Html code will be here
TALLERES MECTOR | PLASTIC COIL FEEDING SYSTEM
Manufacturing of a continuous plastic coil feeding system designed to automate material feeding into the production line, connected to a Kiefel machine. The system enables fast and safe coil changes without stopping the process.
- Double coil loader for PET material, connected to the Kiefel machine inlet.
- Small coil loading system.
- Pneumatic shafts, minimum 2 units per machine.
- Automatic hoist with trolley and rail for fast and safe coil changes.
- Electrical integration, PLC, safety systems, testing and operator training.
- PET Coil Loading System
- Plastic Coil Feeding Area
- Top View of Plastic Coil Feeding Layout
Equipment Elements
The project involves the design and manufacturing of a continuous feeding system for 1,000 kg PET rolls connected to the Kiefer machine. Its goal is to eliminate unplanned downtime through an automated splicing system that can be safely operated by a single operator.
- Double Loader: Responsible for receiving the roll from the floor, lifting it, and transferring it to the working position.
- 1-Ton Hoist: Features an electric trolley integrated into a gantry to lift and move the rolls quickly and in a motorized manner.
- Pneumatic Shafts: Manufactured in lightweight aluminum (weighing only 26 kg compared to the traditional 60 kg) and equipped with an engraved metric ruler to center the roll without external measurements.
Operating Cycle
The process operates continuously across four consecutive stages:
1. Loading: Reception of the roll from the floor onto a cradle with support rollers, or by using the hoist.
2. Lifting: Transfer to the unwinding position via a hydraulically driven tilting bridge.
3. Locking: Safety clamping and securing within the work zone.
4. Process: Continuous unwinding and splicing to ensure a constant flow of plastic without stopping production.
1. Loading: Reception of the roll from the floor onto a cradle with support rollers, or by using the hoist.
2. Lifting: Transfer to the unwinding position via a hydraulically driven tilting bridge.
3. Locking: Safety clamping and securing within the work zone.
4. Process: Continuous unwinding and splicing to ensure a constant flow of plastic without stopping production.
Plastic coil feeding system
Safety and
Control Architecture
Control Architecture
To guarantee a safe and automated operation, the system includes:
- Double Interlock: A redundant safety system combining a pneumatic piston and a mechanical pin.
- Pneumatic Protections: Lock valves that prevent the load from falling in the event of a loss of air pressure.
- Sensors and PLC: Presence sensors that verify the roll's position before moving the bridge, controlled by a smart PLC that manages recipes, alarms, and real-time diagnostics. This control standard replicates previous Mector systems to facilitate spare parts and maintenance.
Efficiency and
Operational Performance
Operational Performance
- Staff Reduction: The entire system is optimized so that a single operator can perform the loading, shaft change, and splicing autonomously and without physical overexertion.
- Time Savings: The use of this continuous system drastically reduces roll changeover time, dropping from 15 minutes with a traditional manual system to just 3 minutes.
