Training On Straw Line

 Our Product
 Process flow / Line overview
 Doctor Machine training

- Prepared by Aniket Rasal

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Our Product

We produces three types of STRAW.

1. 125/4
2. 145/4
3. 165/4

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Process flow / Line Overview

1. Material Storage
2. Extruder
3. Water Bath
4. Puller
5. Stripper
6. U Machine
7. Doctor Machine
8. Z folder
9. Packaging

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 1) MATERIAL STORAGE

For Homo-polymer For Co-polymer

This is a material storage tank, There are two types of material stored in the tank, Homo-polymer(Hard) & Co-
polymer (soft). This material filled into the tank by suction pump, The capacity of tank for Co-Polymer is 5 Ton &
for Homo-polymer is 8 ton. This material goes into extruder through suction process.
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 2) EXTRUDER

Temperature indicator

The material from storage tank is received by the suction pump on the hopper, The material is stored in the
hopper, The Hopper has a weight function (Calculated in the gram) so it sends the material to the mixture in a
certain percentage (75% Homo-polymer & 25% Co-polymer).The material Homo-polymer & Co-polymer is mixed
with colour pigment (White) in mixture, This material comes into barrel, Barrels are made of heat resistant & high
strength material. Through the rotation of screw, polymers are moved & pressurized in the barrel, The polymers
gradually melted by mechanically energy generated by turning of screw& by heaters arranged along with barrel.
The molten polymer forced through a die which shapes the products, Air is passes through the products which
gives hollow shape to the product, By adjusting air pressure we change the diameter of product. Initials/YYYY-MM-DD /5
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 3) WATER BATH

Water storage tank

The hollow tube passes through the water bath way, This way used for cooling purpose of product. The
standard water temperature for cooling is 18 degree. Changing in water temperature can affect the diameter of
the product.
The water that comes out of the water tank & goes through condenser and enters in the water bath and the
same water goes from water bath into the tank. This cycle runs continuously. Initials/YYYY-MM-DD /6
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 4) PULLER & STRIPPER

Required Quality

Straw Length ID Weight

size (mm) (gm)
125/4 238 3.89 5.6 - 6
145/4 278 3.89 6.6 - 7
165/4 317 3.85 7.5 - 7.9

The hollow tube coming from the water bath is received on the puller& stripper, Here puller pulls the
tube and stripper cuts the tube into the set dimension. All sets of straws go into the bin in order by
applying 50mm strip.We collect 10 straws from the bin & check the quality (Length, Weight, Diameter)
of straws every hour.

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 5) U MACHINE

Required Films
Straw Top film Bottom Film Thickness
(Printed)
125/4 164mm 169mm 18micron

145/4 204mm 209mm 18micron

165/4 244mm 249mm 18 & 21micron

The raw material made from the stripper is attached to the U machine, The straw passed through the U
machine are guided in the mandrel which is attached to the mandrel wheel. The mandrel wheel rotates by
indexing gear box. The straw is corrugate at the corrugation unit then compressed and this straw goes into
bending unit ,This unit shapes the straw in U shape. This U shape straw passes through a pocket roller and is
packed by films with the help of sealing rollers. The U machine produce 20000 straws per hour when machine
continuously run on 100% or 60Hz speed. The required films for U machine according to straws are given in
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the table. Internal
 6) DOCTOR MACHINE

Output of U machine (Packed straw) connected to doctor machine, Here we check whether all the straws
are packed in good condition with the help of sensors. If the straw is not good at that time we remove the
straw, splice the web & run the machine. This web of straws fall into box through the Z folder.
The speed of all doctor machines is different
eg.. 1) 1540 straws are passed on a doctor 6 in one minute at full speed.
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2) 1380 straws are passed on a doctor 3 in one minute full speed. Internal
7) PACKAGING

 Capacity of boxes

Sr. No Straw Type Qty

1 125/4 42000
2 145/4 34000
3 165/4 32000

 Total numbers of machine available on

line.
Sr. No. Machine Name Qty
1 Extruder 6
2 Puller & Stripper 6
After checking all material from doctor machine,
The material comes in box by Z folder and Boxes 3 U machine 32
are packed after the box is filled to its capacity. 4 Doctor Machine 6

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 DOCTOR MACHINE
1. When you comes at doctor machine first of all you have need to check all the 5S of doctor
machine area,U machine area & check whether all sensors are working.

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 2. Prepare two empty boxes and kept on doctor machine as shown in picture, Keep OK box at Right
side & NOT OK box on left side. Place the box in the right place that activates the sensors,
Sensors sense the position & direction of box, If sensors are not activated then machine does not
starts. Right Side Box web drop inside the box & leaving the web outside the box shown in
picture, And Left side box web drop inside the box.

OK NOT OK

Right Left Box Sensors Right Left

(A) (B) (C) Internal
3. Before starting work check that all sensors are working which displayed on the indication panel

Indication Panel

Machine will continue running till any defective straws pass through the range roller or sensors
& panel will indicate the location of straw on indication panel.

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Web Missing Sensors –
Which Activates when web is
missing.
Straw missing sensors – Which
activates when straws are missing.
How to check sensors ?
By manually removing straw of left &
right side respectively and start the
machine and check whether sensors
are working.
(A)
Miss pack sensors - Which activates
when miss pack straw comes.
How to check sensors?
By applying 6 folds of tape on right & left
side respectively (A) check the sensors.
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4. Get a new bin containing U straw from U machine and place another empty bin at the output of
U machine. Place a bin as like this the arrow points towards the machine. Check the print & sealing
quality every time you take the bin from U machine

Print Quality ( Non readable

from plane side )

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5. Cut web 1 from fresh new bin web 2 from doctor machine and Attach the two web by overlap
the web on splicer and press the handle and keep the handle pressed till red indication lamp
glow and goes off. And start the machine by pressing start button.

Web 1 Web 2
Splice Table
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6. Machine continue running till any defective straws pass through the sensors, Once machine stops for
any defective material. Panel indicate the location & defect of straw , pull out defective material by near
to splice table by pressing jog button. Remove the defective material and splice the both web, Check
splice quality and continue machine.

Defects
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 Doctor machine operator must perform some activities while operating machine

1.Changing the film –There are two types of film one is printed (B) & another is non printed film (A).The
size of required film according to the straw is given in the table below. The films need to be changed when
the previous film ends . While applying new film it is necessary to remove dust accumulated layers of film
and after applying film it is necessary to check the centring of film. And direction of film shows in picture.
Straw Top film Bottom Film Thickness
(Printed)
125/4 164mm 169mm 18micron
145/4 204mm 209mm 18micron
165/4 244mm 249mm 18 & 21micron

(A) (B)

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2. Attend the short stops of U machine – The U machine has a display indicating the
reason for stopping of the machine, So operators need to attend the shorts stop & start
the machine .

Sr No. Shorts Stops

1 Load left in fault
2 Load right in fault
3 Unload left in fault
4 Unload right in fault
5 No bottom strip 50mm
6 Upper film not present
7 Synchronous alarm
8 Bottom film not present
9 Door open Indicating Display
10 Temperature alarm
11 Sealing down fault
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3. Need to clean rollers – The sealing roller and dancing roller of U machine must be
cleaned in each shift. Operator must use hand gloves and scrubber when cleaning, Do not
bypass any switches when cleaning rollers.

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4. Remove the 50mm- Operators need to remove 50mm time to time because when the 50mm role
limit is exceeded it causes no bottom strip fault, so to avoid this short stops we remove it in running
condition of machine.

50 mm
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7. When the straw counter meets the target you need to replace the box and pack the full box(A), Reset
the counter & Start machine. If any straws are removed due to defect then add the that number of straws
in the counter (B). Apply green tape for inlet & red tape for outlet after packaging (C). When three pairs of
boxes get ready then prepare a pallet (D).
(A) (C) (D)

Inlet
(B)

Outlet Internal
 8.Documentation is must imp while working, Operator is required fill out two sheets,
1) Doctor control sheet which is filled while working (A).
2) Positive checklist which is filled after making the pallet (B).
Apply the box number label which is taken according to PO number (C)on each boxes and pallet number
label (D) on each pallet according to sheet, If pallet label is scanned then apply green tape on label .

(A) (C)

(B) (D)

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THANK-YOU

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