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

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

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.

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

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: (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

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 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

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