Kraft paper laminated with aluminum foil.

2 year ago

45 0 

Foshan Senruiyuan Machinery Technology Co.,Ltd

2 year

Product details

2. Machine Overview

The Water-based Laminating Machine is Senruiyuan’s flagship vertical, roll to roll laminating machine designed for both water-based wet lamination and thermal laminating machine. It is purposely over-specified to handle every substrate that modern converters encounter—from 100 g poster paper to 350 g food-grade board, from 8 µm plain OPP to 25 µm metallized PET and aluminum foil. Where competitors often force a choice between speed, quality, and economy, the SRYMR-1300 was engineered to deliver all three in a single footprint.

3. Core Performance Data

• Max. web width: 1 300 mm

• Laminating speed: 20–150 m/min (water-based glue ≤120 m/min; thermal film ≤150 m/min)

• Unwind / rewind diameter: Φ1 300 mm on both towers—enabling 10-hour non-stop runs on typical jobs

• Paper thickness window: 100–350 gsm

• Film thickness window: 8–25 µm

• Total installed power: 120 kW (380 V, 3-phase, 50 Hz)

• Air demand: 0.7 MPa, 0.1 m³/min

• Machine dimensions: 14.5 m × 4.0 m × 3.1 m (L×W×H)

• Net weight: 16 000 kg — a rigid 30 mm steel-plate frame eliminates vibration at top speed

4. Technology Highlights in Detail

4.1 Shaftless Hydraulic Unwind

Two hydraulic arms lift rolls up to 1 300 mm without manual intervention. An Italian RE multi-point pneumatic brake guarantees constant web tension even when roll diameter shrinks from 1.3 m to core.

4.2 Web Guiding & Tension Control

A photoelectric edge/line guiding system (100 mm stroke) pre-aligns the web before it enters the coating nip. Closed-loop tension is managed by ultrasonic or load-cell sensors feeding back to Siemens servo drives; tension accuracy is held within ±0.5 % of set value, eliminating wrinkle-induced waste.

4.3 Electromagnetic Induction Heating

Instead of traditional oil or cartridge heaters, a superconductive steel roller (Φ420 mm) is heated by electromagnetic induction. The contact-free sensor measures surface temperature every 50 ms; the PLC maintains ±3 °C window across the full 1 300 mm face. Heat-up time is 50 % faster, and there is zero risk of oil leakage.

4.4 High-Precision Glue Coating

A chrome-plated mirror metering roller (independent servo drive) delivers coat weights as low as 1.5 g/m² with ±0.1 g/m² repeatability. The split-opening pneumatic carriage allows one-person cleaning in under five minutes. Customers report 30 % adhesive savings versus older gravure systems.

4.5 Enlarged Vertical Drying System

A Φ1 125 mm drying cylinder almost doubles dwell time, while a counter-flow hot-air tunnel recycles exhaust to pre-heat intake air. Result: 30–40 % energy reduction compared with conventional straight-through ovens. In winter trials, the machine still held 120 m/min on 250 gsm board without curl.

4.6 Hydraulic Laminating Nip

A dual-cylinder hydraulic station (max. 12 t linear pressure) drives the Φ300 mm rubber pressure roller. Left-right pressure can be trimmed independently to compensate for gauge variations. The nip opens automatically during splice cycles to protect the mirror roller surface.

4.7 Servo-Driven Surface Rewind

A 7.5 kW Siemens servo motor with 3-inch air shaft delivers constant-torque rewinding up to Φ1 300 mm. Non-stop roll change is possible via a flying splice table, minimizing downtime on long runs.

5. Intelligent Control Architecture

• Controller: German intelligent motion controller with 50 µs cycle time.

• Communication: Profinet real-time Ethernet, compatible with MES/ERP.

• HMI: 15-inch color touch panel with recipe memory, fault diagnostics, and energy-consumption dashboard.

• Safety: CE-certified Category-3 interlocks, emergency-stop rope along operator side, thermostatic air-conditioning inside the electrical cabinet.

6. Energy & Environmental Profile

Water-based lamination inherently eliminates VOC emissions; the SRYMR-1300 adds a 30 % energy rebate through heat recovery alone. A side-by-side audit with a solvent-based line of equal width showed:

• Electricity: 0.11 kWh/m² vs. 0.18 kWh/m²

• Thermal energy: 0.05 kWh/m² vs. 0.21 kWh/m² (RTO included)

• CO₂ equivalent: 0.09 kg/m² vs. 0.30 kg/m²

7. Application Examples Supplied by Users

• Ordinary corrugated boxes with outer lamination for agricultural produce and beverage multipacks in Greece

• Metallized PET laminated 350 g board for Turkish cake plates

• OPP/PET laminated 150 g ivory board for Vietnamese fast-food clamshells

• Aluminum-coated film laminated 250 g board for Iranian frozen-food trays

• Water-resistant and color-glue laminated cartons for Indian monsoon season logistics

8. Installation & After-Sales Commitment

• Delivery: 90 working days after deposit and signed contract

• Warranty: 12 months from successful commissioning

• Installation: Two Senruiyuan technicians for up to 14 days on site; buyer pays USD 100 per day per technician plus round-trip airfare.

• Support: 24-hour online video service, lifetime spare-parts supply, and detailed English manuals, wiring diagrams, and maintenance DVDs.

9. Standard Accessories (Supplied Free)

– 3-inch air shafts for both unwind and rewind

– 600 kg hydraulic film-loading trolley

– Full set of metric and imperial tools, grease gun

– Spare 300 mm pressure rubber sleeve

– Operation and maintenance manuals

10. Return-on-Investment Snapshot (Real-World Case)

A 1.3 m web width converter in Cairo replaced a 10-year-old solvent line with the SRYMR-1300. Running 250 gsm duplex board with 15 µm BOPP at 110 m/min, 6 000 h/year:

• Throughput: 1.3 m × 110 m/min × 60 min × 6 000 h × 0.85 efficiency = 43.9 million m²/year

• Glue savings: 30 % × 2.2 g/m² × USD 2.1/kg = USD 60 700/year

• Energy savings: 0.13 kWh/m² × USD 0.08/kWh × 43.9 M m² = USD 456 000/year

• Avoided RTO maintenance: USD 45 000/year

• Net payback including freight and duties: 14.5 months

11. Future-Proof Design

The machine frame already includes mounting points for a second coating station (solvent-free retrofit) and an inline cold-seal unit for confectionery wraps. The open-architecture PLC supports OPC-UA, making it Industry 4.0-ready for predictive maintenance and remote OEE dashboards.

12. Conclusion

The SRYMR laminating machine is not merely a laminator—it is a strategic tool that allows converters to migrate to greener, faster, and more profitable production today while preserving the flexibility to adopt tomorrow’s technologies. By combining electromagnetic induction heating, servo-level precision, and an energy-recycling drying philosophy, Senruiyuan has delivered a machine that meets—and often exceeds—the performance benchmarks of European flagship lines at a fraction of the capital outlay.