During the entire solventless composite process, tension control is important, and the precise tension control of solventless laminator is the premise of ensuring the quality of the composite film.
Tension Control Methods Of Solventless Lamination Machine
The solventless lamination machine mainly has two tension control modes, one mode is a "floating roller" and the other mode is a "micro shift".
The "floating roller" tension control has the advantages of large range control, adapting to the wide substrates, but the structure is more complicated.
The "micro displacement" type tension control has the advantages of high precision, high sensitivity, but since the detection range is small, the absorbance of the material roll fluctuation is small, so this method is generally only suitable for relatively thick or non-molar material.
In actual solventless composite production, a solventless laminating machine may adopt different tension control methods in different sections.
Instruction For Tension Control Of Solventless Lamination Machine
1. During the solvent-free composite, the requirements for tension control are higher than that of ordinary compounds. The main reason is that there is no solvent composite initial adhesion, and the operational control is difficult, which may lead the quality problems. In addition, the solvent-free composite speed is much higher than the dry lamination machine.
During the solvent-free composite, the tension after the thin film is slightly greater than the main arrangement, and the winding tension is greater than the rewinding tension. The winding taper is controlled within 20%. For different materials, each part of the tension control is different, and even the film of the same material produced by different manufacturers, its tension has to be slightly adjusted.
2. In the solventless composite, not only the accuracy of the tension control system, the matching of the tension between the two composite rolls is emphasized. Under the current technical conditions, many tension control systems have very high accuracy performance, which can meet the needs of solventless composite production. However, in the process of solventless composite operation, this is often encountered, which the matching of the two-layer materials is more difficult, which not only requires a good tension control system but also carefully understand the material features. More accurately, the tension of solvent-free composite requires that the elongation of the two-layer rolls is consistent by controlling the tension to ensure that the two-layer material does not occur the relative slip during the solventless composite.
3.The rewinding tension and pressure are the key to solventless composite tension control. Since the combination of the composite film and the overall condition of the material roll, are determined by the rewinding tension and pressure, adopting the segmentation independent tension and segment tension taper are the most ideal control mode.
It should be noted that the segment tension taper is mainly to compensate for the need for linear tension to the requirements of different material winding tension. Different tension tips can be effectively guaranteed to ensure the neatness of the winding while reducing the generation of core wrinkles.
Unwinding Device And Loading Pattern Of Solventless Lamination Machine
Unwinding device The solventless laminator is mounted with an aluminum foil unwinding frame and an ordinary unwinding frame. In general, the path of the aluminum foil unwinding frame is shorter with a smooth guide roller, often adopting "micro displacement” tension control. The ordinary unwinding frame is long, often adopting the "floating roller" tension control.When using an aluminum foil unwinding frame, only one frame is in a working condition during the composite process, that is, the ordinary unwinding frame is in a non-working state. Due to the simultaneous compounds of the two films, two unwinding frames are required to work at the same time.
Accordingly, there must be two tension control systems in the working condition.
Loading Pattern
There are two main methods of the solventless laminating machine and the reliability of the air shaft and shaftless pneumatic shaft are high.
The shaftless cone top type of loading pattern has the advantages of simple, fast, high efficiency, low operation intensity, but it has high requirements for the core tube and in order to ensure safety, this loading pattern has a higher requirement for equipment parts Also the manufacturing cost is relatively high.
In the current market, medium and high-speed solvent-free lamination machines with speed at 400 to 600 m / min, basically adopt air shaft loading patterns.
Tension control plays an important role for the whole solventless composite process and learning the tension control well can do a great favor for the work efficiency of solventless laminating machine.
Sinstar Packaging Machinery Co., Ltd is founded in 2005, is a professional solventless laminating machine manufacturer with advanced systems, such as “Coating Clearance Memory System”, “Foolproof Glue Preparation System”, “Accurate Coating Weight Detecting System”, “Zero Error Tension Stabilizing System”, types including WRJi9 series, S1L90 series, and WRJFi9 series solventless laminator. Sinstar has professional and unique invention patents, appearance patents and utility model patents.
Why should choose Sinstar solventless lamination machine
1. Adopts advanced green and eco-friendly packing technology
2. No wrinkle when 0.06 mm thickness aluminum foil goes through the running roller.
3. Process parameters online printing out.
4. High viscosity glue feeding and coating applicable.
5. Active unwinding for aluminum foil through motor control.
6. Simple operation.
7. More capable, more refined, with a five roller coating system.
8. Width setting for digital glue spray.
9. Digital tension system
10. Intelligent dynamic analyzing system
The solventless lamination machine is equipment which is applied to solvent-free adhesive composite. There’re two types including single station solventless lamination machine and double station type. Sinstar solventless laminating machine will be one of the best choices for advanced flexible packaging machinery.
Solventless lamination is a method of compositing two or more substrates by using a solvent-free adhesive. The solventless lamination machine is mainly composed of two major parts including the solventless laminator and adhesive mixer. It mainly completes the operation of the unwinding, tension control, glue, composite and rewind. The adhesive mixer is a special device for quantifying the adhesive to the host. Here, we mainly introduce the types of solventless laminating machines.
Single Station Solventless Lamination Machine
Today, the single station solventless machine is widely used, which is determined by a variety of factors.
1. Due to the low initial adhesion of the solvent, the tension control requirements of the substrate are high. Therefore, during the solvent-free composite, the single-station solventless lamination machine has the advantages of shorter material feeding, high accuracy tension control and low waste rate.
2. Since the solvent-free adhesive has a certain opening time, it does not require a dry composite high-temperature drying system, using a single station solventless laminating machine, can realize the operation of the roll change during the downtime.
3. the manufacturing of the single station solventless laminator is relatively simple, and the cost is low. Moreover, the single station solvent-free lamination machine is compact, covering a small area, and one person can operate in general.
Overall, most of the solventless lamination machines, are the single station model, accounting for more than 70%.
Double Station Solventless Lamination Machine
The double-station solvent-free lamination machine is installed on an unwinding rack with two material rolls and can realize the reel alternation without downtime.Advantages And Disadvantages Of Double Station Solventless Lamination Machine
Advantages
Compared with the single station solventless laminating machine, the double station type mainly has the following advantages.
1. High efficiency. Normally, the stable working speed of the solventless laminating machine is 300 ~ 600 m / min, which is about 2 to 3 times higher than the dry laminating machine. The double-station solventless laminator can greatly reduce the time of roll changing and downtime, improving production efficiency, with generally 70% higher yield.
2. Significantly reducing operational difficulties. Single station solventless laminating machine requires frequent replacement rolls, one unwinding or rewinding unit is replaced once every 15 to 30 minutes, which greatly consumes the operator’s physical strength. The physical strength of the personnel will be accompanied by a certain degree of tension, which will inevitably affect the progress and product quality. The roll changing without the downtime of a double station solventless lamination machine can avoid this.
3. Improve production stability. The double-station solventless lamination machine greatly reduces downtime, improving tension control and adhesive viscosity consistency, which will improve production stability.
Disadvantages
However, there are some potential disadvantages for double station solventless lamination machine, because the material feeding is long with higher tension control requirements and the waste rate will also increase accordingly, and there may be unfavorable effect for solventless composite products with lower initial adhesion. In addition, the cost of a double-station solventless lamination machine is also significantly higher than the single station type.
For more information, please visit the article page of useful knowledge of solventless lamination machine.
Sinstar, the full name is Sinstar Packaging Machinery Co., Ltd, which is founded in 2005 with location at high-tech industry zone of Rongchang District Chongqing City and is a professional supplier which is engaged in the research, development, production, sales and service of solventless laminating machine with annual production capacity of 200 sets.
Since the very beginning, Sinstar has been adhering to the design concept of “Innovation Changes The World, Innovation Masters The Future”, insisting on continuous technological innovation. We develop many unique technologies such as “Coating Clearance Memory System”, “Foolproof Glue Preparation System”, “Aimed Coating Weight Direct Input System”, “Accurate Coating Weight Detecting System”, “Multiple Mixing Ratio Protection System”, “Zero Error Tension Stablilizing System”, “Fast Cleaning System”. Now we have several series of solventless laminators including WRJi9 series, WRJFi9 series, S1L90 series, WRJSLi5 series and in China market so far we have more than 1000 customers because of the excellent characters of our machines: simple operation, safety, durability and perfect service.
Sinstar has a strong team of research and development, 30% of the company’s total staff are engineering and technical personnel who have been engaged in flexible packaging machinery industry for more than 20 years. Some of them are packaging industry engineers or doctoral talents and have ever participated in the formulation of the national standard GB/T 34150-2017 for non solvent laminating machine. In 2015, the design of Sinstar solvent free laminating machine won the second prize (Innovation category) of the second Cross-strait (Zhangzhou) Industrial Design Innovation Competition.
Sinstar has 220 authorized patents, including 8 for invention, 204 for utility model and 8 for appearance design. It has 10 trademarks and 2 software copyrights. The company has been awarded as “National High-Tech Enterprise”, “National Intellectual Property Advantage Enterprise”, “Chongqing Gazelle Enterprise”. In the 2019 Boao Forum for Chinese Entrepreneurs, Sinstar was selected as one of the brands symbolizing China’s economic resilience.
Determined to provide green and environment friendly flexible packaging machinery for the world, Chongqing Sinstar Packaging Machinery Co., Ltd helps to set up the first line of defense for food and drug.
Solventless lamination is a method that uses solvent-free adhesive to combine two or more substrates together. The solventless lamination machine provides the high-precise coating with a weight-detecting system and the machine is the best combination of coating and laminating position, driven coating system and automatic unwind & rewind for high efficiency, consistent tension & minimum waste during roll changes.
Applications
The solventless laminating machine has environmental and high-precise coating features and is widely used for all kinds of flexible laminating bags with two-layer, three-layer, four-layer. It is suitable for light packaging, including OPP / CPP, PET / PE, PA / PE, OPP / VMCPP. It has covered the whole field of flexible packaging for the laminate of paper-plastic, plastic-plastic and aluminum-plastic.
Rational Solventless Laminator Sı L90 series
Features
Combination of ergonomics &green packaging technology.
Redefining tension(Rational tension)
Farewell to sensuous tension（Tactile tension)
Same tension at high and low speeds
Width setting for digital glue spray
Intelligent dynamic analyzing system
Automatic analyzing
One-button multiple-points position system
Have fun of wisdom during operation
Digital tension system
External roll-diameter status display
Models:S1L90-1000A, S1L90-1300A, S1L90-1600A
Solventless laminator WRJ i9 series
The WRJ i9 solventless laminator has several advanced systems, which includes coating weight directly inputting system, multiple ratio protection system, coating clearance memorizing system, fast cleaning system, zero-error tension stabilizing system, precise coating weight detecting system and foolproof glue preparation system.
Features & Advantages
1. Adopts advanced green and eco-friendly packing technology
2. No wrinkle when 0.06 mm thickness aluminum foil go through running roller
3. Process parameters online printing out
4. No bubbles on the surface of laminated films of aluminum foil structure right after finishing laminating
5. High viscosity glue feeding and coating applicable
6. Accurate swinging arm tension to control aluminum foil movement
7. Active unwinding for aluminum foil through motor control
8. Special taper curve of rewinding tension for laminated films of aluminum foil structure
9. More capable, more refined, with five roller coating system
10. Closed-loop tension control via dancer roller
Models: WRJ i9-1000A, WRJ i9-1300A, WRJ i9-1600A
Solventless laminator WRJF i9 series
Features & Advantages
1. Simple Operation
2. Reliable solventless laminator
3. More capable, more refined, with five roller coating system
4. Rigid shaftless unwind-rewind units
5. Closed-loop tension control via dancer roller
6. Computer Controls for all machine functions
Models: WRJF i9-1000A, WRJF i9-1300A, WRJF i9-1600A