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The production process

Copyright 2018 gianpan31

Currently the product is produced through the following production process comprising the steps of:

- Mixing the product;

- Extrusion;

- Flexographic printing;

- Thermo-welding and cutting.

- Packaging

- Recycling of production waste

Mixing

The raw material , under shape of granules, is placed in a silo mixer through a dispenser is introduced to the dye , and this is also in the form of granules, based on the color to give the product. Everything is mixed to be used in the next processing step.

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Extrusion

The next stage of the production process involves the construction of coils of plastic tubular film, which takes place by means of a system of extrusion for the film. The extrusion plant for film serves to get the film (film) directly from the plastic material in granules. From the mixer the material passes into the chamber of lamination, composed of a cylinder made from electric resistance external to the heating where it is allocated a worm that has the function of the suggested material mixing and forcing the exit from the die of the extrusion. It comes out in the form of a tubular, and its interior is introduced a certain amount of compressed air, depending on the width to give to the bag. The working temperature varies from 140°C to 220°C depending on the type of material used. The film obtained is stretched to obtain the desired thickness and in the machine there is a column of the guide (high as 7 m on some machines), which serves as a support for the tubular plastic to allow cooling. A group coupling consisting of a pair of steel cylinders and has the function to crush and pull the tubular, which, once crushed, it undergoes a treatment called “corona treatment”, obtained by the discharge-electronic high-frequency necessary for the next phase of flexographic printing. The tube so produced by the rewinder, located at the end of the machine, is collected in coils .

estrusione

Flexo Printing

The coil is mounted on the bracket where the roll film is rolled out. The plastic tubular film is passed through a forced passage , which is in contact with roller door cliché, which soaking of the ink contained in the appropriate compartments, imprinted on the film, the written and the logo that you want to achieve. The printed film in its path is in contact with the hot air, which will allow the ink to dry; finally, you will ribobinato for the next phase of welding and cutting. The machine in the company is made up of 6 trays for the ink from which it is possible to realize a print with 6 different colors. If the customer requires a print with multiple colors overlapping, then you will another type of printing called Cmyk (colors overlay). The flexographic printing is very important because in this phase of processing is to determine the quality of the product, a fundamental characteristic for our company.

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Thermo-Welding, cutting, and packaging

The machine used to perform this type of operation is a thermo-welding machine for the production of bags.

The machine operates in the following way: the coil is mounted by the operator on the machine; the film begins to move in a fixed path, and thanks to the notches imprinted in the printing process, all of which are placed at the same distance from each other, determines the length of the bag. The signal will be read by a photocell that will operate the welding bar, welding and cutting at the same time our film. Then through an arm, and a small press, on the machine, will be shorn of the material. According to the mold mounted on the press will determine the type of product to be made. The bags are ‘ammazzettati’ in a predetermined number and through a conveyor belt are taken out of the machine, next to which is located the operator, who will place in the appropriate scatoli the product.

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Recycling of processing waste

During the production, you are to determine waste, which arise for example, from the operation of the extruders, the material removed in the phase of welding and cutting, and so on. These waste products are recovered through a recycling plant (plant regeneration): in fact, the gap is immersed in a mill, is ground and made into flakes; through a cyclone fan is transported into a storage silo which feeds the extruder of the regeneration, after you have filtered the material and cutting it to granules, cools it in a circuit in contact with water circuit to the air in case of bioplastics). The product obtained (granule raw material regenerated) not being non-toxic is used for the production of trash bags.

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