Melamine Impregnated Paper Making Machine

• Customization: Available
• After-sales Service: 1 Year
• Warranty: 1 Year
• Model NO.: 1500B-2-3
• Grain: Straight Grain
• Bonding Strength: Ⅲ(Nc)
• Plywood Type: Veneer Boards
• Formaldehyde Emission Standards: E0
• Specifications: 1220*2440*18mm
• Place of Origins: Wuxiqiangtong
• Grade: Excellent Grade
• Usage: Outdoor
• Trademark: NTC
• Origin: Nantong Youxin
• Package Size: 3000.00cm * 5000.00cm * 6000.00cm
• Package Gross Weight: 45.000kg
• Lead Time: 60 days (1 - 1 Sets) ; To be negotiated ( > 1 Sets)

Product Description

1.1 Applications

The paper impregnation line use urea formaldehyde resin, phenolic adhesive to impregnate, coat, dry and stack paper base material.

With the decorative paper impregnation line, for the production of:

Melamine resin impregnated papers, for the Low-Pressure Laminates (LPL).

Melamine resin impregnated overlay paper, decorative paper and balance paper for flooring.

Melamine resin impregnated overlay paper for the High-Pressure Laminates (HPL)

Phenolic resin impregnated paper for plywood lamination.

1.2 Scope of application

The production line use fixed amount 40 ~ 250g/ square meters, width 900~1400 mm melamine/phenolic paper. The wet strength of melamine/phenolic paper is not less than 0.75kgf/15m.

1.3 Environment for line running

This production line is suitable for no corrosion and water soluble resin (Like urea resin, melamine and phenolic resin)

High-temperature resistant requirement: F level, Explosion-proof grade

Environment temperature: 10~40ºC

Relative humidity ≤90% (Temperature at 20ºC)

Altitude not more than 1000m

 

Part 2: Impregnation line parameters

2.1 General parameters

Model	NTC1500A-2-3 Two Steps Line
Width of raw paper	900~1400 mm
Max. roller width	1500 mm
Mechanical speed	4~100 m/min
Working line speed	15~18 m/min for melamine resin
Working height	1350 mm
Heating method	Thermal oil
Dryer working temperature	120~180ºC

2.2 Dimensions

Raw paper roll diameter	φ1100 mm
Weight of roll paper	1200 kg
In-diameter of paper axis	3''(76mm)
Dryer length	3750 mm
Effective drying length	(2+3)× 3750=18750 mm
Effective drying width	1500 mm
Total line length	~44,000 mm
Total line width	~3800 mm
Total line height	~4500 mm
Total line weight	~46,000 kgs
Operating area	On the right side, run along paper
Driving area	On the left side, run along paper

2.3 Power and energy consumption

Driven power	3 phase,380V,50Hz
Control power	2 phase,220V,50Hz
Total installation power	~125 KW
Heating medium	Thermal oil
Compress air pressure	0.5~0.7 Mpa
Compressed air consumption	~8 m^3/h as the installation volume
Cooling water pressure	0.2~0.4 Mpa
Cooling water consumption	~8 m^3/h at 45 degree temperature weather which means biggest volume, This is calculated by 60m/min speed volume, if line speed is 30m/min then means only consumption 4m^3/h

Remark: Compressed air volume means max. Demand which means at maintaining when all the cylinders are open need 8m3/h also means installation volume. While the normally running consumption is 0.5 m3/h. But when paper is broken or changing paper, need to open all the doors then that time consumption is 2m3/h. So to make sure the line can be worked at all conditions, need to prepare the 8m3/h compressor.

 

2.4 Line capacity calculation

The real capacity of this model impregnation line not only depends on the design of the machine, but also depends on the glue mixed, paper quality, and the temperature of working environment, wind capacity of recycling fan, the mature operation of the workers etc.

Calculation is based on:

Resin	Melamine
Temperature inside oven	120~180ºC
Raw paper density	80 g/m^2
Raw paper width	1300 mm
Resin contain of impregnated paper	130%~150%
Volatility of resin	6~7%
Working line speed	20 m/min
Working time	330 days/year x 3 shifts/day x 8 hours/shift

Production capacity per day for 4x8 feet paper:

15 m/min / 2.5 m  x 60 mins x 20 hours = 7200 sheets papers per day at least.

 

Part 3: Details of supplied machinery

3.1 Semi-auto unwinder

This unwinder is scroll type with two-axle type, it is equipped with two inflatable roll and safety chuck. 

When uncoiling, magnetic particle damping device could offer enough tension to paper. This machine has paper receiving device. It can make the new roll of paper to stick to the end of last roll of paper without stopping the machine, the high-speed cutter can cut the rest of last roll of paper to achieve continuously impregnating. One staff is enough for paper receiving.

Including: frame, aluminum roller, damping device, paper receiving device, 2 set two cylinders' roller inflatable gas system, 2 set electronic magnetic powder brake and safety chuck.

 

3.2 Impregnator (First step dipping)

Impregnating machine consists of frame, coating section, breathing system, impregnating roll unit, meter device, glue tank and heating device for glue tank etc.

This impregnating machine is used in first impregnating. Using coating roller to do the single down side coating for the paper, angle size of coating is adjustable, then resin glue will penetrate into the paper from down side, and drive out the air from upper side completely. The coating device is equipped with breathing system, according to the different requirement for raw paper, resin glue and impregnating ways, the breathing system can control and adjust the height of breathing section, in this way to make the paper reach to enough amount of glue and adjust the flatness of paper. Resin infiltrate into the paper fabric and less low down the wet tensile strength, then the process of impregnating can go smoothly.

Raw paper will be feeding into the glue tank after coating section and breathing section. Adjusting the gap of metering roll can control the resin content and impregnating uniformity of bond paper accurately, the motion accuracy of metering roll is ≤ 0.003mm.

Configuration technical requirements: includes frame, S roller, Back coating part, Impregnating roller part, Metering roller φ290, Metering device, breathing system, the middle part of stainless steel (430) glue tank with spacers, the glue tank lifting and lowering is controlled by a worm gear reducer, and the metering roller adopts NSK bearings imported from Japan, the wall thickness of the roller can not be deformed, (the upper and lower motors of the breathing roller).

It consists of:

a) Frame structure

b) Back side coating

c) Breath part

d) Impregnator part

e) Squeezing part

• It has automatic and manual both operation model.
• In manual operation, the controller is in one side but can adjust two sides.
• In automatic model, it can adjust automatically by setting value through cabinet panel beside it.
• The gap between the squeezing rollers are shown in the screen, and you can adjust.
• It consists of below rollers:
• 2 pcs steel roller with chromed surface with Φ290mm diameters, 3.5mm tube thickness, jumping accuracy is < 3 um under 100m/min speed, 0.3mm chrome surface and it has 50 CR hardness.

f) Glue tank

g) Glue tank heater

 

 

3.3 Dryer (6 sets Ovens)

• Pneumatic automatic big door for easier operation and better heat preventing;
• Three-layers heat insulations design to save energy 20% at least;

 

3.3.1 Drying ovens

The machine consists of drying section, dehumidification system, automatic door, temperature control system, etc. The length of each drying section is 3750mm.

The heating medium of the drying section is thermal oil or steam or natural gas direct burning system. According to the requirements of the drying process, each drying section is a temperature zone. The working temperature can be set independently and the temperature of the zone can be automatically controlled by the temperature control system, so that the actual temperature is basically consistent with the set temperature. ; The temperature is generally controlled between 120 and 180 °C. Each drying section has a wet outlet, and the opening of the wet outlet is controlled by a manual damper, and the operator sets the opening according to the process requirements.

 

3.3.2 Drying oven structure

The frames of each drying section and air curtain section are welded parts of rectangular steel pipes and square pipes (50/100), with high strength and small deformation. The drying section is composed of bellows, air ducts, specially designed nozzles, hot air blowers, threading chain guides, etc. The frame is surrounded by thermal insulation wall panels and thermal insulation doors, and the thermal insulation doors are double-sealed and manually opened. Each section of the drying section has butterfly dampers up and down the hot air duct, the insulation layer is 15cm, 2 cold plates are used for the outer side, 2 galvanized sheets are used for the top plate, and 2 galvanized sheets are used for the inner side and the air duct plate.

No.	Name	Qty.	Value	Note
1	Hot wind fan	5 sets	WFF-8.6#
	Motor	5 sets	Y132M2-4
	Power	KW	15	Has inverter
2	Moisture dryer fan	1 set	WFF-9.0#
	Motor	1 set	Y00L1-4	Liddell/Beide
	Power	KW	22
3	Hot air exchanger	5 pcs	TOCC-SR-01
	Nozzle	50 pcs		import patterns
4	Platinum thermal  resistance wire	5 pcs	Pt100	Press plenum
6	Temperature meter	5 pcs		America HONEY
7	Gas burner (If gas type)	5 pcs		Chinese brand

Supply range: Drying units, moisture exhauster

3.4 Roller Coater (Second step coating)

The machine consists of frame, upper and lower mesh coated squeegee device, the second smoothing device, lifting devices. Second over coating machine is used to make paper coating liquid surface covered by the smoothing process requirements after reaching the glue. This machine is used twice on the plastic, paper tape into the secondary coating coater, and then the upper and lower for recoating, the surface evenly covered with glue. (Note: choose accurate mesh size, which directly affects the amount of secondary glue) Then it is smoothly polished to ensure the tape is even and smooth when it goes into the secondary oven.

Configuration requirements: upper and lower roller coating change speed frequency and converter speed. Smooth roller adopts cylinder lift, frequency positive and negative control, high and low angle can be adjusted on a smooth, plastic tank made of stainless steel (S430), roller bearings use imported NSK.

No.	Name	Qty.	Value	Note
1	Reducer	1 set	K47-2.2kW	Top coating
2	Reducer	1 set	K47-2.2kW	Bottom coating
3	Upper coating roller	1 set	R27-1.1kW
4	Lower coating roller	1 set	R27-1.1kW

Supply range: Frame, upper and lower coating machine. The machine take mesh coating.

 

3.5 Cooling Unit

The paper is taken out of the drying section and entered into the cooling section. The length of the cooling section after drying is 3750mm, which is mainly composed of rack, sealing plate, air box, air duct, cooling heat exchanger, nozzle, circulating fan, moisture exhaust air outlet, etc. The upper and lower air volume can be adjusted separately through the air door.

No.	Name	Qty.	Value	Note
1	Cooling fan	1 set
	Motor	1 set	7.5 kW

 

3.6 Web aligner

Paper tape will run deviation after long distance operation, so after move out of the drying section, the alignment machine can bring the paper to the middle position. Upper supporting rollers adopts movable roller, and lift by cylinder.

No.	Name	Qty.	Value	Note
1	Photoelectric deviation  rectifying system	1 set	Precision control
	Detector E3Z-D62	2 sets		OMRON

 

3.7 Pulling machine (Dia. 800mm)

The tractor not only provides power for the normal operation of the paper strip, but also has the function of  further cooling the high-temperature paper strip coming out of the dryer to a suitable temperature for subsequent processing. The traction rollers are two cold water rollers of φ800mm, two φ350mm and φ200mm, and cooling water can be passed through the rollers. With cylinder platen roller.

No.	Name	Qty.	Value	Note
1	Reducer	1 set	K57-4kW	Pulling roller
2	Reducer	1 set	K57-4kW	Paper chain

 

3.8 Rotate Cutter

A pair of paper feed rollers are set up and down in front of the shearing knife, and the fixed-length cutting is realized by the action of the paper feeding roller and the cutter. The upper and lower pressing rollers are guided by linear bearings and lifted by the air cylinder. The speed of the feeding rollers is adjustable and is set at the edge of the feeding paper, which is convenient for adjusting the tightness of the paper. Can be cut from 18g to 200g paper. Can set automatic counting alarm, adjust the length at will. And equipped with positioning shearing device.

No.	Name	Qty.	Value	Note
1	Reducer	1 set	R47-4kW	Feeding roller
2	Reducer	1 set	4.5kW	For cutter
3	Encoder	1 set	2000P	Ormon

 

3.9 Paper output stacking table 1 set and lifting table 1 set (Belt with lifter type)

Function: Paper sending drive, adjustable paper sending speed, easy to stacking, convenient out feeding, lifting up and down and can bear the 3 tons weight.

No.	Name	Qty.	Value	Note
1	Reducer	1 set	KAT37-2.2KW	Conveyor
2	Air blower	1 set	CZR-68, 250	Shanghai
3	Lifting motor	1 set	Y90L-4/2.2 kW

Supply range: lift-valve, Hydraulic lifter, frame, roller conveyor, and belt and power device.

 

3.10 Electrical control system

The electric control system includes 4 sets electric control cabinets, one-time dip touch control cabinet, paper pick-up control cabinet, and shear count control cabinet, which are mainly composed of the following control units.

(1) The main drive control system adopts Mitsubishi frequency conversion control system.

(2) The hot air circulating fan is controlled by frequency conversion speed regulation.

(3) In addition to the emergency stop button on the main control electric control cabinet and the fuselage operation station, there is a pull wire emergency stop switch at the appropriate position of the production line, and the wire connection must be uniformly numbered according to the electrical drawings.

Electrical control configuration and information

Name		Specification	Qty.	Brand
PLC		FX3U	1 set	Mitsubishi
Touch panel		10.4	4 sets	Buke
Inverter	S roller motor inverter	D740	1 pcs	Mitsubishi
	Back coat roller motor inverter	D740	1 pcs
	Breath roller motor inverter	D740	1 pcs
	Glue roller	D740	1 pcs
	Paper chain gearbox and motor	D740	1 pcs
	Pulling roller motor inverter	D740	1 pcs
	Smooth roller	D740	1 pcs
	Secondary coater motor	D740	2 pcs
	Secondary smooth motor	D740	1 pcs
	Paper pull motor feed motor	D740	1 pcs
	Servo cutter			Delta
	Hot wind fan motor	15 kW	6 pcs	INTV
	Moisture exhaust fan	22 KW	1 pcs
Other electrical parts	Photoelectric switch	E3JK-DS30M1	1 pc	OMRON
		E3Z-D62	2 pcs
	Getting touch switch	TL-Q5MC1	1 pcs
	5 pins coder	E6B2-CWZ6C	1 pc
	Temperature controller valve	DN50	6 pcs
	hot resistance	pt100	6 pcs
	Temperature controller meter		6 pcs	Honeywell
	Power supply		3 pcs	Delta, Taiwan
	AC contactor		11 pcs	Schneider
	Power switch		25 pcs
	Air switch		1 pcs
	Limit switch		5 pcs
	Start/Stop button		40 pcs
No.	Name	Specification
1	Electrical power wire	RVV3x10
2	Electrical power wire	RVV3x6
3	Electrical power wire	RVV3x2.5
4	Electrical power wire	RVV3*1.5
5	Electrical power wire	RVV6x0.5
6	Electrical power wire	RVV4×0.5
7	Shielded wire	RVV10×0.5
8	Shielded wire	RVV6x0.5

Safety suggestions:

• Supplier offer safety system to avoid damaging operator and equipment.
• Cover all rotating wheel and gear.
• The safety line below measuring roller should be connected to the emergency stop device.
• Set up a preventing tripping bar / system for the metering roller to avoid finger or others being tripping.
• The wire must be protected by a wire slot or bushing. National standard wire is necessary.

 

Other components brand

Components	Brand
Reducer and motor	TGS
Air cylinders	SMC
Bearing	Key parts NSK

 

 

Part 4: Supplied by the buyer side

• Venues, buildings, equipment, installation tools, equipment, installation materials such as: anchor plate, plate, Rod, steel structures, standard parts (bolts, nuts, washers, etc.).
• Standard installation tools and equipment such as welding machines, cranes, hoists, and other hand tools.
• Cleaning equipment and tools.
• Safety protection devices of fire-fighting facilities.
• Material transport and handling equipment, such as truck, driving, etc.
• Workplace power distribution and power systems, power distribution Cabinet.
• Moisture exhauster insulation works.
• Reached the production line of compressed air pipe.
• To line master workshop of the electric control box cable.
• Electronic control systems and equipment grounding facilities.
• Workshop machinery and electrical equipment, machinery and tools.
• Spare parts, wearing parts, consumable materials, raw and auxiliary materials, such as the storage place facilities.
• Debugging using the paper, rubber and other raw materials.

 

Part 5: Duties from the supplier

• All the cables and connectors between the main electrical controlling cabinet to the working line.
• Moisture exhauster pipes
• All the machine parts must be new made, any second hand is forbidden.

 

Part 6: Quotation of standard impregnation line

Model	NTC2100A-2-3 Two Steps Line
Equipment List	No.	Name	Qty.	Unit
	1	Semi-auto unwinder	1	Set
	2	Paper impregnator (Dipping)	1	Set
	3	Dryers (auto door)	5	Sets
	4	Second coater	1	Set
	5	Cooling unit (with exhaust unit)	1	Set
	6	Web aligner	1	Set
	7	Pulling machine	1	Set
	8	Rotary cutter	1	Set
	9	Belt conveyor with lifer for stacking	1	Set
	10	Electrical control system	1	Set
Total Amount	196,000.00 USD Say untied states dollars one hundred and ninety six thousand only
Price Term	FOB Shanghai, China
Delivery Time	100 days after receiving deposit, excludes Chinese statutory holidays.
Payment Terms	30% deposit, 70% paid before delivery, this is negotiable term.
Transportation cost & Insurance	At the buyer's side, not include in above offered price
Quality Test	After getting all equipment, buyer should ensure all conditions for installation and commissioning of equipment within 20 days
	After finishing installation and test, buyer need to offer receiving report within a week. Otherwise equipment is deemed to be qualified.
	Without supplier promise, buy could not using equipment. Otherwise equipment is deemed to be qualified.
Installation and commissioning Installation	Installation and commissioning is guided by seller
	The quotation doesn't include all the costs related to the installation work.
	Guiding installation and test fee: 200 USD per day per person
	Round flight tickets & Board & lodging are covered by the buyer
	The cost of quarantine or post-infection treatment due to the corona in the buyer's country is under the buyer's side