1. BASIC DESIGN FEATURES of Vacuum Metalizing Machine
Vacuum Chamber, Subdivided Into :-
- High Vacuum Evaporation Chamber
- Winding Chamber, protected against metal Vapour and Degassing material with high pumping speed.
- High Vacuum Evacuation System
- Web Transport Mechanism with Drive and Control
- Evaporation System
- Cryogenic Pumping System / Cold Trap
- Vacuum Instrumentation and Control
- Power Distribution and Control System
2. WEB SPECIFICATIONS
- Web Width: 1100 mm max.
- Roll Diameter: 450mm max
- Core Diameter: 76 mm
- Shaft Clamping System: Pneumatic Expander
3. SUBSTRATE
- Materials – PET , BOPP , PVC , BOPET , CPP , PE , etc. [ 12 µ to 40 µ ]
- PAPER [ 45 GSM ]
- Only Good Quality Metalizing Grade Films from reputed manufacturers is to be used for desired results.
4. MECHANICAL SPECIFICATIONS – CHAMBER SIZE
- Length: 1.35 mt approx.
- Diameter: 1.2 mt approx.
- Material: Mild Steel
- No. of Chamber: Single
5. EVAPORATION
- Wire Feeder Nos.: 9
- Boats: 9
- Power Per Boat: 10 KVA
6. L.T. TRANSFORMER
- Capacity: 10 KVA
- Quantity: 9 Nos
- SCR Controller: 9 Nos.
7. VACUUM CYCLE TIME
Clean & Empty Chamber
Atm. To 1x 10 [-4] torr : 7 +/ 1 Minute
Loaded Chamber
Atm. To 1×10[-4] torr : 15 +/ 1 Minute
8. GENERAL DETAILS
- Coating Procedure: The substrate passes over the Evaporator Source at constant adjustable. Speed over a Chilled Roller.
- Coating Speed: 250 to 350 meters/minute – adjustable depending on substrate and required Optical Density.
- Uniformity of Coating: [+][-] 10% or better.
- Process Pressure: 5 x 10[-4] torr.
- Type of Coating Source: Thermal Evaporator with Resistance Heated , Boron Nitride Boats.
- Kind of Coating: One Side
- Coating Material: Aluminum
- Aluminum Purity: 99.98 %
- Diameter of Al Wire: 1.2 mm and 1.5 mm
- Supply Source: Continuous Wire Feed
- Dimension of Boats: 127mm x 13mm x 6.5mm
- Typical Evaporation Rate: 5 gm / minute per 100 mm width.
- Total Connected Load: Approx. 225 KW
9. SCOPE OF DELIVERY
The Scope of Delivery Includes:
- One Base Frame
- One Mild Steel Chamber with Supports , Connecting Flanges , Viewing Ports and End Closing Plates on Movable Flanges
- Vacuum Pumping Unit
One Web Transport System , consisting of:
- One Roller Support Structure
- Winding Shafts
- One Coating Drum with Coating Polished Surface
- One Protection Shield for Coating Drum
- One Web Winding / Re-winding System with Controls and Drives for various Motors
One Aluminum Evaporation System, consisting of:
- Evaporator Boats
- Water Cooled Boat Clamps
- Aluminum Wire Feeders
- L.T. Transformers
- SCR Controllers
- One Pneumatically Operated Shutter for the Boats
One Chilling System for Chilled Coating Drum
One Cooling System for Cryo-Panels
Vacuum Instrumentation and Controls
Free Standing Remote Control Center for necessary Operating Instruments, complete wiring with indications for :
- Web Speed
- Vacuum Inside the Process Chamber
- Temperature of the Aluminum Evaporators
- Electric Current at Each Aluminum Evaporator
- Various Vacuum Pumps
Facilities To Be Provided by Customer at Own Cost (Not in Scope of Supply)
- Electrical Power Supply up-to the Control Panels including provision for proper Grounding of Equipment
- Mains Isolator Switch to Disconnect Plant from Mains Voltage Stabilizers, necessary to avoid damage to sensitive Controls and Electrical Equipment.
- Compressed Air and Water Supply as per requirement of the Plant
Necessary Piping Work to:
- Convey compressed Air to the Plant Inlet
- Convey Water to and from the Plant
- Carry the exhaust of the Mechanical Pump combinations , away from the Processing Area
The Customer should also ensure that:
- Foundation work is carried out as per Lay-out Instruction Sheet.
- Suitable and Adequate stocks of proper Grade and Specification of Aluminum Wire , Films etc. are available at site for our Engineers to conduct the Trials after installation.
Qualified Production, QC Personnel who can be trained at our Factory on Kolkata or at your Factory Site during Installation and Trials by our Engineers.
One Lot of Evaporation Boats (500 Nos) are included in the Turn-Key Package which should be sufficient to cover production for at least One Month on Two Shift Running Basis – or initial three months start-up period
UTILITIES TO BE PROVIDED BY CUSTOMER
- Water for Pumps – at 15-20 Deg. Cel. – 150 Lts / minute
- Power (For Metalizer Plant only) – 400 V, 3 Ph , 50 Hz – 150 KVA
- Power (For the Entire Plant) – 400 V , 3 Ph, 50 HZ – 200 KVA
- Compressed Air – Pressure o.4 – o.6 MPA – 0.05 CBM / minute
- Working Floor Area (For Metalizing Plant) – 10 mts x 10 mts
- Working Floor Area (For the Factory) – 20 mts x 25 mts
- Factory Height (minm.) – 4 mts
Video of Vacuum Metalizing Machine
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