TECHNICAL SPECIFICATIONS :

Web Edge Guide System
Shaft less System at Unwinder & Rewinder.
3 Drive System for Synchronised auto Tension Controller for Unwinder, Rewinder and Main Drive.
Touch Screen System for easy Operating.
Viewing - Inspection Box for both side.
Stroboscope for full width for Defect Detection.
Pneumatics System for Nipping.
Double Direction with Reverse System.
2nd Small Rewinder for Rewind the wastage.
Winding System :- Shaft less Center Winding
Web width Max./min 1000mm / 500mm
Max. Reel dia. at Unwinder :- 800mm. (500 Kgs.)
Max reel dia. at rewind :- 800mm. (500 Kgs.)
Core ID at unwind :- 76mm & 152mm
Core ID at rewind :- 76mm & 152mm
Core OD at Unwind & rewind
Plate Thickness :- 30mm
Substrates :- Polyester, BOPP, LDPE, Laminates
Mechanical Design speed :- 225 meters per minute
Operating speed :- 200 meters per minute
Tension at Unwind & Rewind :- 20N to 280N

Created to cover the growing needs of solventless lamination on flexible packaging market. Enhanced performances, on one hand, and the easy operating features on the other, are the main reasons to select this machine, joined with its ability to handle a wide range of laminating jobs. The machine has been specially designed, focusing on short and medium runs on solventless applications over plastic films. The machine is made to deliver optimum performance and productivity.

Frame Structure

Distintively designed and precisely machined strong and sturdy, steel frame structure, with stiffening tie-rods; maintains accuracy over long dependable life and ensures less vibration even with optimum line speed. The structure enhances illumination of the working area. The mechanical construction of each component, which undergoes extensive tests ensures optimum performance and longer equipment life.

Removal of the metering cylinder

Quick and simple removing of the metering cylinder, which is achieved through unlocking the driving system on this cylinder.

Adhesive metering System

R1 : First feeding roller, heated and manually rotated both side.
R2 : Feeding roller is heated and independent motorized from R1, allowing the floating system created to facilitate the cleaning process.
R3 : Metering roller rubber coated ; easily interchange – able for different web widths.
R4 : Heated and motorized roller allows a perfect delivery of adhesive over the substrate coordinating speed with R3.

Shaft – Less Unwinders & Rewind

Shaft less unwinders wed tension control by using pneumatics brakes & rewind wed tension control by using latest generation AC motor and AC drive the system maintains the set tension precisely throughout the reel run, the system mainly composed of AC motor and AC drive.

Control System

A. C. Drive based closed loop controller for web handling by using latest generation 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 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.

Laminator Unit

The laminator unit comprises a heated chrome – plated, ground steel roll, with double walls and an internal coil to cnsure the perfect and uniform heating on its whole width, and a rider roll coated with hard rubber and driven by pneumatic pistons which can be adjusted at both ends.

R5 Lay on roller provides the complement to get a smooth and homogeneous adhesive layer.

Backup roll at laminating unit is provided ensures uniformity and smoothness in impression of air bubbles etc., at either substrates

TECHNICAL SPECIFICATIONS:

Photocell Line Guide System
2 Drive System for Main drive & Rewinders
Touch Screen System for easy Operating
Pneumatic Break System at Unwinder Operating by 2 Drive System
Differencial Shafts at Rewinders
Shaft less System at Unwinder
Laser Light System at Rewinder for easy to loading Paper Core
Tension setting range between 20N to 300N
Layon Roller operated pneumatically
A.C. Drives for Main Drive & Rewind

STANDARD UNIT FEATURES:

Calculative Designed, Strong & heavy duty mild steel structure.
4 Drive System for Synchronized Unwinder, Main drive & both Rewinders.
Touch Screen Panel for easy & smart operating.
Minimum Wastage & minimum dependency on labour due to increased automation and easy operating system.
Cork Coated, Dynamically balanced, Specially desingned low friction idler rollers made of aluminium alloy, mounted on low friction bearing.
Digital Web Line Guiding System.
High Performance Differencial Winding Shafts.
The System Consist of AC digital Drive, load cell for feedback, Ultrasonic Sensor etc.
Each rewinder equipped with pneumatically loaded lay on assembly with contact pressure control.
Shaft less System for unwinder ( Optional)

TECHNICAL SPECIFICATIONS:

Web width : 1000, 1300, 1500 mm
Maximum operating speed: 150 M/min.
Maximum Cylinder Circumference: 350 to 900mm
Shaft less System for Unwinder
Plate Thickness – 45mm
Low friction ball screw compatible with auto register control system.
Slide type one side drying hood system.
Low friction dynamically balance guide rolls.
Rubber Roll Impression system with linear guide ways.
Printing Materials: POLYESTER, BOPP, LDPE, PAPER, ETC.
Roll Outer Diameter: 800mm on Unwinder & Rewinder
Registration Control System – Vertical Motorised
5 Drive System for Unwinder, In feed, Main Drive, Out feed & Rewinder

OPTIONAL ATTACHMENTS:

Web Video System
Automatic Registration Control System
Air Shafts & Safety Chucks
Cylinder Circumference – Up to 1100mm
Ink Circulation System

We have high precision German Super Finishing Machine to achieve high gloss mirror finish subsequent to the grinding operation. We use special abrasive tools to reduce peak to valley height and impart High Gloss Mirror Finish to the Roll resulting in a surface finish of 0.005 Micron Ra Value on the Roll.

Maximum Capacity: 
Ø524mm X 6000 mm Length 
10 Tons Weight Capacity

We are specialized in Grinding various types of Rolls to close geometric tolerance on precision German grinding machines.

Taper Below 5 micron(depends on Roller construction)
Concentricity Below 5micron(depends on Roller construction)
Ovality Below 5 Micron(depends on Roller construction)
Camber Profile: 3-5 micron station to station variation.

Our grinding capacity :

Ø 1850mm X 6500mm Length
Ø 900mm X 10000mm Length
10 tons weight capacity.

With an infrastructure of 3 Roll Grinding machines and 5 Cylindrical Grinding machines, we can grind Calendar Rolls, Work Rolls, Back Up Rolls, Dryer Cylinder, Rams, Calendar Rolls for PVC, Granite Rolls, Rubber Rolls etc.

Brahmani Grinding & Engineering offers a unique technology for Hard Chrome Plating of dies used in automobile industries, which in-turn provides various advantages and result oriented benefits to the customer.

The thin hard chrome layer which gets deposited on the working surface of the tool due to the HCP process has the following properties:

1.Nonstick in nature, Low Friction, Smooth Surface Finish:- These properties results in:
a) Improved material flow in the drawing process helps in…
i) Eliminating defects (such as wrinkling, Scoring, Splitting) on the car panel
ii) Zero panel rework time, man power, consumable cost
iii) Reduce panel rejection & panel rework rates
b) Highest lubricity, hence use of lubricants reduced by 90%
c) Shorter press operation time

2. Hardness (900 VPN/ 62 HRC), Good Wear Resistance:- These properties results in:
a) Increased die tool life: More wear & tear on un-plated dies takes place which causes the panel quality to decline as the shape of the die changes. The die then must be repaired by welding & subsequent re-profiling. This results in the additional costs such as…
i) Cost of skilled welding technician
ii) Costly welding material
iii) Cost of skilled polishing technician to reshape / re-profile the die
iv) Cost of tryout & adjusting the profile on the die tool
v) Cost of loss of production
vi) Increased loss of Idle time and effort, Indirect cost of electricity & other material

b) Die geometry is maintained at all times, even after multiple chrome plating hence panel quality remains consistent.

c) Re-plating of the die tool possible once the thin hard chrome plating layer disappears after thousands of stampings      process.

d) Hardness of 900VPN (62 HRC) is achieved by Hard Chrome Plating process at plating temperature of around 580 C, hence      virtually no heat distortion.

e) Other competing hardening process like Flame/Laser/Induction hardening, Plasma nitriding cannot achieve hardness of      more than 600 VPN, whereas HCP process achieves a hardness of 900 VPN.

f) Hard chrome plating can be applied on basic cheaper grades of Cast Iron like GG25E instead of expensive grades of      casting.

We have over 15 years of extensive experience in Hard Chrome Plating Rolls/ Dies of various sizes and base materials.

We have world class technical know-how through our 3 technical collaborations.We can HCP upto:

Ø1000mm X 7000 mm Length
Ø900mm X 6000 mm Length
Ø350mm X 6000 mm Length
10Tons weight capacity.
1,25,000 Amp Rectifier Capacity.

We can Hard Chrome Plate, Work Roll, Auto Dies, Mass Quantity Jobs, Centerless Bar Hard Chrome Plating, PQF Mandrel Bars, Dryer Cylinders, Baskets, Baffles for Chemical Industrial, Calendar for PVC, Doctor Roll, Super Calendar Rolls, Rams, Tie Bars, Metering Bar, T- Dies, Crane Booms etc.

Our roll department is staffed with technicians with over a century of combined texturing experience who is dedicated to our common goal: a quality product with a speedy delivery.

Capabilities include texturing of any size embossing roll and chemically etching aggressive and fine patterns to desired depths. We are capable of shipping in excess of five rolls each week.

Consistent communication between technician and consumer creates a trust unmatched by anyone in the field. Customers are always welcome to stop in and see the status of their roll.

Applications of embossing rolls are many, including refrigerator faces, linoleum, vinyl wraps and textured wallpaper.

Our unequalled expertise has secured our place in the embossing roll industry for over fifteen years. Our knowledge and superior workmanship ensures us to be the primary texture source to the roll industry for the next thirty-five years and beyond.

Is a family of processes that use a concentrated heat source to melt feed stock materials while imparting kinetic energy. When the hot energetic particles impact the surface of the part being coated they rapidly solidify. As subsequent particles impact the surface, a deposit thickness is built up

Providing Thermal spray services since 1998 we have made a place in the list of top thermal spraying companies in India by keeping ourselves updated with the latest technology equipments & a team of well trained engineers & technicians. We know provide solutions to your all round surface wear problem.