A dream cast

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Hall 17 | Booth C22

Inspired by the precision and high level of automation of modern CNC machine tools, Reifenhäuser Cast Sheet Coating has developed Mirex MT, a patent pending polishing stack technology which is said to be the first and only system in the market that combines modern digital technique with sophisticated mechanical engineering. The company will be presenting the new Mirex MT polishing stack for the first time at K show. Reifenhäuser Cast Sheet Coating has also launched a new contact roll with special micro structure for Midex rotary arm winders. The roll helps reduce production costs, enhance the winding quality and increase production safety.

The polishing stack works at the push of a button and the set data are 100% reproducible. (photos: Reifenhäuser Cast Sheet Coating)

Reifenhäuser Cast Sheet Coating claims that the Mirex MT product range allows film producers to adjust the polishing nip more precisely by a factor of 10. In contrast to other polishing stacks, nip adjustment of Mirex MT can be effected fully automatically, even during running production. In the past, the line had to be stopped for manual adjustment of the correct nip on a trial and error basis. The system works at the push of a button and the set data are 100% reproducible.

The high level of automation is said to have a positive effect both on the film quality and production cost. Due to the uniform thickness profile over large web widths, producers are able to obtain film of improved precision while saving raw material. Due to the automatic adjustment, set-up times are said to be only a quarter of the time needed in the past. The amount of waste can be reduced by 75%, depending on the production conditions.

Triple savings in energy

Hydraulic systems are completely dispensed with so that the polishing stack is suited for cleanroom production. Film producers can benefit from triple savings in energy: no need for hydraulic pumps in permanent operation, improved efficiency of roll drives, no energy-intensive adjustment of the nip.

Optimised roll drives

Mirex MT combines the roll set-on system and the nip adjustment system forming a mechatronic drive unit. The angular position of the first polishing roll can be varied by 30° using an X-Y adjusting device. Individual drives arranged on both sides of the roll facilitate axle crossing of the first two rolls – a prerequisite for a uniform film thickness profile. Reifenhäuser Cast Sheet Coating has optimised the existing roll drives by combining several low-backlash planetary gearboxes with servomotors and torsion-resistant couplings.

Mirex MT is available in three designs, depending on application, film thickness and production capacity: Smart, Standard and High Quality.

New contact roll for cast film winders

The new roll is said to save producers a complete production step. A precise build-up of edges can be ensured so that rewinding of the film can be dispensed with in many cases.

A special micro structure and soft rubber-coating improves the contact to the web and prevents undesirable film warts which avoids blocking of the film layers in the winding process. In the past, particularly thin PP film of less than 30µ was affected. Producers usually counteracted this phenomenon by using expensive additives. Now, these can be reduced to a significant extent, says Reifenhäuser Cast Sheet Coating.

The roll is also said to eliminate the need for electrostatic charging of the film used in the past to improve the winding quality, even though it was detrimental to the working conditions of the operating staff due to possible electrostatic discharges. These are not only unpleasant to people, but may become a safety risk, depending on the environment, for instance, in production halls where colours are worked with at the same time. The roll is available as of now and can be retrofitted to all Midex rotary arm winders.

The new contact roll for Midex rotary arm winders is said to save producers a complete production step. (photo: Wentus, Höxter)

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