VIVAS Co.

SJ-FS5.5-120A/1200 Extrusion Line

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Modern technologies were applied in development of this equipment. The line consists of extruder, stretching module and winding module. The equipment uses polypropylene (PP) or high-pressure polyethylene (LDPE) for production of threads (tapes).

Production chain: raw material heating, film production, cutting into threads, stretching and thread forming, winding threads on bobbins, feeding bobbins with threads to circular loom. This machine is universal in terms of raw material options.

Screw, drum and other important parts of the machine are made of special alloy steel.

SJPL-Z65/30-700 High-speed Extrusion Line

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Line features:

The machine for manufacturing flat PP yarn is controlled by microprocessor control. Frequency converter regulator readings, setting and display of technical parameters are presented exclusively in digital form.

Main machine units are made of high-quality materials. Features increased length/diameter ratio and expanded PP melt zone of screw barrel, soft plasticizing effect, low energy consumption. Progressive automated technology is used for filter replacement in flat yarn tension unit.

Instead of firing plate, hot drawing oven is used and principal technical index of the line reaches the best international standards.
Winding machine uses non-friction motor and features constant flat yarn tension during operation.

Line structure

1. Extruder with T-Die head 2. Cooling bath 3. Longitudinal slitting machine
4. Fixing device 5. Tape extraction unit 6. Hot air supply 7. Tape tension and stabilization unit
8. Loading hopper with dosing and mixing device 9. Automatic switch
10. Stacker 11. Fibrillator (for oriented film production)
12. Additional tension device

The line combines compact structure with pleasant design, features smooth operation, flexible and reliable control of production processes, advanced engineering in manufacturing, convenience and reliability in operation.

1. Extruder with T-Die flat slot head

Screw operation is optimized using Hi-Q computer to achieve better melt homogenization and its feeding to flat slot head. Flow geometry calculation process is computerized to optimize distribution and minimize film size variation across width. Other extruder features include original screw coil structure, cold start protection, microprocessor PID control, melt temperature and backpressure indicators, pneumatic extruder trolley movement.

2. Cooling bath (for film quenching)

Cooling bath for film quenching has special design minimizing water turbulence, temperature controller for monitoring water mass temperature uniformity. Includes extruding rubber rollers, suction pipes and film water excess cleaners.

3. Longitudinal slitting machine

Longitudinal slitting machine is installed on separate bracket with reciprocating knife block, which provides vibration-free film cutting and increases knife service life.

4. Water removal system

Water removal system consists of 4 specially designed water suction pipes, three rubber rollers, one steel roller for thorough removal of residual moisture from film surface.

5. Fixing device

Provides subsequent non-slip tape tension

6. Tape extraction unit

Allows accumulation and removal of defective tape from process. Includes effective aspiration system consisting of suction nozzles, pipeline system, waste box.

7. Tape tension and stabilization (annealing) unit

Combined PP tape tension and stabilization unit with 5/6 rollers has independent drives separately for tension and stabilization zones. Roller configuration can be organized depending on final requirements by mixing normal, hot and cold rollers. Oil-heated rollers allow controlling residual shrinkage in stretched tapes. Water-cooled rollers provide constant normal temperature of tapes going to parallel winders.

8. Automatic filter change unit

Automatic filter change unit allows controlling filtration pressure before and after filter screen. It also allows setting specified values of such pressure for process control. On order, 10-meter long belt filter screen is supplied.

9. Fibrillator (for orientation of tape molecular structure to give it additional strength)

Fibrillator, placed between hot air supply system and tape tension and stabilization unit, is intended for changing orientation of tape molecular structure to give it additional strength. Needle roller has independent drive, needle replacement possibility with adjustable pitch (needle placement) is provided to give required fibrillation structure. Modular fibrillator design allows simultaneous production of both fibrillated and non-fibrillated tape.

10. Additional tension device

Additional tension device is used to give tape low-shrinkage properties (low relative elongation at break). The unit consists of three heated rollers with independent drive of oil circulating system.

11. Hot air system

For upper and lower tunnels, two independent hot air supply blowers are used, computerized general control of heating and air flow speed sets uniform temperature and flow over the entire heated surface, which is necessary for production of high-quality tape.

12. Computerized automatic control - touch screen

Friendly interface combined with latest PLC control allows recording operating parameters, monitoring, controlling all main machines included in the line. Computer automatically records various denier parameters to eliminate unqualified operation problems.

Inverter winding machine (high-speed winders)

These parallel winding machines are the most suitable solution for winding flat/fibrillated tape for use on both circular looms and flat looms.
High-speed magnetic winders with electronic control system meet high accuracy and flawless quality requirements while eliminating complex mechanisms in their design and significantly reducing electricity consumption.
Placed sectionally on strong deformation-resistant frame with 12 spindles on each.
Speed regulation using 3-phase frequency converter.

Circular Loom Six-Shuttle Machine SBY-850X6S

This new series of circular looms is developed based on advanced technologies, extensive research and practical experience of operating similar machines both in China and abroad. Designed for weaving flat PP and LDPE threads into sleeve fabric.

Circular loom SBY-850X6S is equipped with 6 shuttles with rotation speed of 180 revolutions per minute.

Circular loom productivity is 2.4 meters per minute. Productivity during working day reaches more than 2900 meters.

This machine has unique patented high-speed weaving system. Thanks to high-efficiency lubrication system, wear of rubbing parts is reduced, electricity consumption is reduced, noise level is reduced and, ultimately, maintenance costs. Circular loom series SBY-850X6S is equipped with emergency automatic shutdown system in case of thread break, controlled by microcomputer. Electromechanical main motor control system allows smooth speed regulation. Electronic control system allows easy adjustment of yarn thickness, automatically compensates breaks and allows achieving high weaving quality.

Advantages:

★ New surface cam driving structure;
★ Shuttle type - disc-less, minimum friction, stable operation;
★ Latest weft&warp detection system, minimum losses, high efficiency;
★ New automatic weft feeding system, reducing losses;
★ Automatic synchro-controller guarantees production of smooth-textured fabric;
★ Maximum shuttle rotation speed of weaving machine – 180 rpm with productivity 2.7 meters/min. Faster, more stable with minimum power consumption.

QF850 Automatic PP Sleeve Cutting and Sewing Machine

1 Maximum roll diameter - 1200mm
2 Roll width: 300-850mm
3 Cutting length: 500-1250mm
4 Cutting accuracy: ±1.5mm
5 Bottom hem width: 20-30mm
6 Productivity: 20-36 pcs/min
7 Bag sewing machine: NewlongDN-2H2
8 Stitch length: 7-12mm
9 Air compressor power: 3.7kW
10 Main motor power: 3.7kW
11 Heating power: 2kW
12 Total power: 9.4kW
13 Weight: 2200kg
14 Overall dimensions: 5000×3000×1000mm

Granulator-Extruder for Production Waste Recycling

Model	SJ-FJ110
Screw diameter	110 mm
Screw length to diameter ratio	15:1 and 10:1
Screw rotation speed	50-60 rpm
Main motor power	11kW
Auxiliary motor power	7.5 kW
Cutting device power	0.37 kW
Heating power	12 kW
Productivity	30-80 kg/hour
Weight	1000 kg
Overall dimensions	4500x2000x1100mm

DB-100. Baling Press

Model No.	DB-100
Working dimensions	1200x600 mm
Maximum pressure	2.5MPa
Working cylinder length	1100 mm

Working Personnel

Note. 1. This calculation is made only for workforce requirement for
line operation, management personnel not included.
2. Calculated for standard 3 shifts per day (8 hours/shift) or 12 hours for 2 shifts per day

Requirements for Production Area, Electricity, Water

Note:

1. Installed power consumption is about 253KW, 380V, 50HZ, actual energy consumption is 60%-70% of installed power or approximately 150KW.

2. Water is used only for cooling extrusion line units. Underground tank with pump is equipped outside production workshop.

3. Actual area occupied by equipment is 530 m2, workshop height should be 5 meters, workshop width - minimum 30 meters. However, it should be taken into account that considering the need for passage arrangement, material storage areas, semi-finished and finished products, proposed production area is L 60m x W 30m x H 5m

Environmental protection
Environmentally friendly production, noise level below 75DB.