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1. MACHINE DESCRIPTION 1.1 General The SIAPI machine mod. EA1S produces PET bottles cavities by a stretch-blowing twostage process. It is intended for productions of containers with a capacity that ranges from 10 to 30 l (3 to 8 us gal). It is possible to go from one type of container to another by simply replacing the mould, adjusting the stretching rods, and recalling the specific program, without any other field regulation. 1.2 Structure It is a monobloc machine, with an electric-welded steel frame. It is electrically driven, and a PC controls it. The low part of the machine is entirely enveloped in sheet panels lined with sound proofing material; transparent panels enclose the upper part. 1.3 Functional concepts Preforms are loaded by an automatic device on a disposal called preform carrier, from which they will be unloaded once they have become finished bottles. The preform-carriers proceed on a closed-loop by an intermittent motion in the loading, unloading, and blowing sections, and at constant speed in the heating section. During the whole process, the bottle is always with its neck up. The heating takes place by irradiation in ventilated ovens, the ventilation is prograable in order to optimise the absorption. 1.4 Optional Auxiliaries They are: - the Gaylord dumper; - the water cooling chiller to cool the moulds and the preform carriers; - the oil-free compressor for the blowing air. 2. DESCRIPTION BY OPERATIONAL UNITS 2.1 Bedplates They are made of strong electro welded steel structure, and their frame consists mainly of square section pipes and heavy-thickened plates. The whole thing forms a monolithic body, which is worked at the machine tool after its welding and its eventual normalisation. The bedplates lay on the floor by means of self-aligning, antivibrating, and adjustable supports in order to adapt them to possible unevenness. 2.2 Elevator and automatic distributor It is mechanically independent and it has its own frame. It consists of a hopper, a band, and an automatic distributor. It brings the preforms from the ergonomic loading level to that of automatic distributor and it puts them in a little robotics hand side, which can rotate the preform in order to present to the inserting guides the side of the neck. The hopper is lined with food-polyethylene sheets. The automatic distributor controls the hopper s functioning by means of photoelectric cells, which register the emptying of the loading tracks. 2.3 Preform carrier The whole driving mechanism of the preforms and the bottles is based on this disposal. It is a discoid pallet with a hole in its centre through which the neck of the preform is introduced and hooked to stainless steel jaws. 2.4 Loading In this section, the preforms are ranged at the end of the track and are inserted into the preform-carrier. 2
The parts touching the preforms are made of anodised aluminium-alloy; otherwise, they are made of stainless steel. 2.5 Transport Preform carriers slide on treated-steel guides following a straight-line that curves at the two ends of the machine. In the heating section, the preforms rotate as well, so they can be evenly exposed to the irradiation. There is also find a carrier cooling system under the guides. In the blowing section, pneumatic pistons singly move the preform carriers. 2.6 Heating The heating process takes place in ventilated stainless-steel ovens comprising adjustable supports for the lamps and for the rapid electrical connections. Each lamp is assembled on its own adjustable support. The power delivered by each line of lamps is independently adjustable, so it is possible to optimise the preform s thermals profile. The total power can be varied without altering its percentile distribution. At the heating section s exit, there is a reader for the preform s temperature, which is active whenever the loop temperature control is selected. 2.7 Mould and connected part The single-impression mould it is made of aluminium alloy with steel inserts; it has a movable steel bottom. The mould open and close by means of a gripping toggle, driven by a system with a brushless motor. 2.8 Blowstretching group The stretching is carried on by a system based on a toothed guide, driven by a brushless motor. The medium and high-pressure valves are electrically controlled and have a stainless steel shutter. The discharged air is filtered and silenced. 2.9 Unloading The finished bottles remain hooked to the preform carrier until they are drawn from the mould and expelled by means of a pneumatic slide, onto a band transport system. 2.10 Control unit It is based on an innovative PLC, with a LCD monitor and an industrial keyboard. The control unit allows a clear, powerful, and multi-language human interface. Its main functions are: - creation, modification, and recall of the different work programs and of relative options. - visualisation of the machine conditions, with a constant indication of the real production rate, of the prograed heating percentage, and of all relevant parameters. - numerical visualisation of the power distribution. - visualization and memorisation of the diagnostic messages. 2.11 Telematic service The machine is prearranged for the telemetric service, through which the SIAPI experts can help the customer in case any functioning problem should occur. The PLC is equipped with a transfer card that must be connected with the issued modem. 2.12 Pneumatic system It was built with standardised components, which can be easily changed. It is provided with manual controlled light state signalling electro-valves, cylinders with magnetic limit switches with led and transparent, numbered pipes. 2.13 Ventilation system It consists of centrifugal metallic fans, some of which are controlled by inverters; the ducts are made of zinc-plated steel and aluminium 3
2.14 Protections Protections envelop the whole machine. The low part of the machine is entirely enveloped in sheet panels lined with soundproofing material; transparent panels enclose the upper part. All the doors are protected by circuit breaker. The transparent parts allow a constant and safe control of the machine functioning. 2.15 Safety The machine is designed and built to Machine Directive 89/392/CEE and later amendments, and is therefore provided with solutions and devices designed to guarantee safety. It has the CE mark and for EU countries comes with the prescribed Declaration of Conformity. 4
3. TECHNICAL DATA (*) The output depends on preform design, preform thickness, bottle design and quality of PET resin (**) It depends on the regulations (real production, pressures, etc.) PRODUCTION DATA Number of mould cavities Maximum container diameter Maximum container height Maximum container neck diameter Maximum container capacity Max nominal output for a 6 l bottle Efficiency No. l bph % 1 340 570 85 5 30 700 95 ELECTRICITY SUPPLY Voltage Frequency Total installed power Installed power for motors Voltage tolerance admitted Frequency tolerance admitted Auxiliary power supply Distribution Power factor V HZ kw kw V DC Cos 220 or 380 or 460 50 or-60 92 28 +/-5% +/-1% 24 3PH +PE 0,9 COOLING SYSTEM Water input temperature Water input pressure Flow rate Cooling capacity C bar l/min kcal/h 10 3 80 18.000 SERVICE AIR Nominal pressure Typical rate(**) Filtration (filter) Humidity bar Nm³/h Micron 6 120 0,5 dehumidified BLOWING AIR Nominal pressure Air rate(**) Filtration (filter) Humidity Oil HEATING Installed power Heater units Lamps per unit bar Nm³/h Micron kw No. No. 38 470 (30l@300b/h) 0,01 Dehumidified Oil free 64 2 16 5
ABSORPTION Absorbed power (*) kw 30-45 ENVIRONMENTAL CONDITIONS (for conditions different from those shown, consult the SIAPI technical dept.) Ambient temperature Ambient humidity (without condensation) Maximum altitude DIMENSIONS Length Width Height Mass CONNECTIONS Service air connection (6 bar) Blower air connection (40 bar) Water connections FEEDER Length Width Height ELEVATOR Length Width Height C % m.a.s.l. kg Inches Inches Inches 10-40 5-90 1000 3000 2100 3550 6000 1 1-1/2 1 1220 620 2200 2980 1300 2480 MATERIALS AND TREATMENT COMPONENT MATERIAL TREATMENT Structural parts Steel Minimum double coat of paint (primer and alkyd base finish) External panels Aluminium Magnetostatic epoxy powder coating External panels Polycarbonate - (transparent) Heaters Stainless steel Polishing Sundry elements Anticorodal Anodic oxidation Guides etc. Alloy steel Aonia hardening 6
BOUGHT IN COMPONENTS Below are listed the brands of the main bought-in components. Choice is based essentially on criteria of technical reliability, availability, and company standards. On request and with a special coercial agreement different makes can be used for some components, to comply with the customer s specifications. In this case, SIAPI ensures functionality, but cannot guarantee duration or the future availability of spares COMPONENTS USED BRAND MECHANICAL COMPONENTS Reduction units Bearings Ball runners and relative guides Toothed belts Rossi SKF Bosch Megadyne PNEUMATIC COMPONENTS (6 bar) Cylinders and actuators Solenoid valves Accessories FESTO FESTO FESTO and SMC PNEUMATIC COMPONENTS (40 bar) Valves Manual cocks Siapi Flutec ELECTRICAL COMPONENTS PLC Brushless motors Drivers Touch Screen General knife switch, cut-out Automatic switches, cut-outs and contactors Stabilized power supply units 24 V DC Terminal boards Safety guard control unit Safety switches, mechanical and inductive limit switches Asynchronous motors Heater Power controllers Photocells Telemecanique Siemens Siemens Phoenix Contact Siemens Pilz MT Helios Eurotherm Datalogic 7