Service & Support
Comprehensive Services For The Complete Blown Film Plant
No matter where you are located, shubham is committed to serving and providing you with the necessary information with regard to our products and services. Our technicians and engineers are a telephone call away – ready to support you with innovative and cost-effective solutions that will keep your business running at peak performance. Our commitment get commenced as our machine reach to our customer ( our commitment commenced the moment our machine reach to the customer). Our team will be ready to serve you by phone/ fax or email.
Technical Support & Training
Highly skilled technical team at shubham is keen to support our customers at any point of time. This includes Imparting training during machine trail and testing at the time of dispatch and machine installation, erection & commissioning at customer’s end, guidance to machine operators and educating maintenance personnel to the core areas where care should be taken and avoid unexpected breakdown.
Spare Parts
With huge spare holding capacity, shubham can supply spares in very short span of time whether requirement is normal or urgent.
Manual
Shubham provides instruction and operation manual that furnish complete technical detail of the machine for its operation and maintenance. These includes information on electric, pneumatic diagrams, operational instruction, trouble shooting, maintenance guidelines, spare part list etc…
We at Shubham are committed to serve and provide you with all the necessary information you need with regards to our products and services, no matter where you are. Our technicians and engineers are just a call away – ready to support you with innovative and cost-effective solutions that will keep your business running at peak performance. Our commitment gets commenced the moment our machine reaches to our customer. Our team will be ready to serve you by phone/ fax or email.
Highly skilled technical team is keen to support our customers at any point of time. This includes Imparting training’s during machine trail, machine testing at the time of dispatch, machine installation, erection & commissioning at customer’s end. Guidance to machine operators and educating their maintenance personnel to the core areas where care should be taken to avoid unexpected breakdown’s.
With huge spare holding capacity, shubham can supply spares in a very short span of time whether the customer’s requirement is on normal bases or urgent.
Shubham provides instruction and operation manual that furnishes complete technical detail of the machine for its operation and maintenance. These includes information on electric, pneumatic diagrams, operational instruction, trouble shooting, maintenance guidelines, spare part list etc.
Foundation of the plant is to be done as per Foundation plan Drawing or see that the foundation is properly dried up and the bolts are tightened Securely. Alignment of the extruder, die and vertical take-up are to be done accurately on the plump line of die center. Electric supply is given to the units shown in the electrical layout Drawing or all units in the plant are to be properly earthed.
Check for the lubrication of all the gearboxes, Chain assembly and bearing points.
Water circulation to be provided in the water jacket fitted to the hopper throat.
A water pump of 1 HP should be installed for water circulation in the cooling jacket of the extruders and in the scrubber. For keeping this water cold enough a sufficiently large (At least 200 Gallons) Water tank should be installed and the water inlet in this tank should be provided with a number of spraying nozzles for cooling.
Assemble head with clean parts and screens with heavier screen nearer to the breaker plate.
Make sure temperature is high enough.
Make sure water is circulating in the feed zone of the barrel.
Make sure enough material is on hand.
Make sure the head has been uniformly tightened when hot. Once a leak starts it will not stop until the head is dismantled, clean and retightened.
Feed little at a time until the operation smoothness out.
Inspect controllers - see if all are working properly.
Keep the temperature of screen changer housing and rotating head 15 to 20C higher than processing temperature during the starter. In order to avoid over loading of extruder.
For tubular film, the first extruded is bunched and passed off through the nip rollers. The "Bunch" and the following film cannot be too thick or it will not go through the nip rollers, As the tube is being formed, air is introduced through the die in small amount to keep the tube a lightly blown. After threading is complete more air is blown to bring the bubble to the desired size. Care is needed to keep the die faces clear of molten resin as these may latter be decomposed, become difficult to clean and cause die lines. The first minutes of production always yield scrap material, as the system must reach equilibrium. The following may have to be adjusted to get uniform thickness. The extrusion speed and take up speeds must be balanced to get the desired thickness. The film is wound on the winding cores after selecting suitable tension on torque control. It is advisable to provide thin coat of silicon grease at the die lip to avoid sticking of melt, Also all the threaded portions including bolts and nuts are giving thin coat of any suitable grade of antisieeze compound which enable easy dismantling of the die parts
The following paragraphs lists some of the problem commonly encountered in film extrusion, along with their suggested solutions.
FAULTS |
CAUSE |
SUGGESTED REMEDIES |
|---|---|---|
Blocking |
High Extrusion temperature which produce high film temperature and causes antilock or slip additive to volatilize at the extrusion die.
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Lower the film temperature by
(A) Reduction Die temperature (B) Reduction Cooling temperature (C) Increasing distance between Die and Nip rollers. |
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High Tension wind up casing Pressure on film roll. The Higher the film temperature at wind up the greater this effect.
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Reduces the tension at the winding stage.
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High Pressure on the film at the Nip roll causing internal blocking.
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Reduce the pressure at the Nip rolls.
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Unfavorable environmental conditions during extrusion or storage can also cause blocking High room temperature warms the Film while stacking the rolls creating High-pressured. Very low temperature On the other hand, may cause film shrinkages. Both extremes in temperature cause film blocking.
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Film characteristics which affect Blocking are film smoothness And density. Higher density film Have harder surface and consequently Less tendency to block.
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Wrinkles |
Die out of adjustment causing gauge variation that again results in an uneven pull as the nip rolls thumb on the roll.
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Adjust the Die.
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Film too cold when it reaches The nip rolls and therefore, its Stiffness may cause crumpling at the nip and wrinkle less.
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Increase the film temperature at nip rolls by slightly lowering their height or raising the melt temperature or increasing the screw speed / the Nip roll speed extrusion rate.
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Guide boards not properly aligned with the Nip Rolls.
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Adjust.
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Webbing of the bubble due to air currents.
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Support the tube with horizontal guide bars at two or three locations.
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Poor Transparency |
Low blow-up ratios.
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Try a blow up ratio between 2 & 3.
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Low melt temperature
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Use a fine screen pack.
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Non - Uniform Gauge. |
Width of the Die opening incorrect.
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Increase temperature.
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Lines in the Extrusion Direction. |
Die lines.
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Increase Die temperature.
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Fish Eyes. |
Non-homogeneous raw materials.
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Use fine Wire mesh.
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Dust particles.
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Check the raw materials.
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Rough |
Too law temperature
|
Increase Temperature.
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Waves on the surface of the film. |
Die temperature a little higher.
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Reduce the temperature.
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A. Strict Maintenance schedule should be followed to keep the plant in good working conditions. A checklist should to keep and followed. The main items on the check-list are follows:
Flush and change oil in drive gears.
Proper lubrication of all the parts that require greasing or oiling.
Scrub down machine and clean area around it.
Visually check contact of band heaters.
Check condition of belts in belt - drive.
Grind down breaker plate surface to affect better seal.
Inspect thrust bearing for wear.
Test die and extruder heater for 'BURN OUT'
Change frayed electric wires.
Check tightness of all foundation bolts.
Flush and clean insides of take up rolls.
Check all the electrical points.
Check nip rollers for uniform surface. If the surface is not uniform, regarding is essential.
Check water-circulating unit.
Check tightness of bolts of all the motors, gearboxes, bearing housing etc. that are fitted on the plant.
Regular lubrication of all the moving parts of the plant is the most important aspect of preventive maintenance. In this plant, following are the components that will have to be taken care-off for regular lubrication.
The tools required for extruder cleaning are as follows:
Wire Brush.
Blow Lamp.
Brass Blades
The Cleaner Can.
Silicon spray
With these, the most tenacious melt can be removed from the metal surface of the machine. When the head is opened, the first to be cleaned is breaker plate. Then get at the die and the head. And If Necessary the screw can be taken out easily and it may be cleaned along with the barrel. Magnesium Oxide Should be used for better cleaning
