Frame Structure

Distinctively designed and precisely machined, strong and sturdy, steel frame structure completely machined on CNC-VMC, maintainsaccuracy over long dependable life and ensures less vibration even with optimum line speed. The structure enhances illumination of the working area.

The precise mechanical construction of each component, which undergoes extensive tests, ensures optimum performance and longer equipment life.

Control system

All the printing units, unwinder, rewinder, in-feed and out-feed are individually driven by servo motors-drives and controlled and supervised by the high performance PLC/PPC having its own intelligent software.

‘Fiber optic bus system’ used for maintaining tight synchronization between all the drives by providing fast, reliable and jitter-free communication.

Operator interface

Master operator control panel mainly consists of full colored touch screen operator interface located at rewind side and remote operator control panel located at unwind side, facilitates easy operation.

Unwind group

Turret type unwinder with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC.
The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller and cutting blade assembly etc.
Pneumatically expanded shafts and safety chucks to hold the reels.
Unwind web tension control by using latest generation AC servo motor and AC drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motors and drives, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back.
Electro-electric edge guiding system with Ultrasonic edge sensor.

Operating method ISO integrated with 'SAP' ERP operating system Spread in 19,000 (sqm) with build up area of 10,000+ (sqm)

In-feed system (Draw unit)

The system maintains set tension between in-feed and first printing unit precisely and isolates the printing unit from tension disturbance of the unwinding zone. The system mainly composed of matt chromium plated steel roller, AC servo motor and drive, load cell and rubber covered nip roller with pneumatically adjustable pressure.

Print unit control panel

Each print unit control panel consists pneumatic controls for drying hood, doctor blade and impression rubber roller & electrical controls for manual length and side-lay registration setting, blower control, temperature display for drying chamber and emergency stop.

Trolley system
For quick change of engraved cylinder & the whole inking group facilitates fast and easy job changes. Trolley consists of hollow type cylinder mounting shaft assembly with quick locking check nut, double ink basin and speed variable air motorized Ink pump.

Idle rollers
Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness

Chill rollers Low friction design chill rollers, made of Aluminum alloy with stain steel inner sleeves for effective web cooling.

Sleeve type Impression assembly

The sleeve system, consists of an air mandrel with a rubber covered fiberglass sleeve, provides functional flexibility.Sleeve type rubber covered impression roller raising lowering on precision linear bearings ensure smooth and precise displacement. Pneumatic working impression controls with independent pressure adjustment for both the sides. Sleeve made of fiberglass or fiberglass and carbon. Hardness: between 70 and 85 shore A

Transmission

The printing cylinder shaft is directly connected to the drive motor without gears, which eliminates mechanical backlash, ensures consistent operation over time and offers true direct drive solution.

Viscosity Controllers (optional)

An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.

Doctor blade group

Designed to ensure a straight profile of the blade resulting in lesser blade pressure, better printing quality and longer cylinder life. The blade locking by eccentric rod without tools. The group allows horizontal, vertical and angular adjustment for the doctor blade position on engraved cylinder. Pneumatic doctoring pressure with adjustment possibility from the unit control panel.

Automatic register control system

Automatic length and side-lay register control system with full colored touch screen operator interface facilitates automatic mark centering and recognition. Automatic selection of different control parameters during machine speed changes and control parameters individually configurable to different materials for easy operator selection.

Drying system

Ink drying is obtained by blowing hot air on the web through air nozzles. The optimized airflow minimizes heat consumption and avoids solvent retention in the printed substrate. The system mainly composed of single hood drying chambers, ventilation modules, connection ducts, central exhaust system and thermic fluid heating system.

Single Hood Drying Chamber Opening-closing by means of pneumatic piston, horizontally sliding on the rails, to allow easy access for web threading and cleaning.

Ventilation Module suitable to send and re-circulate the process air. The module composed of AC frequency drive controlled centrifugal fan, thermal oil heat exchanger and necessary controls and feedback device for temperature.

Central Exhaust System Composed of AC frequency drive controlled heavy-duty centrifugal fan to collect solvent contaminated air from all the printing units through central duct. The ducts fitted with manual adjustable dampers.

Out-feed system

The system maintains set tension between last printing unit and out-feed precisely and isolates the printing units from tension disturbance of the rewinding zone. The system mainly composed of matt chromium plated steel roller AC servo drive, AC servo motor, load cells and rubber covered nip roller with pneumatically adjustable pressure.

Web Video Inspection System

Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).

Rewind Group

Turret type rewinder with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC/PPC. The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller, and cutting blade assembly etc. Pneumatically expanded shafts and safety chucks are provided to hold the reels.

Rewind Web Tension Control By using latest generation AC servo motor and AC drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and AC drive, pneumatically loaded low friction dancing roller assembly and load cells for tension feed-back.

Lay–on Roller Assembly Pneumatically operated lay on roller assembly complete with pressure gauge and regulator for control of the pressure on the rewind reel.

Viscosity Controllers (Optional)

Rewind Web Tension Control An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.

Automatic Defect Detection System (Optional) Automatic defect detection system detects printing defects before they are seen by the human eye. The moment any of the defect like Color variations, Doctor Blade Streaks, Mis-registration, Spots, Splashes etc. are detected, the relevant Image of the printed area is displayed on the screen and the red alert switches on. All defects are marked and classified.

Frame Structure

Distinctively designed and precisely machined, strong and sturdy, steel frame structure completely machined on CNC-VMC, maintains accuracy over long dependable life and ensures less vibration even with optimum line speed.

Control system

Unwinder, rewinder, common for all print units, in-feed and out-feed are individually driven by servo motors-drives controlled and supervised by the high performance PLC/PPC having its own intelligent software.

‘Fiber optic bus system’ used for maintaining tight synchronization between all the drives by providing fast, reliable and jitter-free communication.

Operator interface

Master operator control panel mainly consists of touch screen operator interface located at rewind side and remote operator control panel located at unwind side, facilitates easy operation from both the end Electro-electric Edge Guiding System with Ultrasonic edge sensor and PMDC motor.

Unwind group

Unwind Web Tension Control by using latest generation AC servo motor and drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and drive, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back. Pneumatically expanded shafts and safety chucks to hold the reels.

In-feed system (Draw unit)

The system maintains set tension between in-feed and first printing unit precisely and isolates the printing unit from tension disturbance of the unwinding zone. The system mainly composed of matt chromium plated steel roller, AC servo motor and drive, load cell and rubber covered nip roller with pneumatically adjustable pressure.

Print unit control panel

Each print unit control panel consists pneumatic controls for drying hood, doctor blade and impression rubber roller & electrical controls for manual length and side-lay registration setting, temperature display for drying chamber and emergency stop.

Idle Rollers

Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness.

Out-feed System

The system maintains set tension between last printing unit and out-feed precisely and isolates the printing units from tension disturbance of the rewinding zone. The system mainly composed of matt chromium plated steel roller AC servo motor and drive, load cells and rubber covered nip roller with pneumatically adjustable pressure.

Rewind Group

Rewind web tension control by using latest generation AC servo motor and drive. The system maintains the set tension precisely through out the reel run. The system mainly composed of AC servo motor and drive, pneumatically loaded low friction dancing roller assembly and load cell for tension feed-back.

Pneumatically expanded shafts and safety chucks to hold the reels.

Transmission

Five drive servo driven automatic web tension control systems : Load cell and or dancer based closed loop Servo motor control & drive on (1) Unwind (2) In-feed System (3) Printing Station (4) Out -feed System (5) Rewind.

Automatic Register Control System

Automatic length and side-lay register control system with full colored touch screen operator interface facilitates automatic mark centering and recognition. Automatic selection of different control parameters during machine speed changes and control parameters individually configurable to different materials for easy operator selection.

Doctor blade group

Designed to ensure a straight profile of the blade resulting in lesser blade pressure, better printing quality and longer cylinder life. The blade locking by eccentric rod without tools.

The group allows horizontal, vertical and angular adjustment for the doctor blade position on engraved cylinder. Pneumatic doctoring pressure with adjustment possibility from the unit control panel.

Drying System

Ink drying is obtained by blowing hot air on the web through air nozzles. The optimized airflow minimizes heat consumption and avoids solvent retention in the printed substrate.

The system mainly composed of single hood drying chambers, ventilation modules, connection ducts, central exhaust system.

Ventilation Module suitable to send and re-circulate the process air. The module composed of AC frequency drive controlled centrifugal fan, thermal oil or electric heat exchanger and necessary controls and feedback device for temperature.

Connection Ducts and piping for the delivery and re-circulation between drying chamber and ventilation module. Adjustment of air balancing by means of manually operated dampers.

Central Exhaust System

composed of AC frequency drive controlled heavy-duty centrifugal fan to collect solvent contaminated air from all the printing units through central duct. The ducts fitted with manual adjustable dampers.

Impression Rubber Roll

Pneumatically operated impression rubber roller raising lowering on precision linear bearings. The precision linear bearings ensure smooth and precise displacement.

Pneumatic working impression controls with independent pressure adjustment for both the sides.

Motorized web video inspection system

Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).

Motorized Ink Pump

Speed variable, air motorized Ink pump on each station with ink flow/pressure adjusting valve

Lay–on Roller Assembly

Pneumatically operated lay on roller assembly complete with pressure gauge and regulator for control of the pressure on the rewind reel.

OPTIONAL ATTACHMENTS

Turret System
Turret system with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC/PPC.

The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller and cutting blade assembly etc.

Pneumatically expanded shafts and safety chucks to hold the reels.

Thermic Fluid Heating System 

Oil or gas fired Thermic Fluid Heating System (instead of electrical heating system) : The system consists of main Boiler & Radiator (heat exchanger) on each printing station with necessary valves, fittings, etc...

Viscosity Control System

An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.

Trolley System

For quick change of engraved cylinder & the whole inking group facilitates fast and easy job changes. Trolley consists of hollow type cylinder mounting shaft assembly with quick locking check nut, double ink basin and speed variable air motorized Ink pump.

Machine Control System

Entire machine is controlled and supervised by PLC/PPC. The ‘BUS SYSTEM’ for machine automation maintains tight synchronization between PLC/PPC and drives, providing fast, reliable, and errorless communication. Master control panel consists touch screen operator interface located at rewind side and slave control panel at unwind side provide easy access

Frame Structure

Carefully and methodically machined strong and sturdy heavy duty steel frame structure machined on CNC-VMC, maintains accuracy over long dependable life. Distinctively designed structure ensures less vibration even with optimum line speed. All components undergoes extensive tests, ensures optimum performance and longer equipment life.

‘integral’ Shaftless Unwinder

Unwinder with hydraulic operated reel lifting system consists of two solid arms mounted on precision linear guide ways, which allows lateral displacement for web guiding. This arm assembly is mounted on a hydraulic operated pivoting steel fabrication for pickup of the parent reel from the floor level to working position. Mechanical self expanding chucks suitable for 76mm and 152mm cores are provided.

Unwind Tension Control

Automatic web tension control system on unwind consists of latest generation AC digital drive, servo motor and pair of load-cell. The system maintains tension precisely through out the reel run up to the core diameter.

web Guiding System

Digital web guiding system maintains precision alignment of the web entering the draw unit. The web is guided by edge and printed (continuous or broken) lines. The system consists of true color line sensor and PMDC motor etc.

Draw Unit

By using latest generation AC digital drive and servo motor, web tension control is maintained precisely. The draw unit pulls the substrate from unwind and isolates the tension between unwind and rewind.

Draw unit mainly composed of AC servo motor and drive, mat chromium plated steel roller and pneumatically loaded rubber covered nip roller.

Rewind Tension Control

Hi-performance differential winding system consists of AC digital drive, servo motor, load-cells, ultrasonic sensor etc. The system allows the operator to enter the set tension, taper tension and over speed values according to the nature of substrates and the system will maintain the desired tension automatically.

Differential Winding System

Hi-performance differential winding system utilizing ‘Ball lock’ units, ensures constant tension regardless of different width of the reel being rewound on the same shaft. Normal web profile variation is automatically compensated by the differential winding system. It also increases productivity and minimizes ‘downtime.’

Lay-on Rollers

Each rewinder is equipped with pneumatically operated lay-on assembly, consists of PU coated rubber rollers and backing rollers on a pair of arms mounted over linear guide ways. 

The linear displacement of the arms allow desired positioning of lay-on and also provide ease to replace different widths of rubber rollers.

Slit Reel Unloading

Pneumatically operated shaft supporting arms facilitate quick unloading of the slit reels from differential shafts to unloading stand. The unloading stand provides support to cantilevered differential shafts during unloading operation.

The machine :

By perfectly integrating the new generation of electronics and ergonomically designed mechanical components, the machine is made to deliver optimum performance and productivity.

Pelican’s range of converting equipments is designed and developed to achieve high standards in flexible packaging. Its state-of-the-art technology offers excellence in converting solutions.

Frame Structure

Distinctively designed strong and sturdy, heavy-duty steel frame structure, completely machined on CNC-VMC, maintains accuracy over long dependable life and ensures less vibration even with optimum line speed.

The mechanical construction of each component, which undergoes extensive tests, ensures optimum performance and longer equipment life.

Unwind & Rewind Group 

Web guiding system for unwind station. Air Shaft and Safety chucks on unwind and rewind station.

Operator Interface

Master operator control panel and remote operator control panel consists 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.

Web Tension Control

Direct web tension control by using three drive control system consists of Load cell based closed loop vector controlled individual AC frequency drives for (I) Unwind station (II) Main drive (III) Rewind station. Unwind : Auto web tension control system by using vector controlled AC drive & motor

Main Drive : Vector controlled AC drive & motor

Rewind : Auto web tension control system by using vector controlled AC drive & motor

Plate Cylinder Group

Hydraulic throw-off system for plate cylinder with separate hydraulic motor ensures continuous rotation of anilox roller which will not allow ink dry-up during machine stop operation. (Optional)

Idle Rollers

Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness.

Motorized Ink Pump

Speed variable, air motorized Ink pump on each station with ink flow/pressure adjusting valve

In-feed & Out-feed System (Draw unit)

The system mainly composed of matt chromium plated steel roller, and rubber covered nip roller with pneumatically adjustable pressure.

Drying & Exhaust System

Drying Chamber: Mainly consists of AC frequency drive controlled heavy-duty blower with connection duct and dampers to balance fresh and recycling air.

The optimized air flow, minimizes heat consumption and avoid solvent retention in the printed substrates.

Central Exhaust System: AC frequency drive controlled solvent extraction system to exhaust contaminated air from all the print stations through central duct.

OPTIONAL ATTACHMENTS

Ceramic Anilox Rollers 
Robotic plasma coated and laser engraved with improved cell structure ceramic anilox rollers with quick change over mounting arrangement..

Chamber Doctor Blade

Specially designed chamber doctor blade group, ensure straight profile of the blade resulting in lesser chamber pressure, better print quality & longer anilox roll life.

Motorized Web Video Inspection System

Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).

The machine

By perfectly integrating the new generation of electronics and ergonomically designed mechanical components, the machine is made to deliver optimum performance and productivity.

Pelican’s range of converting equipments is designed and developed to achieve high standards in flexible packaging. Its state-of-the-art technology offers excellence in converting solutions.

Frame Structure

Distinctively designed strong and sturdy, heavy-duty steel frame structure, completely machined on CNC-VMC, maintains accuracy over long dependable life and ensures less vibration even with optimum line speed.

The mechanical construction of each component, which undergoes extensive tests, ensures optimum performance and longer equipment life.

Impression Cylinder Assembly

High-precision grounded, chrome/nickel plated central impression Cylinder: Precisely ground with closer TIR tolerance, assembled on high precision bearings, double wall structured for water circulation.

Control system

Master operator control panel and remote operator control panel consists 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.

Web Tension Control

Multi drive servo driven automatic web tension control systems : Load cell based closed loop servo motor control & drive on (I) Unwind (II) Main motor (III) Out-feed (IV) Rewind.

Unwind : Auto web tension control system by using latest generation AC servo motor and drive.
Main Drive : AC servo motor and drive. Out-feed : The system maintains set tension between last printing unit and out-feed precisely and isolates the printing units from tension disturbance of the rewinding zone. The system mainly composed of matt chromium plated steel roller AC servo motor and drive.
Rewind : Auto web tension control system by using latest generation AC servo motor and drive.

Unwind & Rewind Group

Web guiding system for unwind station.
Air Shaft and Safety chucks on unwind and rewind station.

Idle Rollers

Specially designed, dynamically balanced low friction-low inertia idle rollers made of Aluminum alloy, mounted on low friction bearings, enhance rotational smoothness.

Plate Cylinder Group

Hydraulic throw-off system for plate cylinder with separate hydraulic motor ensures continuous rotation of anilox roller which will not allow ink dry-up during machine stop operation.

Ceramic Anilox Rollers

Robotic plasma coated and laser engraved with improved cell structure ceramic anilox rollers with quick change over mounting arrangement.

Chamber Doctor Blade

Specially designed chamber doctor blade group, ensure straight profile of the blade resulting in lesser chamber pressure, better print quality & longer anilox roll life.

Drying & Exhaust System

Drying Chamber: Mainly consists of AC frequency drive controlled heavy-duty blower with connection duct and dampers to balance fresh and recycling air.

The optimized air flow, minimizes heat consumption and avoid solvent retention in the printed substrates. Central Exhaust System: AC frequency drive controlled solvent extraction system to exhaust contaminated air from all the print stations through central duct.

Motorized Web Video Inspection System

Motorized web video inspection system consists of high quality CCD color camera, Industrial PC & Monitor (facilitates sequential inspection of the lateral and entire print repeat of the web).

Motorized Ink Pump

Speed variable, air motorized Ink pump on each station with ink flow/pressure adjusting valve

OPTIONAL ATTACHMENTS

Viscosity Control system
An individual system for each printing unit measures and controls the viscosity of the ink. The system is having features like Automatic calibration of the viscosity, Automatic rinsing, Programmable process parameters, Synoptic display of the alarms, Function chronometer at the unit, self cleaning operation etc.

Turret System

Turret system with flying splice facilitates automatic reel change-over without stopping the machine. The whole function is controlled and supervised by the high performance PLC/PPC.
The system mainly composed of push button initiated motorized rotating disc, pneumatically loaded automatic splicing arm, PU covered pasting roller and cutting blade assembly etc.
Pneumatically expanded shafts and safety chucks to hold the reels.

The Machine

Pelican's range of converting machinery is designed and developed to achieve high standards in flexible packaging. It's state-of-the art technology offers freedom to carry out even difficult jobs.

Salient features:

Carefully and methodically machined strong and sturdy heavy duty frame structure having good combination of plate with cast iron, to maintain over long dependable life. This distinctively designed frame structure mounted on heavy-duty base.

AC Digital drive based automatic web tension control systems: Load cell and or dancer based closed loop AC digital vector controlled Five drive system on (1) Primary unwind station (2) Secondary unwind station (3) Coating station (4) Laminating station (5) Rewind station. These types of control loops ensure constant tension through-out reel run, right up to core diameter

Pneumo / hydro web guiding system, air shaft with safety chucks on both the unwinding station

Pneumatically operated impression rubber roller and doctor blade System

High efficient nine meters Insulated-drying chamber divided in four zones with exhaust system consists with hot air generator or thermic fluid heating system with automatic temperature controller.

Pneumatically openable four zone drying chamber for web threading and cleaning

Gravure type coating station accommodates integral shaft type or hollows type coating cylinder

The machine is fitted with worm gearboxes, which ensure smooth rotation at all speed level

Remote operator control panel fitted on coating station and laminating station to facilitates easy operation of the system

Catwalk through-out the length of the machine

Quick change-over pressure roller assembly

Over and above other features also exist

Material Substances :

For coating:
Pet 12-30 microns
Nylon cast 30-80 microns
BOPP 18-80 microns

For laminating:
LDPE / HDPE 25-150 microns
BOPP 18-80 microns
Nylon cast 20-80 microns
Pet 12-30 microns
Various Co-ex 12-30 microns