General Description of Model Sail Pulp-molding Production Line

Model Sail Pulp-molding Production Line is designed to manufacture various kinds of pulp-molding products by using waste paper as feedstock. The pulp is prepared by pulping with appropriate chemicals dosed when necessary. The products are shaped by the means of vacuum-absorption with molds on the shaper, and then dried and reshaped.

Based on the automation levels, the production line falls into two types, i.e. Model Sail-A and Sail-B.

The equipment of Model Sail Production Line has a stable and reliable performance, fairly high level of automation (5 ~ 7 operators are required for a single shift) and a high versatility. It is only necessary to change a set of molds for turning out a new variety of products. It needs a space as small as 200m2 (5m' 40m' 4.5m). The furnaces for drying systems can be provided as coal-fired, oil-fired or gas-fired types according to the requirements made by the customers. Automatic conveying type or hand-push type drying tunnels can also be provided according to the requirements made by the customers. As early as at the beginning of 1990s this production line was exported to Russia, the Southeast Asia, the Gulf Region and Libya and was well received there. Since the awareness of environmental protection has been enhanced in the whole globe, recently the customers at home and abroad have come to us one after another and contacted us for making cooperation in this field. A spring season of the pulp-molding industry is drawing.

The pulp-molding products can be widely used as the bedding materials for packaging the various kinds of commodities such as eggs, fruit, bottled or canned beverages, glass or porcelain products, handcrafts, small-sized machinery and parts, electronic and electrical products, toys, etc., taking the place of bedding materials made of EPS foamed plastics and corrugated boards, which not only have a good protective property and buffer function, but also can be recycled, and they are the typical products for the new tide of "Green Packaging" that is rising nowadays.

The pulp-molding products can also be widely used in the agriculture, horticulture and tourist industry. For example, the pulp-molding products of square-set cocooning tools for silkworm breeding, seedling pots, flower baskets, flower pots, fireworks balls, decorative balls for Christmas, etc., which have been developed by us, are warmly welcome by the customers. As the scope of utilization is extended, they will have positive effects on increasing agricultural production, innovations of gardening and cultivation and enriching people's life, as well as the environmental protection.

As the pulp molding is a technology that is prevailing internationally and becomes aroused domestically, and the development of this technology will be accelerated with the development in market economy and the expansion of commodity circulation especially after China entering WTO, it has a vast prospect and strong vitality.

Model Sail Production Line for pulp-molding products is suitable for the national conditions of our country and has such features as convenient operation, small scale of investment, short period of return on investment, high versatility, moderate output and avoiding the long-distance transportation of products. It is a project suitable for the township enterprises and to completing with packaging trades.

Flowchart of Model Sail Production Line for Pulp-molding Products

Features:

The production line is provided with a simple process, compact structure and reliable technique. It reaches as a whole, and even partially surpasses the level of the same type as manufactured abroad.

It is a proven product and has been manufactured in batch production.

Automatic or semi-automatic drying systems are completed with the production line according to the actual local conditions.

Presentation on Main Equipment of Sail Pulp-molding Production Line

(I). Special-purpose equipment

Shaper: It is critical equipment in the production line.

Model Sail shaper is developed, designed and manufactured by our company. It passed the national level appraisal in 1993, and it was honored as one of the national-level major new products to be introduced by five ministries and commissions i.e. the State Science and Technology Commission, China Industry and Commerce Bank, the Ministry of Labor, the Experts Bureau, the Technical Supervision Bureau. It won the Golden Cow Prize of Excellent-quality Products of Jiangsu Province in 1994. It has the following features:

It has a stable and reliable performance with a structure of pneumatically-driven four guide pillars for vertical elevation.

PLC is used for controlling with an easy operation and a high level of automation.
With a relatively large working table surface, 2~4 sets of molds can be installed according to the different kinds and sizes of products, and products in different shapes can be manufactured on the same working table.

Based on the automation levels, it falls into two models, i.e. Model Sail-A Production Line and Model Sail-B Production Line.

Model Sail-A: It is so called generally as the semi-automatic production line. The transferring mold is fixed at the upper position opposite to the shaping mold and receives passively the wet product transferred by the shaping mold when it is rising, completing the transfer action of the wet product. However, the wet product is received manually with pallets and transported into the oven.

Model Sail-B: It is so called generally as the full-automatic production line. It differs from Model Sail-A in that the transferring mold is statically at the upper position opposite to the shaping mold, waiting for vertically rising action of the shaping mold after it has adsorbed pulp to complete the combination of the shaping mold with the transferring mold, transferring product from the shaping mold to the transferring mold. Then there is a horizontal movement to allow the wet product to transfer from the transferring mold to the conveyor belt of the drying system.

Main technical parameters: the theoretical output is 300 pallets per hour. The surface of working table is 1230' 460mm. The achievable height of products is about 120 ~ 150mm. The special model shapers can also be designed according to customers' requirements.

Molds:

Molds are the critical parts of the production line. The different molds can be used to produce various products for different purposes.

Our company has relatively strong resources and unique techniques for the development and manufacture of molds.

The molds consist of the frame, mold core and stainless steel mesh.

Copper or composite aluminum materials are used to make the molds according to the requirements.

An integral structure or an assembling structure is used according to the requirements, which is convenient for the operation and maintenance.

With a high precision of manufacture of molds, the products are provided with a tidy and nice looking.

The products can have a maximum depth up to 120mm, maximum size of 520mm' 420mm and minimum coning of 8o.

Model SAIL Drying System:

The drying system consists of three sections i.e. furnace, heat-exchanger and drying tunnel (oven). Depending on different fuel supplies, the furnace can be coal-fire, or oil-fired, or gas fired. The hot flue gas at high temperature discharged to a heat exchanger and the clean hot air after the heat exchanger is supplied directly to the drying tunnel (oven) for drying products.

At present, there are two types of drying systems to be incorporated in Model Sail Production Line.

Model SAIL-2 hot-air tunnel type drying system: Products are dropped from the transferring mode of shaper onto the conveyor belt which is composed of the receiving pallets, and transferred automatically to the dying tunnel. Dried products are conveyed automatically from the drying tunnel. The whole process of manufacturing and drying is fully automatic, and synchronized with the operation of shaper. It is used to complete with Model-2 Shaper.

Model SAIL-1 hot-air oven type drying system: Products in the production line are received manually with the pallets and the pallets full of wet products are placed on the carriage of the trolley. When the trolley are loaded with the pallets full of wet products, they are pushed into the drying oven. The trolley loaded with the wet products goes into inlet end of the oven and pulled out the outlet end of the oven when the products are dried out. Model SAIL-1 oven is suitable to receiving products manually. When there are sunny days, it is convenient to have products dried out by sunshine. Such model can also have the steam supply from a boiler. It is used to complete with Model-1 Shaper.

Steam from boilers can be used to supply to the tunnel or the oven as the above mentioned two models of the drying systems is required. They require steam of 0.7t/h at a pressure of 0.7Mpa. The enterprise that has such waste heat boiler can select this scheme.

(II). Auxiliary Equipment

The auxiliary equipment consists of several general-purpose components with finalized designs, and there are mainly:

Pulper
Vacuum pump
Air compressor