination unit
- Third layer hot-air lamination unit
- Fourth layer unwinder
- Perforation unit
- Forming cylinders
- Chiller unit
Nylon
Tie
Single-layer
Polyethylene
Polyethylene
Air
Air
1 kg
1 kg
5% thickness
lost after 14 days
50% thickness
lost after 14 days
Note: Independent Comparison
35
POWER
BUBBLE™
The POWER BUBBLE system is the pinnacle of
standard mono-extrusion technology. Thanks to
its power and flexibility, this machine produces
a vast array of air bubble films.
TECHNICAL DATA
in-line mono-extrusion
Starting from an appropriate formulation of
LDPE pellets with HDPE, PP, hexene - octene
LLDPE and mLLDPE, the universal single-screw
extruder produces high-performance, low
thickness materials.
With cast extruder
A single operator can fully control the entire
POWER BUBBLE manufacturing process with
the system’s fully integrated touch screen
controls. Using its on board network connection, the machine’s operation can be remotely
monitored via Internet. The system’s modular
configuration is adjustable for any production
output and lends itself to many useful upgrades, such as a 3rd layer lamination unit, a
perforation unit, etc…
min. 35 g/m2 - max. 600 g/m2
printed film - air bubble film laminated with non-woven -
WEB WIDTHS
From 1,25 to 3,5 m
90 m/min
Ø 450 mm
Ø 10 x 4 mm
CAST DIE
Two separate dies
etc...
REFERENCE Machine
2,5 m / two layers
Standard production size
600 kg/h (75 g/m2)
13.500 m2/h (40 g/m2)
Diameter of screw extruder
Ø 130 mm L/D=30
Average power consumption
125 kW-h
36
RAW MATERIAL
LDPE pellets
OPTIONAL EQUIPMENT
- TRIPLEX winder
- VIR winder
- Perforation unit
- Forming cylinders
- Chiller unit
POLYBOLL™
in-line mono-extrusion,
medium/low production
speeds and outputs
POLYBOLL is Torninova’s authentic entry-level
in-line extrusion system. These machines
process LDPE pellets to produce a wide range
of excellent-quality air bubble films at moderate outputs. With its simplified structure and
no-frills finishing, the POLYBOLL is the most
suitable solution for medium-to-small market
necessities. The POLYBOLL production process
is completely automatic and fully controllable
by a single, un-skilled operator. This machine
allows a new bracket of customers (e.g. air bubble film distributors and converters) to enter and
learn the production market while substantially
containing their up-front investment costs.
printed film - air bubble film laminated with non-woven etc...
The POLYBOLL system is also ideal for air
bubble film manufacturers intending to relocate
production facilities directly in distant, but profitable, new markets, while drastically reducing
transport costs and writing off, in the shortterm, the initial investment. The POLYBOLL
system’s modular configuration lends itself
to many useful upgrades, such as a 3rd layer
lamination unit, a perforation unit, etc…
REFERENCE Machine
2,5 m / two layers
200 kg/h (75 g/m2)
4.500 m2/h (40 g/m2)
Diameter of screw extruder
Ø 95 mm L/D=30
90 kW-h
TECHNICAL DATA
RAW MATERIAL
LDPE pellets
With cast extruder
WEB WIDTHS
From 1,25 to 2,5 m
min. 35 g/m2 - max. 300 g/m2
30 m/min
Ø 270 mm
Ø 10 x 4 mm
CAST DIE
one die with double delivery
OPTIONAL EQUIPMENT
- TRIPLEX winder
- VIR winder
- Perforation unit
- Forming cylinders
- Chiller unit
37
MAC
BUBBLE™
off-line processing
MAC BUBBLE is a traditional off-line system
which processes LDPE rolls for high-output air
bubble film production. A thermoform process
laminates two individual films using Tefloncoated cylinders heated by a diathermic oilcircuit connected to electric heating units.
The result is high-speed air bubble film production with superior lamination quality, even
for films of larger widths. In some cases, the
production speeds achieved by MAC BUBBLE
machines are much higher than those of an
extrusion-based machine, even when starting
from very high thickness films.
The MAC BUBBLE system also has an on-board
network connection which allows machine function to be remotely monitored via Internet and
the system’s modular configuration lends itself
to many useful upgrades, such as a 3rd layer
lamination unit, a perforation unit, etc…
printed film - air bubble film laminated with non-woven -
TECHNICAL DATA
RAW MATERIAL
Rolls of LDPE pellets and coated materials
By diathermic oil cylinders
WEB WIDTHS
From 1,25 to 3 m
min. 35 g/m2 - max. 600 g/m2
65 m/min
Ø 450 mm
Ø 10 x 4 mm
etc...
REFERENCE Machine
2,5 m / two layers
560 kg/h (75 g/m2)
9.750 m2/h (40 g/m2)
85 kW-h
38
OPTIONAL EQUIPMENT
- TRIPLEX winder
- VIR winder
- Perforation unit
- Forming cylinders
- Chiller unit
AIR
BASIC™
medium output/medium speed,
off-line processing
AIR BASIC is Torninova’s patented off-line system which processes LDPE rolls to produce air
bubble film of various bubble sizes for technical
packaging and reflective insulation.
A thermoform process laminates two individual
films using a special heating bar to blow hot-air
over the films. Compared to traditional off-line
systems, this process significantly reduces
energy consumption and provides maximum
production-plan flexibility with its “stop-onphase” procedure. Such special features serve
to significantly reduce inventory, transportation
and energy costs.
Because the AIR BASIC system is so versatile
and easy to use, a single, un-skilled operator
can quickly perform production changeovers
without wasting material at restart. The
on-board network connection allows remote
monitoring of machine function via Internet and
the system’s modular configuration lends itself
to many useful upgrades such as a 3rd layer
lamination unit, perforation unit, etc. The AIR
BASIC series is still one of the most purchased
lines for production of air bubble film for technical packaging and reflective insulation.
TECHNICAL DATA
REFERENCE Machine
1,6 m / two layers
OPTIONAL EQUIPMENT
190 kg/h (75 g/m2)
* 360 kg/h (75 g/m2 )
3.350 m2/h (40 g/m2)
* 6.250 m2/h (40 g/m2)
50 kW-h
* 65 kW-h
RAW MATERIAL
Rolls of LDPE and coated materials
By hot air
*(or by hot air + diathermic oil cylinders)
WEB WIDTHS
From 1,25 to 1,6 m
min. 40 g/m2 - max. 500 g/m2
35 m/min *(65 m/min)
Ø 400 mm
Ø 10 x 4 mm
- TRIPLEX winder
- VIR winder
- Perforation unit
- Forming cylinders
- Chiller unit
39
TWIN
BUBBLE™
in-line processing for reflective
insulation materials with double
bubble layers
reflective bubble foil insulation - air bubble film laminated with coated aluminium foil - air bubble film laminated
with MPET film - air bubble film packaging - bubble solar
pool cover - air bubble film laminated with PE-foam - air
bubble film laminated with LDPE film - air bubble film
TWIN BUBBLE is a patented in-line system
with an extrusion line specifically developed
to produce reflective bubble foil insulation for
construction applications. The TWIN BUBBLE
series uses LDPE pellets to produce multi-layer
compound (sandwich) bubble foil, PE-foam and
aluminium foil, all in a single process.
TECHNICAL DATA
The system basically consists of two “twin”
bubble lines producing two bubble foils (laminated with coated aluminium film) in opposite
directions; in the middle there is a lamination
station that welds the components together.
The final multilayer product is then collected on
the winder at the end of the line.
WEB WIDTHS
From 1,25 to 1,6 m
The TWIN BUBBLE system can even produce
flame-retardant materials certifiable for all
different Worldwide Standards.
With cast extruders
FINISHED AIR BUBBLE FOIL WEIGHT
min. 80 g/m2 - max. 625 g/m2 (double bubble)
30 m/min
Ø 270 mm
Ø 10 x 4 mm
laminated with HDPE film - air bubble film laminated with
coated kraft paper - air bubble film laminated with printed
film - air bubble film laminated with non-woven - etc...
CAST DIES
Two dies with double delivery
+ one with single delivery
REFERENCE Machine
1,6 m / five layers double bubble
325 kg/h (290 g/m2)
1.050 m2/h (290 g/m2)
Diameter of screw extruders
two (Ø 80 mm L/D=30)
+ one (Ø 55 mm L/D=30)
130 kW-h
40
RAW MATERIAL
LDPE pellets, flame retardand addivitive,
coated aluminium rolls
OPTIONAL EQUIPMENT
- VIR winder
- Lamination unit by hot air
- Forming cylinders
- Chiller unit
OPTIONAL
EQUIPMENT
for Air Bubble Film
and PE-Foam Machinery
41
TRIPLEX™
WINDER
fully automatic winder
with very short cycle
time
CORELESS READY (patented)
DUPLEX PLUS™
WINDER
flexible automatic
winder
CORELESS READY (patented)
VIR™
WINDER
contact winder
for jumbo rolls
Torninova’s patented TRIPLEX winder is the fastest automated tapeless and glueless winder
for air bubble film and PE-foam machines. This
turret winder is based on a three-cantilevershaft configuration that allows extremely fast
cycle changes (< 40s). The automatic loading
of new cardboard cores (whole or split) and
extraction of finished rolls is synchronized with
a roller-table at the final collection station. The
new transversal cutting system allows film to
be wound without glue or adhesive tape on the
core. Thanks to its advanced technology, the
TRIPLEX winds various types and thicknesses
of air bubble film and PE-foam, into very short
roll lengths, at a speed of over 100 m/min.
The TRIPLEX can also be installed on existing
production lines.
The DUPLEX PLUS is Torninova’s traditional,
highly reliable tapeless and glueless turret
winder consisting of two cantilever air expansion shafts with automatic inflation/deflation.
Extremely reliable and powerful, the DUPLEX
PLUS winds perfect quality rolls to extremely
accurate lengths and widths, even when divided in-line into sub-formats. The DUPLEX PLUS
can be configured to wind external bubble,
internal bubble or double-system films. The DUPLEX PLUS is available with an automatic FAST
LOADING system for finished roll extraction,
core loading and hot-melt application (both for
initial core gluing and roll closure). The DUPLEX
PLUS can wind air bubble film and PE-foam of
any type and thickness and can also be installed on existing production lines.
The VIR is an in-line contact winder for assembly on air bubble film and PE-foam machines.
With its guaranteed speed performance and
finished roll quality, the VIR produces rolls up
to two meters in diameter and is thus recommended for all customers converting air bubble
film or PE-foam through a second manipulation
phase (bags, envelopes, formats, sheets, etc.).
The larger diameter rolls (longer) are automatically unloaded onto the floor to reduce finished
roll replacement times during the conversion
process. The VIR can also be installed on
existing production lines.
TECHNICAL DATA
TRIPLEX™ CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
air bubble film - reflective bubble foil insulation bubble solar pool cover - air bubble film laminated with
MAX. WORKING SPEED
90 m/min
PE-foam - air bubble film laminated with LDPE film - air
REFERENCE
50 m length roll at 70 m/min of working speed
minated with coated kraft paper - air bubble film laminated
MAX. WINDING DIAMETER
1.100 mm
Bubbles on inside or outside
bubble film laminated with HDPE film - air bubble film la-
with coated aluminium foil - air bubble film laminated with
MPET film - air bubble film laminated with printed film - air
bubble film laminated with non-woven - PE-foam packaging
- reflective PE-foam insulation - etc...
TECHNICAL DATA
DUPLEX PLUS™ CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MAX. WORKING SPEED
90 m/min
REFERENCE
50 m length roll at 40 m/min of working speed
1.400 mm
Bubbles on inside or outside or booth
TECHNICAL DATA
VIR™ CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MAX. WORKING SPEED
90 m/min
2.000 mm
Bubbles on inside
THIRD LAYER
EXTRUSION
LAMINATION
UNIT
THIRD LAYER
DIATHERMIC OIL
LAMINATION
UNIT
THIRD LAYER
HOT-AIR
LAMINATION
UNIT
This lamination module can be retrofitted to
any new or old extrusion-based machine for the
production of air bubble film or PE-foam in net
widths of up to 3 meters. It laminates, in-line, a
3rd film of LDPE or HDPE over the bubble layer.
The melted film from the single flat die adheres
directly to the heads of the bubbles which are
rapidly cooled. The result is a surprisingly lowcost, three-layer LDPE air bubble film.
Additionally, the same melted film can be used
as an adhesive layer for perfectly smooth,
high-speed lamination to other rolled materials
(PE-foam, coated aluminium foil or kraft paper,
printed film, non-woven, etc). The finished
product is an air bubble film with two flat faces,
one of which can be optionally characterized by
a different material.
This fast and powerful in-line lamination module is easily retrofitted to any new or old machine for high-speed production of air bubble film
or PE-foam in net widths of up to 3 meters. The
3rd film layer to be laminated is supplied from
the unit’s double-station film unwinder (with
no-stop changeover). Teflon-coated cylinders
heated by a diathermic oil circuit connected
to electric heating units, laminate the 3rd film
layer over the bubble layer. This lamination
process guarantees the highest production
speeds of any main line and ensures best-quality lamination with all kinds of material (HDPE
film, PE-foam, coated aluminium foil or kraft
paper, printed film, non-woven, etc.). The main
advantage of this lamination unit is its ability
to laminate film directly on top of the air bubble
film with no additional adhesive layer.
This in-line, hot-air lamination system is easily
retrofitted to any new or old machine for
air bubble film or PE-foam production in net
widths of up to 1,6 meters. The 3rd film layer is
supplied from rolls on the unit’s double-station
film unwinder (with no-stop changeover) and
is laminated over the bubble layer using hot
air. Thanks to this air-based heating system,
the unit is especially suitable for lamination of
delicate materials such as PE-foam, coated aluminium foil, printed film, etc. This unit is further
distinguished by its “stop-on-phase” procedure
and very low energy consumption.
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MAX. WORKING SPEED
90 m/min
STACK UNWIND WITH
AUTOMATIC ROLL CHANGE
max. Ø 1.200 mm
printed film - air bubble film laminated with non-woven PE-foam packaging - reflective PE-foam insulation - etc...
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MAX. WORKING SPEED
90 m/min
STACK UNWIND WITH
max. Ø 1.200 mm
printed film - air bubble film laminated with non-woven PE-foam packaging - reflective PE-foam insulation - etc..
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 1,6 m
MAX. WORKING SPEED
35 m/min
STACK UNWIND WITH
max. Ø 1.200 mm
printed film - air bubble film laminated with non-woven PE-foam packaging - reflective PE-foam insulation - etc...
FOURTH
LAYER
UNWINDER
PERFORATION
UNIT
FORMING
CYLINDERS
This unit laminates a 4th layer film (HDPE film,
PE-foam, coated aluminium foil or kraft paper,
printed film, non-woven, etc.) to the base of
the air bubble film, improving or varying the
finished film’s aesthetic and/or mechanical
characteristics. It consists of a double-station
unwinder equipped with two air expansion
shafts for loading the 4th layer film rolls. While
a roll is unwinding on one station, a new roll
can be prepared in stand-by on the other for a
no-stop changeover. This modular unit is easily
retrofitted to any new or existing in-line air
bubble film machine.
This useful independent module is easy retrofitted in-line to any air bubble film machine and
can possibly be used in other types of machines
producing similar films (PE-foam, blow film, etc).
It makes a preliminary cut on the film at desired
intervals (max. 400 strokes/min) before winding, resulting in a finished film roll prepared
in pre-cut sections that are quickly and easily
torn-off when needed. A brushless motor with
encoder drives the double-blade pre-cutting
device and ensures exact, consistent sheet
sizes. The module is available with an optional
trim-cutting unit and suction group.
These chromed cylinders for bubble moulding are the most distinguishing element of
Torninova’s technical know-how. A monolithic steel cylinder, with a special internal
water circuit provides perfectly homogenous
thermoregulation, guaranteeing the highest
production performance and maximum stability
with material of any thickness. The sector
vacuum system used for bubble thermoforming
increases efficiency and conserves power. The
push-to-connect design allows for fast cylinder
changes. The cylinders can be manufactured
to custom bubble shapes and dimensions and
are available for all types of air bubble film
machinery.
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MAX. WORKING SPEED
90 m/min
STACK UNWIND WITH
max. Ø 1.200 mm
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
air bubble film packaging - bubble solar pool cover
- air bubble film laminated with PE-foam - air bubble film
MAX. WORKING SPEED
90 m/min
laminated with LDPE film - air bubble film laminated with
CYCLE TIME
max. 400 stroke/min
per - air bubble film laminated with MPET film - air bubble
MIN. PERFORATION LENGTH
110 mm (45 m/min)
HDPE film - air bubble film laminated with coated kraft pa-
film laminated with printed film - air bubble film laminated
with non-woven - PE-foam packaging - etc...
TECHNICAL DATA
CAN WORK WITH:
WEB WIDTHS
From 1,25 to 3 m
MOULDER ROLLER DIAMETERS
From 270 to 500 mm
BUBBLE SHAPES
Spherical, square and other shapes
STANDARD BUBBLE SIZES
Ø3 - Ø6 - Ø10 - Ø15 - Ø25 - Ø30 mm
and other diameters
insulation - bubble solar pool cover
Converting
Machines
for Air Bubble Film
and PE-Foam
48
49
MAX
ONE™
The MAX ONE machine produces various sizes
and types of envelopes, bags, sheets, formats,
tubulars and sleeves, starting from rolls of air
bubble film and PE-foam.
bag-making and sheeter machine
with needle staking
This All-in-One system ensures ease of use for
even the unskilled operator. Moreover, through
its various automatic devices, a single operator
can manage up to two systems simultaneously.
Can convert:
air bubble film - PE-foam - air bubble film laminated with
bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated
bubble film laminated with non-woven - etc...
The entire process is controlled by the main
touch screen where hundreds of recipes can be
saved and/or loaded. The needles are mounted
on a pneumatic unit which collects and stacks
envelopes or formats into bundles.
Once completed, the bundles are transported
to the collection conveyor. The palletizing
system can stack several bundles at the same
time, thus eliminating the need for operators to
perform this task, a feature that is especially
convenient when producing envelopes or largedimension formats.
This process is completely automatic. After
pre-cutting, bags can be wound into rolls on a
downstream winder.
TECHNICAL DATA
RAW MATERIALS
Two layer or laminated rolls of air bubble film;
PE-foam rolls, laminated and non-laminated;
other similar plastic films
WEB WIDTHS
From 1,6 to 2 m
MAX. STARTING ROLL DIAMETER
1.200 mm (max. weight of 75 kg) on 3-inch
cores
FILM FEED SPEED
max. 120 m/min
NUMBER OF LONGITUDINAL BARS
1, 3 or 5
NUMBER OF TRANSVERSE BARS
2
NUMBER OF LONGITUDINAL KNIVES
6 or more
ENVELOPE AND FORMAT FEED STEPS
min. 100 mm / max. 1.300 mm in automatic
mode; for larger sizes the machine can also run
in semi-automatic mode
12 kW-h
50
SHEETEX™
sheeter machine
with needle staking
Can convert:
The SHEETEX machine is the best solution for
effortless cutting of plastic materials (such
as PE-foam and air bubble film) into sheets of
pre-set length.
Sheets (or multiple sheets) are cut and divided
by self-sharpening blades which require no
adjusting even when material thickness or the
number of layers to be cut varies.
A needle stacker collects the sheets and stacks
them on a table with pivot rotation to facilitate
extraction.
TECHNICAL DATA
RAW MATERIALS
other similar plastic films
WEB WIDTHS
From 1,25 to 1,7 m
1.000 mm (max. weight of 50 kg) on 3-inch
cores
MAX. THICKNESS OF MATERIALS TO BE CUT
16 mm
MAX. NUMBER OF FILMS T
O BE CUT SIMULTANEOUSLY
4 (e.g. 4 rolls of air bubble film with 4 mm
bubble height)
FEEDING LENGTH
min. 100 mm / max. 1.000 mm or more
PRODUCTION SPEED
sheet length cycles/min
150 mm
23
300 mm
21
500 mm
18
1.000 mm
15
1,5 kW-h
51
RP™
coreless
rewinder
Can rewind:
The RP machine is a fully automatic rewinder
that produces coreless, small-diameter rolls
(mini-rolls, max. diameter Ø 350 mm) of plastic
film (air bubble film, PE-foam, EPS, corrugated
paper, etc.)
Once the starting roll is inserted, the RP rewinder automatically begins producing the small
diameter rolls. The operator does nothing more
than simply change the starting roll and replace
the collecting box once it is full. The machine
can also split the starting jumbo reel to produce
2 or more narrower rolls at the same time.
52
The RP rewinder is the perfect choice for
entering retail markets (hardware stores, superstores, DIY, etc.) where air bubble film rolls are
not sold in standard sizes, but rather, in shorter
lengths of 3 to 30 meters.
Avoiding the use of an internal cardboard core
is crucial in this specific market, as its cost is
excessively high in relation to the end product
being sold, a compelling reason to choose the
RP Coreless Rewinder.
TECHNICAL DATA
RAW MATERIALS
other similar plastic films; corrugated paper
WEB WIDTHS
From 1,25 to 1,7 m
PRODUCTION LENGTHS
From 3 to 40 m (max. Ø 350 mm)
PRODUCTION SPEED
approx. 180 rolls/h (length 5 m)
2.000 mm
3 kW-h
RP PLUS™
coreless
rewinder
In addition to producing the same short length
rolls as the RP Coreless Rewinder, the RP PLUS
is capable of rewinding coreless mini-rolls up to
a diameter of Ø 600 mm (containing 100 meters
of air bubble film).
As the diameter of the roll in production grows,
automatic support devices are engaged to
handle the extra weight.
Can rewind:
This off-line rewinder can produce coreless
rolls in standard sizes (50 and 100 meters) for
increased savings of cost and space.
TECHNICAL DATA
RAW MATERIALS
other similar plastic films; corrugated paper
WEB WIDTHS
From 1,25 to 1,7 m
PRODUCTION LENGTHS
From 3 to 100 m (max. Ø 600 mm)
PRODUCTION SPEED
2.000 mm
4,5 kW-h
53
LAM™
lamination
machine
Can produce:
reflective bubble foil insulation - air bubble film laminated with coated aluminium foil - air bubble film laminated
with MPET film - reflective PE-foam insulation - air bubble
film laminated with PE-foam - air bubble film laminated
with LDPE film - air bubble film laminated with HDPE film
- air bubble film laminated with coated kraft paper - air
bubble film laminated with printed film - air bubble film
laminated with non-woven - all lamination with air bubble
film and PE-foam.
The LAM machine is a hot-air lamination system which laminates the entire surface of two
or more rolls of plastic materials (two or three
layer air bubble film, PE coated materials, LDPE
and HDPE films and PE-foam) for value-added
improvement of complex, final products used in
various applications.
Alternatively, by adding electrically-heated
sealing wheels, the extremities of two rolls of
bubble foil can be coupled with aluminium on
the external side (like a “tube”).
Such coupling may also include an additional
internal material (PE-foam or other). The LAM
machine is therefore recommended for plastic
film lamination and/or production of complex
materials specific to the reflective insulation
market.
TECHNICAL DATA
HEATING SYSTEM
Lamination with hot air or infra-red lamps;
longitudinal welding with circular electric
resistances
WEB WIDTHS
From 1,25 to 1,6 m
PRODUCTION SPEED
Lamination from 10 to 35 m/min
longitudinal welding from 5 to 15 m/min
1.500 mm
MAX. FINISHED ROLL DIAMETER
800 mm
LONGITUDINAL WELD WIDTH
From 10 to 40 mm
LAMINATION LAYERS
From 2 to 4
NUMBER OF LONGITUDINAL WELD LAYERS
From 2 to 5
25 kW-h
54
Flexographic
Printing
Machinery
55
FLEXOGRAPHIC
PRINTING MACHINERY
The Mencarelli family engaged in the
production of flexographic presses in the
1969, and has always followed the developments of this industry with great interest.
The Torninova Corporation core business
became top-level cast lines for the production
of bubble wrap, stretch film, extrusion line
for masterbatch & compound and blown film,
because of the complexity and state of the art
technology that these machines require.
Given the past experience manufacturing flexo
presses and the opportunity to cooperate
with some of the most competent and expert
professionals in the market, who introduced
unmatched technological innovations in this
industry, Torninova Corp. has engaged in the
creation of the Torninova flexographic printing machine project, combining specialized
teams of highly experienced and committed
engineers and technicians with a proven capability of designing and producing a wide-range
of reel-to-reel flexo printing presses according
to every Client’s specific need.
56
In addition to state-of-the-art and leading edge
technology, business continuity is of the utmost
importance at Torninova Corp., where great
importance is given to maintaining key people
within the organization to dominate the present
and strengthen the future.
The Torninova flexographic printing machine
division offers central drum and stack lines,
gearless or conventionally driven, all equipped
with state of the art components and technologies available in the market to guarantee quality, reliability, constant performance, extreme
operator safety and easy remote maintenance
processes reduce machine down time to the
very minimum.
The modular criteria used for the Torninova
Corp. presses enable the reproduction of
the same solutions on the different machine
types, ensuring thus the same quality level and
technology regardless of the number of colors
and the requested speed and print repeat.
A new family of machines, an exciting chapter
of Torninova’s 40 year professional journey, but
the value and engagements are just the same:
at Torninova Corp. everybody has the same
level of attention, care for the details and
customer-oriented attitude on every project,
for every single Client, before, during and after
every project.
UNIDRUM™
flexographic printing
machine
TECHNICAL DATA
PRINT SECTION
Central impression drum
NUMBER OF STATIONS
4, 6, 8 and 10
PRINTING WIDTH
Up to 2.000 mm (80”)
Can produce:
REPEAT RANGE REGULAR
430-1.000 mm (17”-40”)
- printed materials on plastic, paper and board
FlexoMaster is a completely automatic,
high-performance flexo-printing press, designed to
guarantee versatility and flexibility along with
a top-level printing quality with easily accessible
control process.
REPEAT RANGE EXTENDED
480-1.300 mm (18.9”-51.1”)
DRIVE TO PRINT CYLINDER
AND ANILOX ROLLER
Gearless
MACHINE LAYOUT REGULAR
Front print
MACHINE LAYOUT SPECIAL PROJECT
Up/down stream equipment
MACHINE MANAGEMENT
PC, PLC communication system
REMOTE SERVICE
Complete remote control, all function
INK AUTOWASH
Fully automatic, programmable
PRODUCTION SPEED
400 m/min (1300 – 2000 ft/min)
DRYING SYSTEM
At customer’s choice
PRINT CYLINDER CONFIGURATION
Sleeve
INK TYPE
Solvent, water based
ANILOX ROLLER CONFIGURATION
Sleeve
SPECIAL INKS
UV
SLEEVE CHANGE OVER PROCEDURE
WEB SUBSTRATES REGULAR
Film, laminates, paper, board
CYLINDERS’ FRONT / BACK MOVEMENT
Servo motors
WEB SUBSTRATES OTHERS
Liner pre-print for corrugated board
DOCTOR BLADE
Aluminum or carbon fibre
MARKET COMPONENTS AND ACCESSORIES
On request
PRE SET AND PRE REGISTER
Included in all versions
PRINT SECTION FRAME
Window type
57
POLYSTACK™
flexographic printing
machine
TECHNICAL DATA
PRINT SECTION
Stack
NUMBER OF STATIONS
2, 4, 6, 8 and 10
PRINTING WIDTH
Up to 2.000 mm (80”)
Can produce:
REPEAT RANGE REGULAR
430-1.000 mm (17”-40”)
- printed materials on plastic, paper and board
FlexoMate stands as a splendid example of stack
technology applied to the flexo-printing industry: the
wide printing width and repitition, along with its
powerful drive and the outstanding mechanical precision make it ideal for every Client’s printing need.
REPEAT RANGE EXTENDED
480-1.300/1.500 mm (18.9”-51.1” / 59”)
DRIVE TO PRINT CYLINDER
AND ANILOX ROLLER
Geared option gearless
mechanical transmission
DRIVE TO IMPRESSION ROLLER
Geared, option gearless
PRINT CYLINDER CONFIGURATION
Integral option sleeve
ANILOX ROLLER CONFIGURATION
Integral option sleeve
SLEEVE CHANGE OVER PROCEDURE
CYLINDERS’ FRONT / BACK MOVEMENT
Manual, single motor, 4 step motors
DOCTOR BLADE
Aluminum or carbon fibre
PRE SET AND PRE REGISTER
Option
58
PRINT SECTION FRAME
Bracket type
MACHINE LAYOUT REGULAR
Front print
MACHINE LAYOUT SPECIAL PROJECT
Up/down stream equipment
MACHINE MANAGEMENT
PLC communication system
REMOTE SERVICE
Option
INK AUTOWASH
PRODUCTION SPEED
300 m/min (830-1000 ft/min)
DRYING SYSTEM
At customer’s choice
INK TYPE
Solvent, water based
SPECIAL INKS
UV
WEB SUBSTRATES REGULAR
Film, laminates, paper, board
WEB SUBSTRATES OTHERS
Liner pre-print for corrugated board
MARKET COMPONENTS AND ACCESSORIES
On request
59
TRN_0113
Torninova S.r.l.
via dell’Artigianato 18
06083 Bastia Umbra (Perugia)
Italy
tel. +39.075.8000655
fax. +39.075.8003914
[email protected]
www.torninova.com

flexographic printing bubble wrap cast stretch film

Transcription

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