Italian composite coating processing new technology

Composite coating is one of the important application technologies for plastics. Calendering, laminating, and extruding are several important techniques for coating processing. Italy's equipment suppliers have developed new coating equipment for different applications, with a wider range of applications, higher efficiency, and the advantages of both aesthetic and mechanical properties.

The main features of the Cema calendering line developed by the Italian equipment manufacturer Comerio Ercole are compactness and versatility. The device can be used to process a wide range of materials: semi-rigid and soft PVC, PUR, CPE and PP. In addition, thermoplastic materials can also be laminated to substrates such as paper, cloth, fabrics, nonwovens or films.

According to the specific requirements, the plastic sheet can be embossed directly in the auxiliary equipment under the calender, and the lower auxiliary equipment is equipped with a device that can quickly replace the embossing roll. The currently available calendering line roller height is between 1,600 - 3,200 mm, the production speed is up to 70 m/min, and the thickness of the calendered material is between 0.04 - 1.0 mm.

The production line has a small footprint, requires a small number of operators, all parameters are easy to set up, and has high production efficiency. It is ideally suited for occasions where it is often necessary to replace product varieties or specifications. The initial investment is not as high as the cost of a traditional calendering system.

The automatic feeding section generally consists of a powder storage bin, a liquid component management system, a weighing device, a bag additive feeding system, and a turbine mixer with a cooler. The compact line of the production line mainly consists of a 2-stage planetary screw extruder, 3-roll calender, embossing mechanism, access and cooling mechanism, substrate automatic unwinding machine, traction mechanism, thickness gauge and control system and automatic roll Take the machine composition.

The 3-roll calender is fed by a conveyor belt that slides laterally along the rollers and a 2-stage planetary screw extruder with temperature control. A metal detector is provided to prevent the feeding of metal powders. 3-roll calenders with embossing, take-up and cooling mechanisms. The calender frame has reinforcing ribs and undergoes a distension treatment to give optimal rigidity and prevent distortion and vibration.

With this special structure, the side frame only serves as a support and does not interfere with the adjustment mechanism. In fact, all mechanical parts are simply fixed to the frame. In this way, it is not only possible to easily adjust and optimize all the mechanical parameters according to the required process conditions, but the maintenance of the equipment is also very convenient.

The calender roll is equipped with a special electric heating system, the temperature can be adjusted between 50 and 220 °C, the entire roll width heating evenly, the temperature deviation between ± 1 °C. Each roller is individually driven by a universal joint and is adjusted by a hydraulic system equipped with an all-digital electronic control mechanism. With this hydraulic adjustment system, precise positioning of the calender rolls can be achieved with precisions of 5 μm and 2 μm, respectively.

The embossing mechanism is designed so that the embossing roll is easy to change quickly and is easily pressed against another roll made of a highly heat-resistant elastic material. Access and cooling mechanisms are also integrated in the calenders, and different solutions can be provided according to specific production requirements.

Substrate unwinding mechanism can use a simple storage rack or an automatic continuous mechanism that does not require a stocker. The substrate can be replaced without stopping the production line, and more space can be saved. The traction mechanism is placed at the exit of the unwinder and is controlled by a load cell to ensure that a stable tension is applied to the substrate. On coilers, product rolls can be automatically replaced without stopping the production line. Winder is equipped with a trimming system. Several technical solutions can be provided according to specific requirements to meet the needs of different occasions, even with the function of automatic traction, weighing and packaging product rolls. Since the function of the calender is also dependent on the level and quality of the electrical/electronic equipment, hardware and software for the entire management system of the calendering line have also been developed.

Because PVC coated paper has unquestionable economic, technical, and practical features, it has replaced expensive bookbinding materials such as leather or cloth. Two technologies can be used to produce this product: one is to apply the PVC slurry directly to the substrate paper, and the other is to laminate the paper and the calendered PVC film together.

The lamination process can be done on a calender or off-line on a laminator. The laminator can also be embossed in the same steps as the calender. Off-line processes can also be used to print on films before lamination and embossing, but adhesives are required to ensure film-to-paper adhesion. After the lamination and embossing are completed, other final processing can also be carried out, for example "contrast dyeing", that is, printing and embossing only on the embossed structure in order to obtain a two-color effect.

Recently, the Italian manufacturer Colombo Officine Meccaniche provided a second laminator-embossing machine for a foreign user. The device was designed specifically for this application. The laminator consists of 2 paper and film rotary unwinders, a trowel-coated rotogravure printing mechanism, a pre-gel heated roller, a preheating roller and a heating drum (diameter 1,400 Mm) composition. The laminated product is then heated by an electric infrared heater to heat the PVC film to the required embossing temperature; the heater is equipped with an IR thermometer and an automatic power controller.

Embossing was performed between patterned water-cooled steel rollers and rubber rollers. Afterwards, the product is cooled by a set of rollers with cooling water before rewinding. The machine can also be used for embossing and laminating PVC film and cloth or two layers of PVC film. The gravure printing mechanism can also be used for printing films: in this case, the path of the laminate is reversed because the plastisol is coated on the back of the film. Therefore, the gravure printing mechanism can change its rotation direction, and equipped with two driving blades on both sides of the gravure roll, and a hot air drying box behind the gravure roll.

Italy's Isotex recently installed two synthetic leather production lines for European customers. In recent years, the silent market of synthetic leather has revealed new vitality and applied high technology. The new formulation materials have gained a lot of applications in the automotive and aircraft interiors industries. Based on Isotex's experience, coupled with open and constructive cooperation with highly entrepreneurial customers, the highest quality standards required by the market were achieved and further enriched.

ISOSKIN is a new extrusion coating line developed by the company and is suitable for the production of synthetic leathers that can be used in a variety of applications: clothing, utensils, travel products, footwear and the automotive industry. The coated product has a particularly soft feel for the clothing and has a very high aesthetic feeling, such as having a glass luster, can simulate a large number of natural surfaces and the like. Coating products combine aesthetics with special mechanical properties such as abrasion resistance, scratch resistance and flex resistance. They also have breathable, waterproof, and chemical-resistant properties.

ISOSKIN can be adapted to production requirements for the production of small water-based or solvent-based coated products, foams, breathable or single-coated products. Series extrusion lines include single head pilot extruders for the production of industrial-wide samples, three- or four-head extrusion lines for all combinations of "wet-wet", hot-laminated, single-coated processes, and A complex 5-head extrusion line manufactured to customer specifications.


Reprinted from: International Plastics Industry Network

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