Well-Known Paper Impregnation Line for Dipping Melamine Resin and Drying

• Customization: Available
• After-sales Service: 1 Year
• Warranty: 1 Year
• Specification: 20-60 m/min
• Trademark: NTC
• Origin: Wuxi
• HS Code: 84392000
• Production Capacity: 20 M/Min

Product Description

1.1 Applications

Our state-of-the-art paper impregnation line expertly employs urea formaldehyde resin and phenolic adhesive to seamlessly impregnate, coat, dry, and stack paper base materials.

With our cutting-edge decorative paper impregnation line, you will achieve production of:

Melamine resin impregnated papers designed explicitly for the versatile Low-Pressure Laminates (LPL) market.

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

Melamine resin impregnated overlay paper tailored for the robust demands of High-Pressure Laminates (HPL).

Phenolic resin impregnated paper, crafted specifically for plywood lamination.

1.2 Scope of Application

Our innovative production line handles precisely controlled amounts ranging from 40 to 250g per square meter, with a width capacity of 900~1400 mm for melamine/phenolic paper. It ensures a wet strength not less than 0.75 kgf/15m for optimal performance.

1.3 Environment for Line Running

This advanced production line is engineered for environments free from corrosion and perfectly suited for water-soluble resins such as urea, melamine, and phenolic resins.

Our system is designed to meet F-level high-temperature resistance requirements and boasts an exceptional explosion-proof grade.

Ideal operating temperature: 10~40ºC

with a relative humidity ≤90% (at a temperature of 20ºC).

The recommended operational altitude is not more than 1000m above sea level.

 

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: The compressed air volume represents the maximum demand: 8m3/h, necessary for maintaining operation when all cylinders are active. While nominal consumption is a mere 0.5 m3/h, during paper break or changeover, door operations require 2m3/h. To ensure seamless operation under all conditions, preparation for an 8m3/h compressor is recommended.

 

2.4 Line Capacity Calculation

The true operational capacity of our impregnation line is dynamically influenced by machine design, glue mixture, paper quality, ambient temperature, recycling fan wind capacity, and the skilled operation by workers.

Capacity calculations are predicated 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

Daily production capacity for 4x8 feet paper is impressive, calculated as:

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

 

Part 3: Details of Supplied Machinery

3.1 Semi-Auto Unwinder

This semi-auto unwinder features a sophisticated scroll type design with a dual-axle setup, equipped with two inflatable rolls and a safety chuck for reliability.

During uncoiling, the magnetic particle damping device delivers optimal tension to the paper. Featuring a paper receiving device, it allows the new paper roll to seamlessly adhere to the end of the previous roll without halting operations. A high-speed cutter efficiently trims the final segment of the prior roll, enabling continuous impregnation. Remarkably, this process requires only a single staff member for paper receiving.

Comprising a robust frame, aluminum roller, and advanced damping device, our innovative design also includes a paper receiving mechanism, two sets of dual-cylinder roller inflatable gas systems, along with two electronic magnetic powder brakes and a safety chuck for enhanced performance.

 

3.2 Impregnator (Initial Dipping Stage)

Our state-of-the-art impregnating machine is ingeniously assembled with a sturdy frame, a precision coating section, a comprehensive breathing system, an effective impregnating roll unit, a meticulous meter device, a versatile glue tank, and an efficient heating device for the glue tank.

This cutting-edge impregnating machine excels in the initial impregnating phase. Utilizing a coating roller for precise single downside coating, it ensures resin glue penetration from beneath the paper, efficiently expelling air from the top. The coating device is enhanced with a dynamic breathing system, tailored to accommodate varying paper types, resin glues, and impregnation techniques, allowing for precise breathing section height adjustments. This guarantees optimal glue absorption and paper flatness, as resin permeates the paper fabric, minimizing tensile strength loss and promoting seamless impregnation.

After passing through the coating and breathing sections, raw paper advances to the glue tank. The gap adjustment of the metering roll precisely regulates resin content and uniformity, achieving meticulous impregnating consistency, with motion accuracy of the metering roll maintained at ≤ 0.003mm.

Technical Configuration Requirements: Incorporates a sturdy frame, S roller, advanced back coating segment, efficient impregnating roller section, and precision metering roller. φ290, High-precision metering device, advanced breathing system, and a middle section crafted from stainless steel (430) glue tank with spacers. The glue tank's elevation is expertly managed by a worm gear reducer. The metering roller uses imported NSK bearings from Japan, ensuring the roller's wall thickness remains undeformed, complemented by dual motors for the breathing roller.

It comprises the following components:

a) Frame Structure

b) Back Side Coating

c) Breathing Section

d) Impregnator Unit

e) Squeezing Section

• Offers both automatic and manual operation modes for user flexibility.
• In manual mode, the controller is located on one side, but it can adjust parameters on both sides effortlessly.
• In automatic mode, settings can be seamlessly adjusted via the cabinet panel for user convenience.
• The gap between the squeezing rollers is clearly displayed on the screen, allowing for easy adjustments.
• The assembly includes the following rollers:
• 2 high-performance steel rollers with a chrome-coated surface Φ290mm in diameter, boasting a 3.5mm tube thickness, with an impressive jumping accuracy of less than 3 micrometers at speeds up to 100m/min, featuring a 0.3mm chrome surface and a hardness rating of 50 CR.

f) Glue Tank

g) Glue Tank Heater

 

 

3.3 Dryer (Comprising of 6 Oven Units)

• Features a pneumatic automatic large door for effortless operation and superior heat retention.
• Three-layer heat insulation design achieves a remarkable energy saving of at least 20%.

 

3.3.1 Drying Ovens

Comprising a sophisticated drying section, an efficient dehumidification system, an automatic door, and a precise temperature control system. Each drying section extends to a length of 3750mm, ensuring optimal drying performance.

The drying section's heating medium options include thermal oil, steam, or a natural gas direct burning system, providing versatile solutions tailored to your specific drying process needs. Each drying section functions as an individualized temperature zone, with the ability to set working temperatures independently. Thanks to the advanced temperature control system, consistent alignment between actual and set temperatures is achieved, ensuring optimal processing. Typically, temperatures range from 120 to 180°C. Each drying section boasts a wet outlet, its opening meticulously managed by a manual damper, allowing operators to adjust according to precise process requirements.

 

3.3.2 Drying Oven Structure

Each drying section's framework, including the air curtain section, is meticulously constructed from robust rectangular and square steel pipes (50/100), ensuring exceptional strength and minimal deformation. The drying section integrates bellows, air ducts, custom-engineered nozzles, hot air blowers, and threading chain guides, all encased in thermal insulation wall panels and doors. These thermal doors feature a double-seal design and manual operation. The hot air duct is equipped with strategically positioned butterfly dampers, both above and below, maintaining a 15cm insulation layer. The outer side is fortified with 2 cold plates, while the top and inner sides are crafted with 2 galvanized sheets, safeguarding the air duct plate.

Supply Range: Drying Units, Moisture Exhauster

3.4 Roller Coater (Second Step Coating)

This innovative machine comprises a sturdy frame, upper and lower mesh-coated squeegee devices, and a sophisticated second smoothing device with lifting capabilities. The second overcoating machine ensures the paper's coating liquid achieves the required smoothness on the surface before applying the glue. By applying a secondary coating, the machine evenly covers the surface with glue, ensuring precision and quality. The choice of mesh size is crucial, as it directly influences secondary glue application. The process concludes with a finely polished finish, ensuring the tape's smoothness and uniformity as it enters the secondary oven.

Configuration Requirements: The upper and lower roller coating change speed frequency and converter speed are paramount. With a smooth roller equipped with a cylinder lift and frequency-controlled positive and negative adjustments, the high and low angle can be conveniently adjusted. The plastic tank, crafted from premium stainless steel (S430), and imported NSK roller bearings exemplify superior quality and durability.

Supply Range: Frame, Upper and Lower Coating Machine. The machine utilizes mesh coating technology.

 

3.5 Cooling Unit

After the drying section, the paper transitions into the cooling section, a critical phase measuring 3750mm in length. This segment features a rack, sealing plate, air box, air duct, cooling heat exchanger, nozzle, circulating fan, and moisture exhaust air outlet. Each component plays a vital role in cooling efficiency. The innovative design allows the upper and lower air volume to be adjusted independently via the air door, offering customized cooling solutions.

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

 

3.6 Web Aligner

To counteract deviation caused by extended operations, the alignment machine re-centers the paper after the drying section. Featuring upper support rollers that adopt a movable roller system, elevation is achieved via a cylinder for precise alignment.

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 is not only integral for maintaining the paper strip's seamless operation but also plays a pivotal role in further cooling high-temperature paper strips exiting the dryer, prepping them for subsequent processing challenges. With two cold water rollers, φ800mm, and additional rollers of φ350mm and φ200mm in diameter, these rollers facilitate cooling through integrated water circulation, complemented by a cylinder platen roller for enhanced stability.

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

In the front of the shearing knife, a sophisticated pair of paper feed rollers are strategically positioned one above the other. They harmoniously work in sync with the cutter to achieve precise fixed-length cutting. Guided by linear bearings, the upper and lower pressing rollers are effortlessly elevated by air cylinders, ensuring seamless operation. The feeding rollers' speed is adjustable, perfectly positioned at the edge of the feed to facilitate easy adjustment of paper tightness. With versatility in mind, it accommodates cutting from 18g to 200g paper. You can set automatic counting alarms and freely adjust lengths. The system is also equipped with a precision 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 The paper output stacking table and lifting table come as an efficient set, featuring a belt with a lifter type mechanism that enhances operational prowess.

Function: This advanced system is designed for optimal paper sending drive, with adjustable speeds that simplify stacking and enhance convenient out-feeding. It smoothly lifts up and down, robustly supporting up to 3 tons of 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 includes: a lift-valve, a hydraulic lifter, a sturdy frame, a roller conveyor, and a belt and power device, ensuring complete and efficient operation.

 

3.10 Electrical Control System

The electrical control system is robustly designed with 4 electric control cabinets, covering one-time dip touch control, paper pick-up, and shear count control. It's comprised of essential control units for seamless operation.

(1) The sophisticated main drive control system incorporates the Mitsubishi frequency conversion control system, enhancing precision and efficiency.

(2) A frequency conversion speed regulation system controls the hot air circulating fan for optimal performance.

(3) Safety is paramount: the main control cabinet and fuselage operation station include an emergency stop button. Additionally, a pull wire emergency stop switch is positioned strategically on the production line, with wire connections uniformly numbered as per electrical drawings.

 

Safety Suggestions:

• The supplier offers a state-of-the-art safety system designed to protect both operators and equipment from potential harm.
• All rotating wheels and gears are securely covered, ensuring absolute safety.
• The safety line beneath the measuring roller is intricately connected to an emergency stop device for instantaneous response.
• A preventing tripping bar/system is established for the metering roller to avert accidental tripping of fingers or other objects.
• Wires are shielded within a protective wire slot or bushing, necessitating the use of nationally standardized wires for safety and compliance.

Part 4: Supplied by the Buyer Side

• Essential elements such as venues, buildings, equipment, installation tools, and materials like anchor plates, rods, steel structures, and standard parts (bolts, nuts, washers, etc.) are to be supplied by the buyer.
• Standard installation tools and equipment, including welding machines, cranes, hoists, and a variety of hand tools are necessary for efficient setup.
• Cleaning equipment and specialized tools are vital for maintaining a pristine working environment.
• Fire-fighting facilities require comprehensive safety protection devices to uphold security standards.
• Material transport and handling equipment, such as trucks and driving apparatus, are pivotal for seamless logistics.
• An efficient workplace power distribution and power system, along with a power distribution cabinet, are critical components.
• Moisture exhauster insulation works are crucial for maintaining optimal operational conditions.
• The production line of compressed air pipes is expertly reached to ensure smooth functionality.
• Master workshop electric control box cables are strategically lined to ensure seamless operation.
• Electronic control systems and equipment grounding facilities are essential for safety and efficiency.
• Workshop machinery and electrical equipment, alongside precision machinery and tools, are vital for superior performance.
• Spare parts, wearing parts, consumable materials, and raw and auxiliary materials are provided, complete with essential storage facilities.
• Debugging requires paper, rubber, and other raw materials for thorough and effective testing.

 

Part 5: Duties from the Supplier

• The supplier is responsible for providing all cables and connectors from the main electrical control cabinet to the working line, ensuring uninterrupted connectivity.
• Moisture exhauster pipes are provided to meet the highest standards of moisture management.
• All machine parts must be newly manufactured, maintaining a strict no-second-hand policy to ensure reliability and excellence.

 

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
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