Air Bubble Film Machinery

Transcription

1 Air Bubble Film Machinery

2 Milestones Plastic, Passion and Technology, together The experience of the Mencarelli family in the mechanical field begins. Birth of Torninova Costruzioni Meccaniche Our First Air Bubble Film Machine 2

3 Today We go Global with Torninova Corporation Over 250 working machines on over five continents Our new Headquarters 3

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5 The experience of the Mencarelli family in the mechanical field began early in the last century, in At the time of its foundation in 1969, Torninova s experience had already developed, leading the company to specialize in technical support for extrusion lines. Later, in 1993, Torninova started designing and manufacturing air bubble film machines, stretc.h film machines and dimpled drainage membrane machines. The company has always been highly involved in research and development in order to offer its customers versatile and flexible systems that combine the most innovative electronic and mechanical technologies. A commitment to meeting the highest possible standards has led the Torninova Corporation to design its complete range of air bubble film machines, stretc.h film and dimpled drainage membrane machines and to acquire top knowhow in the field, now available to its customers. About Us 5

6 HI-TECH AIR BUBBLE FILM MACHINERY Today Torninova Corporation is synonymous for Hi-Tech bubble wrap machinery all around the World. For over 20 years Torninova Corp. has been engaging in the production of top-level equipment, presenting state-of-the art technology applied to air bubble film production lines: all of this has been possible and achieved thanks to the Company s constant engagement in finding innovative, better performing and cost-saving processes and solutions. Torninova s know-how is also based on the willingness to listen to reccomendations and suggestions provided by our clients, who have been helping us to enhance and adapt every single installation, making them suitable for each project s specific necessity and technical requirements. Completely focused on this specific line of equipment, Torninova Corp. strives to take the best possible advantage of market feedback and requirements, updating its equipment to comply with the newest regulations. Each of our lines components are homogeneous and perfectly connected to their counterparts, resulting in a perfectly integrated vanguard installation for the production of air bubble film. All machines are modular and for this reason the whole Torninova Corp. system is easy to upgrade, based on each Client s specific needs, and applicable on existing machines even if supplied by other companies. Amongst Torninova s outstanding specialized bubble foil production equipment the following lines deserve mention for their very special features: The COEX BUBBLE (10), an authentic masterpiece, represents the most advanced technology available for the production of high-performance air bubble film. In fact, the special co-extrusion configuration allows the production of a symmetrically structured (ABCBA+ABCBA), multilayer air bubble film containing an integrated air retention barrier of Nylon-PA6 (layer C). The result is the production of an ultra-light bubble foil with enhanced cushioning and protective properties, far superior to the same-weight mono-extruded bubble wrap film. In practice, better results are ensured with less material and this means an unbeatable competitive edge in the film market. 6

7 The AIR BASIC belongs to the family of the off-line process plants, and is a patented system based on the hot-air thermoforming process, which processes LDPE rolls to produce air bubble film both for technical packaging and reflective insulation. The specialty of this line, compared to traditional off-line systems, is that it significantly reduces energy consumption and provides maximum production-plan flexibility with its stop-on-phase procedure. The AIR BASIC series is still one of the most purchased lines for the production of air bubble film for technical packaging and reflective insulation. The TWIN BUBBLE is the answer to a new profitable sector which produces air bubble film for use as thermo reflective insulation in costruction applications. Requests from Customers involved in such specific markets have led Torninova Corp. to design and produce this new patented extrusion system. This machine allows the production of multilayer compound (sandwich) bubble foil, PE-foam and aluminum foil, all in one-single process. The TWIN BUBBLE system can even produce flame-retardant materials certifiable for all different Worldwide Standards. Furthermore, the POWER BUBBLE, POLYBOLL and MAC BUBBLE air bubble film production lines complete the Torninova Corp. range. All Torninova Corp. equipment lines offer highly developed electronics, mechanical parts especially designed and created in the Company workshop and 24/7 teleservice assistance. Torninova Corp. is a journey of quality and tradition in plastic machinery which continues through generations and stands as a guarantee for Clients Worldwide. A solid technical base, constant focus, continuous development and customised solutions make Torninova Corp. the reliable partner in air bubble film production, ensuring the most effective and worthy results. 7

8 COEX BUBBLE (10) PLUS high-speed/high-output, in-line co-extrusion. For the production of: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - bubble wrap - etc... The World s largest packing corporations use the COEX BUBBLE (10) as it represents the most advanced technology for in-line production of air bubble films containing an integrated air retention barrier. The COEX BUBBLE (10) is a cast co-extrusion system with three extruders. It processes LDPE, TIE and Nylon-PA6 pellets to produce high-performance, symmetrically structured (ABCBA+ABCBA), multilayer air bubble film. The 10-layer structure allows for integration of an air-tight, Nylon-PA6 barrier for longer bubble-air-retention, thus improving the film s cushioning and protective properties, even at reduced thicknesses. For example, a 35 g/m 2 of coex film has the same resistance of a 60 g/ m 2 mono film- a definite competitive advantage! In place of the main single-screw extruder, the machine can be equipped with a corotating twin-screw extruder that brings these main advantages: 1) Up to 30% cost reduction thanks to the less expensive raw materials that can be used (types, quality and grade), including 100% recycled materials; 2) Lower energy consumption thanks to the more efficient kw/kg extrusion ratio; 3) Higher production flexibility thanks to numerous types of raw materials that can be blended together with PE like calcium carbonate, talc, barium sulfate and other charges and reinforced materials Especially suitable for technical packaging and envelopes, the COEX BUBBLE (10) series is fully automatic and includes touch screen controls for custom configuration of production recipes. Thanks to an on-board network connection, machine functioning can be remotely monitored via Internet. The modular configuration of COEX BUBBLE (10) lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc... RAW MATERIAL PE, TIE and Nylon-PA6 pellets THERMOFORMING PROCESS With three cast extruders From 1,25 to 3,5 m FINISHED AIR BUBBLE FILM WEIGHT min. 25 g/m 2 - max. 600 g/m 2 MAX. PRODUCTION SPEED 100 m/min FORMING ROLLER DIAMETER From Ø 400 mm to Ø 600 STANDARD BUBBLE SIZE Ø 10 x 3 mm spherical CAST DIE Two separate dies with feed-block for variable geometry co-extrusion CO-EXTRUSION GEOMETRY base (ABCBA) + bubbles (ABCBA) 8

9 REFERENCE Machine 2,5 m - two layers Standard production size up to 700 kg/h (75 g/m 2 ) WHY COEX BUBBLE (10)? Better film performance ensured with less material equals an unbeatable competitive edge in the film market! Standard production size m 2 /h (35 g/m 2 ) Diameter of screw extruders A= Ø 130 mm L/D=30 (LDPE) B= Ø 45 mm L/D=30 (TIE) C= Ø 45 mm L/D=30 (Nylon-PA6) Average power consumption < 0,4 kw/kg OPTIONAL EQUIPMENT CO-EXTRUSION AIR BUBBLE FILM Polyethylene Tie Nylon Tie MONO-EXTRUSION AIR BUBBLE FILM Single-layer Polyethylene - COROTATING TWIN-SCREW EXTRUDER - TRIPLEX winder Air Polyethylene Air - DUPLEX PLUS winder - VIR winder - Third layer extrusion lamination unit - Third layer diathermic oil lamination unit - Third layer hot-air lamination unit - Fourth layer unwinder - Perforation unit - Forming cylinders - Chiller unit 1 kg 1 kg 5% thickness lost after 14 days 50% thickness lost after 14 days Note: Independent Comparison 9

10 POWER BUBBLE PLUS high-speed/high-output, in-line mono-extrusion For the production of: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc The POWER BUBBLE system is the pinnacle of standard mono-extrusion technology. Thanks to its power and flexibility, this machine produces a vast array of air bubble films. Starting from an appropriate formulation of LDPE pellets with HDPE, PP, hexene - octene LLDPE and mlldpe, the universal single-screw extruder produces high-performance, low thickness materials. A single operator can fully control the entire POWER BUBBLE manufacturing process with the system s fully integrated touch screen controls. Using its on board network connection, the machine s operation can be remotely monitored via Internet. The system s modular configuration is adjustable for any production output and lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc. In place of the main single-screw extruder, the machine can be equipped with a corotating twin-screw extruder that brings these main advantages: 1) Up to 30% cost reduction thanks to the less expensive raw materials that can be used (types, quality and grade), including 100% recycled materials; 2) Lower energy consumption thanks to the more efficient kw/kg extrusion ratio; 3) Higher production flexibility thanks to numerous types of raw materials that can be blended together with PE like calcium carbonate, talc, barium sulfate and other charges and reinforced materials. REFERENCE Machine 2,5 m / two layers Standard production size up to 650 kg/h (75 g/m 2 ) Standard production size m 2 /h (40 g/m 2 ) Diameter of screw extruder Ø 130 mm L/D=30 Average power consumption < 0,4 kw/kg RAW MATERIAL PE pellets THERMOFORMING PROCESS With cast extruder From 1,25 to 3,5 m FINISHED AIR BUBBLE FILM WEIGHT min. 30 g/m 2 - max. 600 g/m 2 MAX. PRODUCTION SPEED 100 m/min FORMING ROLLER DIAMETER From Ø 400 mm to Ø 600 STANDARD BUBBLE SIZE Ø 10 x 4 mm CAST DIE Two separate dies OPTIONAL EQUIPMENT - COROTATING TWIN-SCREW EXTRUDER - TRIPLEX winder - DUPLEX PLUS winder - VIR winder - Third layer extrusion lamination unit - Third layer diathermic oil lamination unit - Third layer hot-air lamination unit - Fourth layer unwinder - Perforation unit - Forming cylinders - Chiller unit

11 POLYBOLL PLUS in-line mono-extrusion, medium/low production speeds and outputs For the production of: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc... POLYBOLL is Torninova s authentic entry-level in-line extrusion system. These machines process LDPE pellets to produce a wide range of excellent-quality air bubble films at moderate outputs. With its simplified structure and no-frills finishing, the POLYBOLL is the most suitable solution for medium-to-small market necessities. The POLYBOLL production process is completely automatic and fully controllable by a single, un-skilled operator. This machine allows a new bracket of customers (e.g. air bubble film distributors and converters) to enter and learn the production market while substantially containing their up-front investment costs. The POLYBOLL system is also ideal for air bubble film manufacturers intending to relocate production facilities directly in distant, but profitable, new markets, while drastically reducing transport costs and writing off, in the short-term, the initial investment. The POLYBOLL system s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc. RAW MATERIAL PE pellets THERMOFORMING PROCESS With cast extruder From 1,25 to 2,5 m FINISHED AIR BUBBLE FILM WEIGHT min. 35 g/m 2 - max. 300 g/m 2 MAX. PRODUCTION SPEED 30 m/min FORMING ROLLER DIAMETER Ø 370 mm STANDARD BUBBLE SIZE Ø 10 x 4 mm CAST DIE one die with double delivery REFERENCE Machine 2,5 m / two layers Standard production size 280 kg/h (75 g/m 2 ) Standard production size m 2 /h (40 g/m 2 ) Diameter of screws extruder Ø 95 mm L/D=30 Average power consumption < 0,6 kw/kg OPTIONAL EQUIPMENT - DUPLEX PLUS winder - VIR winder - Third layer extrusion lamination unit - Third layer diathermic oil lamination unit - Third layer hot-air lamination unit - Fourth layer unwinder - Perforation unit - Forming cylinders - Chiller unit 11

12 MAC BUBBLE high-speed/high-output, off-line processing For the production of: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc... MAC BUBBLE is a traditional off-line system which processes LDPE rolls for high-output air bubble film production. A thermoform process laminates two individual films using Tefloncoated cylinders heated by a diathermic oilcircuit connected to electric heating units. The result is high-speed air bubble film production with superior lamination quality, even for films of larger widths. In some cases, the production speeds achieved by MAC BUBBLE machines are much higher than those of an extrusion-based machine, even when starting from very high thickness films. The MAC BUBBLE system also has an on-board network connection which allows machine function to be remotely monitored via Internet and the system s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc. RAW MATERIAL Rolls of PE pellets and coated materials THERMOFORMING PROCESS By diathermic oil cylinders From 1,25 to 3 m FINISHED AIR BUBBLE FILM WEIGHT min. 35 g/m 2 - max. 600 g/m 2 MAX. PRODUCTION SPEED 65 m/min FORMING ROLLER DIAMETER From Ø 400 mm up to Ø 600 mm STANDARD BUBBLE SIZE Ø 10 x 4 mm REFERENCE Machine 2,5 m / two layers Standard production size 560 kg/h (75 g/m 2 ) Standard production size m 2 /h (40 g/m 2 ) Average power consumption 85 kw-h OPTIONAL EQUIPMENT - TRIPLEX winder - DUPLEX PLUS winder - VIR winder - Third layer extrusion lamination unit - Third layer diathermic oil lamination unit - Third layer hot-air lamination unit - Fourth layer unwinder - Perforation unit - Forming cylinders - Chiller unit 12

13 AIR BASIC medium output/medium speed, off-line processing For the production of: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc... AIR BASIC is Torninova s patented off-line system which processes LDPE rolls to produce air bubble film of various bubble sizes for technical packaging and reflective insulation. A thermoform process laminates two individual films using a special heating bar to blow hot-air over the films. Compared to traditional off-line systems, this process significantly reduces energy consumption and provides maximum production-plan flexibility with its stop-onphase procedure. Such special features serve to significantly reduce inventory, transportation and energy costs. Because the AIR BASIC system is so versatile and easy to use, a single, un-skilled operator can quickly perform production changeovers without wasting material at restart. The on-board network connection allows remote monitoring of machine function via Internet and the system s modular configuration lends itself to many useful upgrades such as a 3rd layer lamination unit, perforation unit, etc.. The AIR BASIC series is still one of the most purchased lines to produce of air bubble film for technical packaging and reflective insulation. RAW MATERIAL Rolls of PE and coated materials THERMOFORMING PROCESS By hot air *(or by hot air + diathermic oil cylinders) From 1,25 to 1,6 m FINISHED AIR BUBBLE FILM WEIGHT min. 40 g/m 2 - max. 500 g/m 2 MAX. PRODUCTION SPEED 35 m/min *(65 m/min) FORMING ROLLER DIAMETER Ø 400 mm STANDARD BUBBLE SIZE Ø 10 x 4 mm REFERENCE Machine 1,6 m / two layers Standard production size 190 kg/h (75 g/m 2 ) * 360 kg/h (75 g/m 2 ) Standard production size m 2 /h (40 g/m 2 ) * m 2 /h (40 g/m 2 ) Average power consumption 50 kw-h * 65 kw-h OPTIONAL EQUIPMENT - DUPLEX PLUS winder - VIR winder - Third layer extrusion lamination unit - Third layer diathermic oil lamination unit - Third layer hot-air lamination unit - Fourth layer unwinder - Perforation unit - Forming cylinders - Chiller unit 13

14 TWIN BUBBLE in-line processing for reflective insulation materials with double bubble layers For the production of: reflective bubble foil insulation - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film packaging - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc... TWIN BUBBLE is a patented in-line system with an extrusion line specifically developed to produce reflective bubble foil insulation for construction applications. The TWIN BUBBLE series uses LDPE pellets to produce multi-layer compound (sandwich) bubble foil, PE-foam and aluminium foil, all in a single process. The system basically consists of two twin bubble lines producing two bubble foils (laminated with coated aluminium film) in opposite directions; in the middle there is a lamination station that welds the components together. The final multilayer product is then collected on the winder at the end of the line. The TWIN BUBBLE system can even produce flame-retardant materials certifiable for all different Worldwide Standards. RAW MATERIAL PE pellets, flame retardand addivitive, coated aluminium rolls THERMOFORMING PROCESS With cast extruders From 1,25 to 1,6 m FINISHED AIR BUBBLE FOIL WEIGHT min. 80 g/m 2 - max. 625 g/m 2 (double bubble) MAX. PRODUCTION SPEED 30 m/min FORMING ROLLER DIAMETER Ø 370 mm STANDARD BUBBLE SIZE Ø 10 x 4 mm CAST DIES Two dies with double delivery + one with single delivery REFERENCE Machine 1,6 m / five layers double bubble Standard production size 325 kg/h (290 g/m 2 ) Standard production size m 2 /h (290 g/m 2 ) Diameter of screw extruders two (Ø 80 mm L/D=30) + one (Ø 55 mm L/D=30) Average power consumption 130 kw-h OPTIONAL EQUIPMENT - DUPLEX PLUS winder - VIR winder - Lamination unit by hot air - Forming cylinders - Chiller unit 14

15 OPTIONAL EQUIPMENT for Air Bubble Film and PE-Foam Machinery CO-ROTATING TWIN-SCREW EXTRUDER In place of the main single-screw extruder, the machine can be equipped with a corotating twin-screw extruder. This system entails a cost reduction of up to 30% thanks to the less expensive raw materials that can be used (types, quality and grade). This type of extruder even allows working with 100% recycled material. Another great advantage is the reduced energy consumption (up to 40% compared to a single-screw extruder). The latter is due to the more efficient kw/kg extrusion ratio. The twin-screw extruder has a high ability of mixing and homogenization of polymers such as LDPE, LLDPE, HDPE, PP, PA and PA compatibilizers, recycled materials, various additives and materials with different MFIs. The screws are configured to plasticize a high percentage of the trimmings and to ensure high and constant pressure on the screen changer. MAX.OUTPUT from 700 kg/h to Kg/h MOTOR POWER From 260 kw to 320 kw BARREL COOLING Air or water cooling L/D RATIO from 32:1 to 36:1 15

16 TRIPLEX WINDER fully automatic winder with very short cycle time CORELESS READY (patented) GLUELESS and TAPELESS READY Torninova s patented TRIPLEX winder is the fastest automated tapeless and glueless winder for air bubble film and PE-foam machines. This turret winder is based on a three-cantilever-shaft configuration that allows extremely fast cycle changes (< 40s). The automatic loading of new cardboard cores (whole or split) and extraction of finished rolls is synchronized with a roller-table at the final collection station. The new transversal cutting system allows film to be wound without glue or adhesive tape on the core. Thanks to its advanced technology, the TRIPLEX winds various types and thicknesses of air bubble film and PE-foam, into very short roll lengths, at a speed of over 100 m/min. The TRIPLEX can also be installed on existing production lines. DUPLEX PLUS WINDER flexible automatic winder CORELESS READY (patented) GLUELESS and TAPELESS READY The DUPLEX PLUS is Torninova s traditional, highly reliable tapeless and glueless turret winder consisting of two cantilever air expansion shafts with automatic inflation/ deflation. Extremely reliable and powerful, the DUPLEX PLUS winds perfect quality rolls to extremely accurate lengths and widths, even when divided in-line into sub-formats. The DUPLEX PLUS can be configured to wind external bubble, internal bubble or doublesystem films. The DUPLEX PLUS is available with an automatic FAST LOADING system for finished roll extraction, core loading and hot-melt application (both for initial core gluing and roll closure). The DUPLEX PLUS can wind air bubble film and PE-foam of any type and thickness and can also be installed on existing production lines. VIR WINDER contact winder for jumbo rolls The VIR is an in-line contact winder for assembly on air bubble film and PE-foam machines. With its guaranteed speed performance and finished roll quality, the VIR produces rolls up to two meters in diameter and is thus recommended for all customers converting air bubble film or PE-foam through a second manipulation phase (bags, envelopes, formats, sheets, etc..). The larger diameter rolls (longer) are automatically unloaded onto the floor to reduce finished roll replacement times during the conversion process. The VIR can also be installed on existing production lines. 16

17 From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min REFERENCE 50 m length roll at 100 m/min of working speed 30 s complete cycle time MAX. WINDING DIAMETER mm TRIPLEX CAN WORK WITH: air bubble film - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... Bubbles inside or outside or both From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min REFERENCE 50 m length roll at 40 m/min of working speed MAX. WINDING DIAMETER mm Bubbles inside or outside or booth DUPLEX PLUS CAN WORK WITH: air bubble film - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... From 1,25 to 3,5 m MAX. WORKING SPEED 80 m/min MAX. WINDING DIAMETER mm Bubbles inside VIR CAN WORK WITH: air bubble film - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... 17

18 THIRD LAYER EXTRUSION LAMINATION UNIT This lamination module can be retrofitted to any new or old extrusion-based machine for the production of air bubble film or PE-foam in net widths of up to 3 meters. It laminates, in-line, a 3rd film of LDPE or HDPE over the bubble layer. The melted film from the single flat die adheres directly to the heads of the bubbles which are rapidly cooled. The result is a surprisingly lowcost, three-layer LDPE air bubble film. Additionally, the same melted film can be used as an adhesive layer for perfectly smooth, high-speed lamination to other rolled materials (PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc.). The finished product is an air bubble film with two flat faces, one of which can be optionally characterized by a different material. THIRD LAYER DIATHERMIC OIL LAMINATION UNIT This fast and powerful in-line lamination module is easily retrofitted to any new or old machine for high-speed production of air bubble film or PE-foam in net widths of up to 3 meters. The 3rd film layer to be laminated is supplied from the unit s double-station film unwinder (with non-stop changeover). Tefloncoated cylinders heated by a diathermic oil circuit connected to electric heating units, laminate the 3rd film layer over the bubble layer. This lamination process guarantees the highest production speeds of any main line and ensures best-quality lamination with all kinds of material (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc..). The main advantage of this lamination unit is its ability to laminate film directly on top of the air bubble film with no additional adhesive layer. THIRD LAYER HOT-AIR LAMINATION UNIT This in-line, hot-air lamination system is easily retrofitted to any new or old machine for air bubble film or PE-foam production in net widths of up to 1,6 meters. The 3rd film layer is supplied from rolls on the unit s double-station film unwinder (with non-stop changeover) and is laminated over the bubble layer using hot air. Thanks to this air-based heating system, the unit is especially suitable for lamination of delicate materials such as PE-foam, coated aluminium foil, printed film, etc.. This unit is further distinguished by its stop-on-phase procedure and very low energy consumption. 18

19 From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min DOUBLE UNWINDING POSITION WITH SEMI-AUTOMATIC ROLL CHANGE max. Ø mm IT CAN WORK WITH: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min DOUBLE UNWINDING POSITION WITH SEMI-AUTOMATIC ROLL CHANGE max. Ø mm IT CAN WORK WITH: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... From 1,25 to 1,6 m MAX. WORKING SPEED 35 m/min DOUBLE UNWINDING POSITION WITH SEMI-AUTOMATIC ROLL CHANGE max. Ø mm IT CAN WORK WITH: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - reflective PE-foam insulation - etc... 19

20 FOURTH LAYER UNWINDER This unit laminates a 4th layer film (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc..) to the base of the air bubble film, improving or varying the finished film s aesthetic and/or mechanical characteristics. It consists of a double-station unwinder equipped with two air expansion shafts for loading the 4th layer film rolls. While a roll is unwinding on one station, a new roll can be prepared in stand-by on the other for a non-stop changeover. This modular unit is easily retrofitted to any new or existing in-line air bubble film machine. PERFORATION UNIT This useful independent module is easy retrofitted in-line to any air bubble film machine and can possibly be used in other types of machines producing similar films (PE-foam, blow film, etc.). It makes a preliminary cut on the film at desired intervals (max. 400 strokes/ min) before winding, resulting in a finished film roll prepared in pre-cut sections that are quickly and easily torn off when needed. A brushless motor with encoder drives the double-blade pre-cutting device and ensures exact, consistent sheet sizes. The module is available with an optional trim-cutting unit and suction group. FORMING CYLINDERS These chromed cylinders for bubble moulding are the most distinguishing element of Torninova s technical know-how. A monolithic steel cylinder, with a special internal water circuit provides perfectly homogenous thermoregulation, guaranteeing the highest production performance and maximum stability with material of any thickness. The sector vacuum system used for bubble thermoforming increases efficiency and conserves power. The push-to-connect design allows fast cylinder changes. The cylinders can be manufactured according to custom bubble shapes and dimensions and are available for all types of air bubble film machinery. 20

21 From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min STACK UNWIND WITH AUTOMATIC ROLL CHANGE max. Ø mm IT CAN WORK WITH: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with coated aluminium foil - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - etc... From 1,25 to 3,5 m MAX. WORKING SPEED 100 m/min SPEED max. 400 stroke/min PERFORATION LENGTH according to film speed; e.g. 250 mm (100 m/min) IT CAN WORK WITH: air bubble film packaging - bubble solar pool cover - air bubble film laminated with PE-foam - air bubble film laminated with LDPE film - air bubble film laminated with HDPE film - air bubble film laminated with coated kraft paper - air bubble film laminated with MPET film - air bubble film laminated with printed film - air bubble film laminated with non-woven - PE-foam packaging - etc... From 1,25 to 3,5 m MOULDER ROLLER DIAMETERS From 270 to 600 mm IT CAN WORK WITH: air bubble film packaging - reflective bubble foil insulation - bubble solar pool cover BUBBLE SHAPES Spherical, square and other shapes STANDARD BUBBLE SIZES Ø3 - Ø6 - Ø10 - Ø15 - Ø25 - Ø30 mm and other diameters 21

22 22 Technical Assistance

23 CALL CENTER Torninova Corp. s integrated use of pioneering mechanics, electronics and information technology is the company s real strength and guarantees efficient after-sales service. The diagnostic software and display panels on the machines ensure the operators mantain high levels of efficiency. Open during working hours (8 am - 12 pm and 2 pm - 6 pm GMT+1, Monday to Friday), the call center offers immediate assistance and provides guidance throughout the process always putting you in direct contact with a qualified engineer able to resolve your particular issue. TELESERVICE SCHEDULED MAINTENANCE With the development of new technologies and its skilled staff, Torninova Corp. can provide its customers with a remote, internet-based supervisory support system which carries out machine diagnostics and any necessary software modifications. Our technicians perform scheduled maintenance on our machines. ON SITE SERVICE SPARE PARTS The company is constantly attentive to customer needs, so specialized technicians are available to provide assistance at the machine installation site. Torninova Corp. is able to ensure rapid intervention. Torninova Corp. guarantees its customers rapid supply of spare parts that may be needed during a machines s entire life-cycle. 23

24 TNV_BUBB_0415 Torninova S.r.l. via dell Artigianato Bastia Umbra (Perugia) Italy tel fax