Poly propylene (PP 520L)

 Transparent (colors without)

 Melting flow index =3~ 12 needed 10 g/10 min
 VICAT Temperature=155 C
 Not to use (PE) and not use recycled (PP)
 In regular I straws M.F.I is not important but corrugated straw is
recommend to use high M.F.I

Co-polymer (QR6701K)
 Add in to PP , stable supply
 M.I= 10 g/10min
 Loader=20~30 % up 50 %
 VICAT Temperature=128 C

Master Batch (M.A)

 Additive for plastic for coloring plastics
 Melting temperature=2~3 %
 Ratio of M.A for min extrude = 1.5 ~ 2% and co-extruder=10%

PP+ co-polymer +M.A= fluorescent

Hopper unite assembly

= Hopper loader + Hopper +color blender unite + co-polymer blender
unite

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
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Film wrapping BOPP or OPP
BOPP: Bit Oriented Poly Propylene
Used 4 sided heat sealing process (2 rolls)
Outside used Corona treatment =30 ~ 40 dyne
Corona treatment help clear printing condition
Film roll width : Flat side(down)=+15 mm and overlapping side
(up) =18 mm (+ 2~ 3mm)/apple corona
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it Film roll =4,000 meter or =4000,000 mm
Film bobbin core=3 inch or = 76 mm
Thickness=15 micron (1 micron =10^-3 mm)
Film showing sharing 0.5 mm in room temperature in 1 ~ 2 days

Water chiller and water Tank (one extrusion)

Shouldn’t inside as one piece (separately installation)
Water tank one ton and more
Water chiller capa:250~ 300 liters/hr (type Air cooling)
Water chiller =minimum 15C
Different between chiller Air and Water?
Air: High noise
Water: low noise
Chiller: compressor one or more, motor drive (puller and bush),
AHU (Unit treatment Air)

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 Air compressor (GA 15 VSDFF Atlas)

 Stander pressure = 6 bar , 1 bar = 1 atom = 100 KP

 Capa electrics =11,25 ~ 15 KW (15 ~ 20 HP)
 Covering range (1~2 extrusion + 3 U-tandem line)
 Separate air tank

Stairs
 Feeding in to hopper of corrugating machine (all one tandem line
need 1 stair)

Straw carton
 Plastic DANPLA or strong paper
 DANPLA: mark name for plastic strong

Straw carton trollery

Straw mega box for Z folding boxing

 800 L x 600 W x 700 H .cm

Cart for mega box

BIN
 PP 75 kg
 Co-polymer 50 kg

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 Measuring tools
1) Straw wall thickness gauge (0~100 micron)
2) Film wall thickness (mitutoyo)
3) Inner diameter gauge (1~6 mm)
4) Digital weighing scale
 Measured by 0.01 g , max = 500 g
 Shouldn’t weighed 10 pcs
5) Vernier caliper
6) Steel ruler (300 mm)

Straw cutting blade

 Size mm: 38 L x 8 W x 0.25 T
 Carbon material better than stainless steel
 Titanium or ceramic coated blade

OLFA blade
 model (SAB – 10B)

Marker pen
 check "EVEN" straw wall thickness

Corona pen
 check treated surface of film rolls grinder
 two wheels for straw cutting blade

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 Gear oil / grease
 maintenance of machine

Adhesive splicing tape

 20 ~ 30 mm width , 3M quality

Box tapes
 2different color (green ,red)
 50 mm width
 Distinguish (start , end)

Poly bag
 Collecting of wastes

Waste bin
 More than 2 waste bin

Steel flat container

 Holt melted

Rubber band
 2 T x 120~140 mm

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g Extrusion Line:
Machine: straw extrusion equipment. DT-E5027B

Screw Diameter: Main Extruder: 50 mm

Co-extruder:25 mm

Power supply: max 40 kw without co-extruder

max 48 kw with two co-extruder

Air supply: 6 bars

Output machine: 50 kg per hours depending (diameter D, length L, wall

thickness T)

 U-shape straws: 4.3 mm OD x 183 mm L (0.45g/pcs) for T.P 250

ml slim
 =1400 ~ 1500 pcs per minute (38 ~ 41 kg/h)

Composed units:

Machine prices:
One complete line without co-extruder = 96,200 $

Tow Co-extruder= 8,600$

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1. Main extruder
 Screw & barrel : treatment of SACM nitrated steel of 50 mm D
 SACM: technology jumpiness used Injection
 Gear box for screw and barrel : Zambello (ZPE-112)
ZPE-112: technology Italy
 Main drive motor : 12 kw (15 HP)
 Die head: type open and easy calibrating the straw Thickness as
fast diameter change
 Remote puller speed control system
 Remote switch-off of main extruder
 Blow motors for cylinder barrel: total 3 sets (200w)
 Two sets of FESTO air - control regulators
FESTO: technology Germany Pneumatic
 Heater control
Die head: 4 steel band heaters (max 460 C)
Screw barrel: 6 Ceramic band heaters
PID type of digital temperature controllers.
PID: Proportional integral derivative
 SSR(solid-state relay) (HSR-2A404Z) : for heater control
contactors

Different between SSR and normal Relay?

SSR ‫ال يحتوي علي جزء ميكانيكي متحرك (فقط االلكتروني) فبتالي ال يولد صوت اتناء فتح‬
‫وغلق الدائرة وقليل االعطال وطول الفترة الزمنية المستعملة‬

 Main motor control :Yaskawa Inverter controller (15HP, VVVF

type, made in Japan)

Inverter: ‫هو جهاز مخصص لتحكم والحماية بالمحركات التي تعمل علي تيار المتناوب‬

 Speed control potentiometers (1010-turn type, made in USA) for

fine and precise speed control ‫لتحكم بسرعة ودقة الدوران‬
 Digital RPM tachometers: to measuring main motor speed per min

RPM: Revolution Per Minute

Tachometers: ‫هو جهاز لقياس عدد دوران المحرك‬

 2,700(L) x 1,200 (W) x2,000 (H) mm

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Co-extruder
 Screw & barrel : treatment of SACM nitrated steel of 25 mm D
 Heater control : 5 band heaters
 SSR for band heaters and also for electrical safety
 Drive motor : 1.5 kw
 Motor control : Yaskawa Inverter controller (2HP, VVVF type,
made in Japan)
 Digital tachometers: fine speed to control of motor
 Speed control potentiometers (10-turn type, made in USA) for fine
speed control
 1,150 (L) x 610(W) x 1,650 (H) m

2. Vacuum cooling tank

 Hi-speed vacuum calibration: 2 vacuum size for 2 different vacuum
chamber controls.
 Length of vacuum = 5,000 mm ,chamber =1,200 mm
 2 different water temperature system
 Motor for vacuum calibration = 2 HP made in USA
 Air wipe: for hi-speed drying water
 3 sets of thermal meters

3. Puller & cutter with conveyor bin

 Capa ( 300 ~ 350 meter /min)
 2 main AC motor of: 2 HP(wheel cutter)+1 HP (puller) Yaskawa
Inverter , VVVF type, made in Japan)

 1 set of drum is used multi length (150 ~ 270mm) ,and diameter (3

~ 8 mm OD)
 Hi-linear speed (2,900 RPM) so need ionizing

Ionizer: device for removing static electricity

‫لتخلص من الكهرباء الساكنة نستخدم التأين‬

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 Remote control speed of puller and cutter
 Synchronizing system between unit puller and unit cutter
‫نظام تزامني بين وحدة السحب و القطع‬
 Straw length control system with keep the same wall thickness ‫نظام‬
‫لتحكم في طول المصاص مع المحافظة علي نفسط جدار سمك المصاص‬
 Rotary fly wheel cutter: cutting accuracy of +-0.3mm, (90+90)
(40+40)(90+40) Japanese ETP

Automatic stop when the cutter wheel cover is opened

 Digital tachometer
 Potentiometer: 10-turn type (made in USA)
 Production quantity control ‫مراقبة كمية االنتاج‬
 Remote switch-off of main extruder
 Control panel : motor stop/start , buttons ,power on light ,volt
meter digital, tachometer digital
 Auto conveyor bin : run maximum 2,800 ~3,000 straws per min
 Construction : the machine is of aluminum profiles
 Haul-off system (2 type )
1. without spiral haul-off gear boxes
2. spiral haul-off system
 2,950(L) x 1,650(W) x 1,350 (H) mm

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 U-straw Tandem line

Composed units:

1. Straw corrugating machine:

 Sensor 1 :detecting corrugation Error on the straws

 Sensor 2:detecting counting accuracy for machine
 Sensor 3:detecting Error for corrugating machines
 Sensor 4: detecting Steel piece (like broken spindle)
 Sensor 5 : inspection for spindle falling out of its position
 Sensor 6: safety for front cover
 Sensor 7: safety for rear cover
 Sensor 8: safety for front of hopper magazine
 Spindle jig (Galvanized): for protection of rust
 Galvanized
 Design Half-moon: for prevent moving Mandrel Slider
 Mandrel Slider

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 Bolt

 U-straw corrugators = ± 700~750 pcs/minute for 4.3mm OD

2. U-straw belting and inspecting machine

 Sensor 1: detecting for broken steel piece and change of flowing
 Sensor 2: feeding inspection beam sensor (on/off switch)
 Sensor 3 :detecting counting accuracy
 Universal joint
 Brick
 Chain for pusher
 Hopper Brush
 PIN holes : for prevention of loose of silicon drum
 Collecting bag: (cotton) Offcut waste of U-wrapper (zeeper on the
bottom)
 Zeeper:
 Safety cover :for heat sealing drum
 Change of motor driving belt by using timing belt : lower the
machines noise
 Change of bearing by using ball bush bearing
 Bearing:
 Guidance plate

3. Z-fold boxing machine (Mega- boxing

machine)
 Urethane roller
 Bracket
 Change plate rail from MC to stainless steel
 Window with polycarbonate cover for easy maintenance
 Reducer
 Sprocket chain :for different faster movement column (up/down)

 U-straw belt-wrapper & inspection machine +zigzag

mega-boxer : ± 680~730 pcs/minute
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 Finished products: U-straw packing : 25,000~36,000 pieces

Calculation
1) One U-straw= mm length (flat side)+ mm (overlapping side) =
mm/piece

Example:

120+123=243 mm

97+100=197 mm

110+113=223 mm

2) U-straw quantity per roll Calculation =

4,000,000mm length ÷ 243mm per U-straw =16,500 pieces
4,000,000mm length ÷ 197mm per U-straw =20,000 pieces
4,000,000mm length ÷ 223mm per U-straw =18,000 pieces

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