ôAir-Basicö (system covered by worldwide patent ITMI20010049) is the latest model to be patented to produce Air-Bubble Film. It is outcome of twenty years of experience and the result of accurate research about all the production process aspects and the most advanced technology. It assures the maximum flexibility ( it is possible to stop the production with the films that remain inserted into the machine ) and minimum energy consumption at an economical retail price but with the utmost reliability. All the Torninova models have the same qualities of solving the many problems of marketing air bubble film such as the high cost of transportation, storage and energy consumption. Furthermore since Air Basic in completely versatile and automatic, only one operator is required to produce any type of multilayered air bubble film thought different materials and bubble size, changing production within few minutes and without scratches. ItÆs just this unique possibility to allow, with a limited investment, both producers and major consumers, to place the system in the specific consumer area, producing the more required air bubble films without transportation charge costs. The Air Basic system is completely automatic, controlled by Plc with touch screen display to program the meters for each roll, the distance between precuttings, the temperatures, the different speed of the nip rolls.
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Mac bubble is the result of many years of torninovaÆs experience in the air-bubble film packaging systems. It is a step ahead in the survey of air bubble film systems, meeting the needs of the most important producers: a high levels production, a completely automatic functioning and a more flexible use allow it to answers to the demand of the growing market. The accurate design and the over dimensioning in his components mixed with the possibilities of the new plc generation, made the system completely reliable to work continuously for 24 hours a day. The accessories developed thanks to the collaboration with our customers can also be used subsequently cause the system is fully modular and arranged for the application of accessories. That gives to the system the right means to satisfy the market requires. The installation of pre-cutting unit controlled by plc, the fast interchangeability of forming cylinders in order to obtain a different bubble sizes, the 3rd and 4th layers producing modules, the possibility of ink-jet printing, the special rewinders according to the needs, the remote control unit to check the system function to distance, are a sample of the technical solutions to assure best systems. Mac bubble systems are made according to the european community rules and for the high components quality they no required additional maintenance. From the first one (made in 1986) they are all in working all around the world.
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"coreless rewinder rp" is a completely automatic rewinder (roll to roll) that allows to rewind air bubble film for packaging in small rolls without internal core ( pony roll )
This rewinder born following the request of our customers to enter in the markets of hardware store, shopping mall, bricolage shop, etc., where the air bubble film cannot be sold in rolls with standard dimensions, but only in small rolls with few meters. This rewinder remove also the problem of the internal core cost that could be to much expensive if compared to the sold material.
The plant is composed by different groups:
Unwinder group complete with bearing brackets for the air expansion shaft with pneumatic closing system where the mother roll with an internal core (° 76mm) is loaded
Central group complete with motorized nip-roll cylinder and pneumatic cut system with blade;
Rewinder group where the material is rewinded without internal core thanks to rewinding rollers, unhooked and the present length and positioned on a basket. The plant also allows, through the application of an adhesive label or tape, to close the produced roll.
Control panel where it is possible to set each parameters of production like number of rolls to produce and length.
Once inserted the roll of departure, the "coreless rewinder rp" proceeds to the production of the rolls without internal core without any intervention of the operator which is only necessary to load a new mother roll and to remove the produced roll from the basket.
The plant is conforming to the ce safety directives and it is furnished complete of manuals of operation and maintenance.
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Lam machine, thanks to its flexibility, is a system that allows to:
- laminate on the total surface two or more rolls of plastic materials as air bubble film of two or three layers, ldpe or hdpe films and foam.
- to effect a joining through longitudinal sealing rollers of 20-40mm of two rolls of air bubble film with aluminium on a side. The coupling can also foresee an inside material of expanded foam or other materials.
The lam plant results therefore very suitable for the production of laminated materials and for those people who intend to produce complex materials for insulation market
The perforating unit is totally an independent group that allows to pre-cut different types of material as film air bubble film, plain pe films, foam, paper to desired intervals. The plant results ideal to put in line with other system as extruders, air bubble film machinery, flexography printing machine. The group, built in steel with auto-level supports, it is composed from a rubber cylinder with neutral movement for the control of the speed of the material, group of pre-cut endowed with brushless motor and cylinder with toothed blades, cylinder of compression brushed and motorization for regulation from keyboard (minimum interval of pre-cut 200mm). The cover protection and the electric plant are conforming to the safety norms ce.
The plant can be completed with the trimming group.
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The demand to offer different productive solutions to its own customers, has allowed Torninova to apply its own technicall ability and experience in the production of air bubble film, in the production of machinery with in-line processing equipped with cast extruders (mono).
The plant Power Bubble put together all the modern technologies and stand out for the following characteristics:
Extruders with a.c. motor mounted in axis and controlled by inverter with nitrided steel barrier screws realized to plasticize and homogenize the material to extrude in different diameters according the request production capacity.
Flat die with double delivery or separated flat dies for a good control and adjustments of the produced films, realized in steel with adjustable deliveries.
Infrared Barrel Heating power saving up to 20%, long heater element life and quicker cooling response times
Forming unit climbed on guide and rack arms that allow the automatized movement from the stand-by position to the production position thought PLC. The forming cylinder is mounted on mobile structure (motorized and controlled by PLC) in both the directions for the regulation of the materials deliver for the flat dies and for its fast interchangeability.
Main control panel managed by PLC, complete with supervision software managed through touch screen that allows the planning and the control of the whole plant.
The forming cylinder is thermoregulated by a water thermoregulation unit in order to maintain more constant its temperature
Produced air bubble film width from 1.000mm to 2.500mm (or more on request)
The plant can be equipped (also in a second time thanks to its modularity) with various accessories:
Forming cylinders with bubbles in different sizes
Perforating unit equipped with brushless motor.
Cast cylinders thermoregulated by diathermic oil units for a better control of the produced films
Third and fourth layer unit that allow the in-line lamination of one or two sides of air bubble film eliminating others processing
Trimmed edge recovery systems that allow the in-line recycling of the trims with hopper feeding extruder
Gravimetric blending and metering for up to 4 ingredients for a more accurate and automated management of the granules to be extruded
Ink-jet printing unit to personalize the material with logos and symbols
The polyboll machine is customizable with different options as moulder cylinders with different bubbles size, third and fourth layer unit, automatic loader for pellets, etc.
The twin bubble machine allow to produce in-line (without further steps) an air bubble film for insulation applications composed of: two layer of air bubble film laminated with coated aluminium foil on the external side. The machine can produce, of course, air bubble film in 2 or 3 layers for the packaging market.
The twin bubble system has the following characteristics:
Two extruder for the production, at the same time, of the two layers of air bubble film and one, placed in the middle, for their lamination.
Two interchangeable forming cylinders
Rewinder with automatic cycle that allow to produce rolls from 25 up to 150 mt and more.
Possibility to add two additional lamination unit by hot air in order to laminate a layer of foam in the centre of the material (between the two layers of air bubble film).
Recommend for the air bubble film production for insulation market
The coex bubble plant, represents the state-of-the art machine among the torninovaÆs production range . It has got all the most sophisticated technologies for air bubble film production, in order to ensure the easy production to the customer, thanks to the full automation of the co-extrusion process, to reach a film with air-barrier effect, that keeps the air inside the bubble for a longer time. The main advantages of such air bubble film are:
Better cushioning protection compared with a thicker mono-extruded bubble film: the co-extruded bubble film offers higher air retention (thanks to the internal layer of PA6) and then ensures effective long-term cushioning performances from packing to final delivery. It means also extra strength of each bubble and then extra protection of the goods.
Better protection with thinner plastic film: it means better performance with less raw material consumption.
Reusable : his long lasting cushioning performances allows to use the same air bubble film for many times.
Recyclable : the co-extruded bubble film could be recycled with other polyethylene material
An air bubble film of 35 g/,2, produced by co-extrusion process, can be compared, in terms of resistance, with a mono-extrusion air bubble film of 55 g/m2. They have same resistance. Considering such relationship, it means that you save the 30% of the cost for raw materials, by using co-extrusion production process.
Mainly, it is composed by three extruders: one for PE layer, one for the PA6 layer and the third one for the TIE layer between PE and PA6. These three extruders, through the last generation of feed-blocks with adjustable geometry allow the production of the special co-extruded air bubble films with ABCBA structure.
You can easily understand the co-extrusion process through the following layout:
The COEX BUBBLE plant has got the following features:
Extruders with a.c. motors mounted in axis and with universal screws in wear-resistant steel, with modular profiles with barrier double thread, in different diameters according to the level of production requested. Every extruder is equipped with a filter and a gear pump with transmission by cardan joint and motor with inverter and feedback loop control. The gear pump, through PID control, adjust automatically the speed of the extruder according to the capacity requested by the production formula and to the desired extrusion pressure.
Two separated flat dies for an excellent control and adjustments of the produced films, realized in steel with adjustable deliveries. The feed-block with adjustable geometry, allows the distribution uniformity of the internal layer of polyamide (PA6) on the whole width of the film, also with thickness less than 0.5 micron.
Gravimetric blending and metering for the ingredients, for a more accurate and automated management of the granules to be extruded.
Forming unit climbed on guide and rack arms that allow the automated movement from the stand-by position to the production position thought PLC. The forming cylinder is mounted on mobile structure (motorized and controlled by PLC) in both the directions for the regulation of the materials delivery from the flat dies and for its fast interchangeability.
Main control panel managed by PLC, complete with supervision software managed through touch screen that allows the planning and the control of the whole plant . The production control occurs by formula that the operator can personalize according to the co-extrusion percentage he needs and to the speed of production.
The forming cylinder is thermoregulated by a water thermoregulation unit in order to maintain more constant its temperature.
Width of the produced film: from 1.000 mm up to 2.500 mm (or more on request)
The plant can be equipped (also after installation, thanks to its modularity) with several accessories:
Moulder cylinder with bubble in different diameters
Perforation unit with brushless motor
Cast cylinders thermoregulated by diathermic oil units for a better control of the produced films
Third and fourth layer unit that allow the in-line lamination of one or two sides of air bubble film eliminating others processing
Trimmed edge recovery systems that allow the in-line recycling of the trims with hopper feeding extruder
Fast Loading system on the rewinder, that allows, in automatic way, to unload the produced roll with closing system by glue and the loading of the new carton core with application of ôhot-meltö glue.
The machines are fully customizable. Contact us to project the most suitable plant for your production and market necessity.
