Manufacturer & Exporter of Converting & Flexible Packaging Machinery
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+91 9512852352
Call Us Now
+91 9512852352
Surface Protective
Film Coating Machine
Surface Protective Film Coating
The machine has been specially designed for various Surface Procative film Coating jobs on Water Based Adhesive.
By perfect integration of the latest generation of automation electronics and mechanical components, the machine is made to deliver optimum performance and productivity with minimum left to right GSM Variation.
Key Features:
High productivity
Easy operation
Optimum energy consumption and ability to handle wide range of LDPE Coating and Release coatings.
| Standard Technical Specification | |
|---|---|
| Machine Type | Surface Protective Film Coating |
| Machine Model | POLESTAR COAT-SPF |
| Configuration | Double Mayer bar With Finnish Roll |
| Max. web width | 1000mm-2500mm. |
| Min. web width | 400 mm. |
| Max. Reel Diameter | 800mm at unwind & rewind. |
| Core Diameter | 76mm, 152mm |
| Max. weight of reel | 800kgs. |
| Heating tunnel chamber | 8-15 nos. |
| Tunnel Length | 12 - 22 mtr |
Servo cum AC Drive based closed loop controller for web handling by using latest generation of electronics. Entire machine operation is controlled and supervised by high performance motion controller having its own intelligent software.
Master operator control panel consists of touch screen (HMI) operating interface that facilitates ease in operation. Safety of operator, machine and electronic modules are achieved with the help of necessary hardware protection and intelligent software routines.
The sturdy heavy-duty frame structure designed carefully and methodically considering the precise accuracy to suit the specified running optimum speed over long dependable life. The precise frame mounting, linking and its balancing ensures less vibration and increase its reliability and durability.
Unwind & Rewinder Unit Comprises of width Steel Plate with supporting bearing Brackets with moving trolley. This entire assemblage makes roll exchange extremely fast, easy and reduces job time.
⦁ Maximum diameter of reel : 800MM
⦁ Maximum weight of reel : 800kgs
⦁ Internal diameter of core for shaft : 76mm & 152mm
⦁ Web tension range : 60-400N
⦁ Web tension regulation : Load-Cell Base
Composition: Load cell roll-based web tension control system consists of…
⦁ Closed loop Vector controller AC frequency drive.
⦁ Pair of load cell for actual tension display and tension feedback.
⦁ AC motor complete with encoder, timing belt pulleys etc
⦁ Air shaft with Safety chucks/Mechanical Housing.
⦁ Shaft body and shaft end journals from steel
Unwind web tension control:
Web tension control system by using latest generation AC drive with AC motor and load cells. The system maintains tension precisely throughout the reel run. The system is composed of:
⦁ AC drive & AC motor
⦁ Load cell roller assembly for tension feedback & actual tension display on HMI
Composition:
⦁ One AC vector drives control, motor with Gear box Remote digital panel.
⦁ Double layer bar coating unit with finish roll which insure minimizing Left to Right Coating GSM
⦁ Load cell base roller for auto tension feedback
⦁ Double jacket Ink Tray with Assembly Coating unit 3 Phase AC motor
⦁Transparent Inspection Box to Inspect Coated Film.
Specially designed, low friction-low inertia, dynamically balanced idle rollers, mounted on low friction bearings to enhance rotational smoothness. Properly ground and balanced the rollers are made of specially graded anti-corrosion steel with Teflon-coating.
PRODUCT
Extrusion Laminating Machine
For Flexible Packaging
Converters who want to enhance and upscale lamination quality and increase productivity at low conversion cost.
A step towards producing more sustainable plastic products and not only lighten the environmental footprint but also by producing recyclable and upcycle goods reduces the load on the waste management.
PRODUCT
Rotogravure Printing Press
The new generation of Rotogravure Press is led by Electronic Line Shaft Technology (ELS). Some advantages compared to conventional mechanical transmissions are : better operator access around the press, reduction in noise level.
By perfectly integrating new generation of electronics and ergonomically designed mechanical components, the press is made to deliver optimum performance and productivity.
PRODUCT
Laminating Machine
Rotogravure Printing Press
This modern new generation press is built to cater demands of the continuously evolving flexible packaging industries.
Machine is designed ergonomically to cater medium and long run length job.
High productivity, low conversion cost, high quality printing, fast job change-over are the key features.
PRODUCT
Slitter
With the combination of proven Aayar and with the advantages of our modern technology.
Slitter is the ideal solution for the modern converter that demands to produce excellent quality rolls, by increasing the productivity, especially on the down-time between working cycles, while minimise the traditional bottlenecks in the slitting area.
PRODUCT
Rotogravure Printing Press Mechanical line
Rotogravure Printing Press
The Press is built with Mechanical line shaft with servo technology.
By perfectly integrating the new generation of electronics and ergonomically designed mechanical components, the machine is made to deliver optimum performance and productivity.
PRODUCT
Solvent – Less Laminator
The machine is designed to handle a wide range of laminating jobs and to cater growing needs of solvent-less lamination on flexible packaging market.
High productivity, easy operating, optimum energy consumption and ability to handle wide range of laminating jobs are the key features.
By perfectly integration of the new generation of electronics and ergonomically designed mechanical components, the machine is made to deliver optimum performance and productivity.
Surface Protective Film Coating
This modern new generation press is built to cater demands of the continuously evolving flexible packaging industries. Machine is designed ergonomically to cater medium and long run length job.
High productivity, low conversion cost, high quality printing, fast job change-over are the key features.
| Standard Technical Specification | |
|---|---|
| Maximum web width | 1300 mm |
| Printing cylinder repeat range | 450 to 920 mm |
| Maximum mechanical speed | 450 m/min |
| Web tension range | 60 to 400 N |
| Standard drying hood length | 2.0 mtr |
| Reel diameter | 1000 mm |
Surface Protective Film Coating Manufacture by
AAYAR INTERNATIONAL
The Machine
The new generation Rotogravure Press is led by ELS technology. By perfectly integration of advanced electronics and ergonomically designed mechanical components to deliver optimum performance, Better operational ease, faster print register response, higher productivity, better print quality, less waste, optimizing ink solvent and energy consumption, faster job changeover etc.
Service Cart (Trolley System)
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Print Station Controls
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
High Efficient Ventilation Module
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Unique Designed Doctor Blade Group
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Unwind Group
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
In-Feed Web Handling Control
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Control System
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Operator Interface
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Print Unit
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Sleeve Type Impression Assembly
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Transmission
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Drying System
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Out-Feed System
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Rewind Group
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
C.P.S System
Specially designed Cart facilitates ease for insertion and extraction from the printing station. Thanks to a special mechanism: Cart slides on linear guide rail which ensures perfect in & out operation; only one operator can easily carry out the operation.
To carry out loading I unloading of gravure cylinder there is a lifting system onboard on the cart, which consist of hydraulic piston, levers etc.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
VMCH Coating Machine
The machine has been specially designed, for various Primary Packaging Blister Coating and Food Packaging jobs on Heat Seal Lacquer applications.
Highly productivity, easy operating, optimum energy consumption and ability to handle wide range of Primer Coating and HSL coating jobs are the key features.
By perfectly integration of the latest generation of automation electronics and mechanical components, the machine is made to deliver optimum performance and productivity with minimum lest to right GSM Veration.
| Standard Technical Specification | |
|---|---|
| Machine Type | VMCH WITH ONLINE SHELLAC |
| Machine Model | POLESTAR COAT |
| Configuration | Three roll /Gravure |
| Max. web width | 1000mm. |
| Min. web width | 400 mm. |
| Max. Reel Diameter | 800mm at unwind & rewind. |
| Core Diameter | 76mm, 152mm |
| Max. weight of reel | 800kgs. |
| Heating tunnel chamber | 8 -10 nos. |
| Tunnel Length | 12 – 15 mtr |
Control System
Servo cum AC Drive based closed loop controller for web handling by using latest generatton of electronics. Entire machine operation is controlled and supervises by high performance motion controller having its own intelligent software.
Master operator control panel consists of touch screen (HMI) operating interface facilitates ease in operation. Safety of operator, machine and electronic modules are achieved with the help of necessary hardware protection and intelligent software routines.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Frame Structure
The sturdy heavy-duty frame structure designed carefully and methodically considering the precise accuracy to suit the specified running optimum speed over long dependable life. The precise frame mounting, linking and its balancing ensures less vibration and increase its reliability and durability.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Unwinder & Rewinder
Unwinder- Rewinder
Unwind & Rewinder Unit Comprises of width Steel Plate with supporting bearing Brackets with moving trolley. This entire assemblage makes roll exchange extremely fast, easy and reduces job time.
Technical Features:
⦁ Maximum diameter of reel : 800MM
⦁ Maximum weight of reel : 800kgs
⦁ Internal diameter of core for shaft : 76mm & 152mm
⦁ Web tension range : 60-400N
⦁ Web tension regulation : Load-Cell Base
Composition:
Load cell roll-based web tension control system consists of…
⦁ Closed loop Vector controller AC frequency drive.
⦁ Pair of load cell for actual tension display and tension feedback.
⦁ AC motor complete with encoder, timing belt pulleys etc
⦁ Air shaft with Safety chucks/Mechanical Housing.
⦁ Shaft body and shaft end journals from steel.
Unwind web tension control:
Web tension control system by using latest generation AC drive with AC motor, load cells. The system maintains tension precisely throughout the reel run.
The system is composed of:
⦁ AC drive & AC motor
⦁ Load cell roller assembly for tension feedback & actual tension display on HMI
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Primer Coating Unit
Primer Coating unit.
Exceptionally designed, and precisely machined, strong and robust steel frame structure, maintains accuracy over long dependable life and ensures reduced vibration even with optimum line speed.
Primer Unit system pulls the substrate from unwinding station and at the same time retains required set tension between Shellac and Coating unit precisely and isolates the Shellac unit from tension disturbance of the unwinding zone.
Composition:
⦁ Load cell base roller for auto tension feedback
⦁ AC motor complete with related assembly
⦁ NIP Rubber Roller with pneumatically adjustable pressure.
⦁ Specially designed pneumatically operated doctor blade assembly ensures a straight profile of the blade resulting in lesser blade pressure, better printing quality and longer cylinder life.
⦁ Gravure system at coating unit.
⦁ Flame proof Motor with adhesive pump and SS tank. for Adhesive viscosity maintain
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Bottom Tendency
Heating tunnel is divided into Zones. All Drying Zone hinged at rare end and enabled to get opened with the help of pneumatic cylinder. The heating tunnel will be accessible by catwalk throughout tunnel length. Idler rollers are driven by timing belt and pulley. Chrome plated/ Teflon coated idle rollers are dynamically balanced and polished provided in the tunnel to guide the web. Tunnel (which is exposed to the atmosphere) is connected to each compartment is insulated to preserve the heat loss.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Coating Unit
Coating Unit: (Heat Seal Lacquer /VMCH)
Steel frame Structure with cross connection Tie Bar Plates, coating unit is linked with shellac unit. It ensures that mechatronics are synchronized at any desired speed. Distinctively designed, and precisely machined, strong and robust steel frame structure, maintains accuracy over long dependable life and ensures reduced vibration even with optimum line speed.
Composition
⦁ One AC vector drives control, motor with Gear box Remote digital panel.
⦁ Three Roll Systems width rubber rolls with Assembly which insure minimizing Left to Right Coating GSM
⦁ Chilling Roll before Coating
⦁ Load cell base roller for auto tension feedback
⦁ Double jacket Ink Tray with Assembly with manual up down working.
⦁ Coating unit 3 Phase AC motor
⦁ Transparent Inspection Box to Inspect Coated Film.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Top Tendency
All Drying Zone hinged at rare end and enabled to get opened with the help of pneumatic cylinder. The heating tunnel will be accessible by catwalk throughout tunnel length. Idler rollers are driven by timing belt and pulley. Chrome plated/ Teflon coated idle rollers are dynamically balanced and polished provided in the tunnel to guide the web. Tunnel (which is exposed to the atmosphere) is connected to each compartment is insulated to preserve the heat loss.
Adhesive drying is obtained by centrally connected hot air input on the web through air nozzles. The optimized airflow lessens heat consumption and avoids solvent retention in the coated substrates. Solvents evaporation is obtained by air nozzles, blowing air on the web in connection with the idle rollers, in order to ensure the drying, avoiding shaking or deforming of the web itself. The optimized airflow minimizes heat consumption and avoids solvent retention in the printed substrate.
The central exhaust system is controlled by heavy-duty centrifugal exhaust blower to collect solvent contaminated air from all the tunnel units through central ducts/piping fitted with manual adjustable damper.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Chilling NIP
CHILLING/ NIP CONSOLE:
It is a Steel frame Structure with cross connection Tie Bar Plates, Chilling unit ensures that mechatronics are synchronized. Distinctively designed, and precisely machined, strong and robust steel frame structure, maintains accuracy over long durability and ensures reduced vibration even with optimum line speed.
Two chilling rolls are tightly synchronized together with ac motor Driven by AC vector drive. The rotary union is provided to ensure chilled water circulation uniformly.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time
Idle Roller
Specially designed, low friction-low inertia, dynamically balanced idle rollers, mounted on low friction bearings to enhance rotational smoothness. Properly grooved, ground and balanced the rollers are made of specially graded anti-corrosion aluminum alloy.
- Possibility to remove only the inking system, leaving the printing cylinder in the printing station
- Possibility to remove only the printing cylinder, leaving the inking system in the printing station
- Possibility to remove the printing cylinder together with the inking system at the same time