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Bi-Axial Rotomoulding Machine
Process, Bi-Axial Rotomoulding Machine and Advantages of Rotational Molding |
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The process
is simple and less unwiedly. |
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The
polymer resin is encumbered in the mould. |
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The mould is
built-in on the arms of the machine. |
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The mould rotates
Bi-Axially in side the oven where hot air circulates to
melts the resin in side the mould. |
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While rotating
the moulds the resin melts under high hotness and sticks
inner face of the mould. |
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Moulds transferred
to cooling station where the mould is acceptable to cool. |
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While cooling
the melted polymer resin freeze and shrivel. |
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The mould is
opened and the finished article is indifferent. |
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| Rotomoldng
process & advantage broadly
the process is classified in to following sub processes. |
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Compounding to
produce coloured of Granules, |
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Pulverising to
convert material in to Resin form. |
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Rotational Molding
to produce the final product |
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First
Process :Compounding by means
of Extrusion |
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The LLDPE raw material with suitable masterbatch
is being fed in to the barrel cylinder through storage hopper.
The barrel is preheated by heating zones and suitable temperature
control system to process the input material. The rotating screw
pushes the material towards die end with uniform and homogenized
plastics melt. The screw is rotated by suitable AC motor coupled
with heavy duty gearbox.The plastics strands extruded from die
are fed in to high speed Pelletiser unit after they get cooled
and traveled through SS water cooling tank. Pelletiser cuts
the strands in to desired size of pellets which can be collected
in to storage silo. |
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Second Process
:Pulverising |
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The compounded or coloured
granules are being fed in to Pulverizig machine as Input material.
The granules are fed in to Disc Mill via vibratory feeder which
feeds the material as per rate of vibration of the device. The
fed material is being crushed in to Mill at very high speed
by one Rotating blade and one stationery blade. The crushed
material is conveyed in to cyclone hopper at height via efficient
suction system. |
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The Rotory Air lock
devise separates the blown air and pulverized resin and allows
the powder passes in to Screen Vibro unit. Vibro screen unit
screens the powder as per mesh used and discharge the final
product in to the storage silo. The course particles are fed
again in to the Mill to repulverise the same. |
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Compounding by means
of High speed Mixer (Incase the Extrusion process is not used
to produce thecoloured Granules) The pulverized resin is being
mixed with other ingradients to prepare a ready formulation.
This process is also being adopted by many processors instead
of producing granules from Extrusion Plant. |
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In the process the
polymers mixed with other ingredients is being loaded in to
Mixer vessel. The mixer vessel is made from special double wall
construction of SS and MS Plates. In which the material is being
mixed by means of specially designed two nos blades running
at very high speed. |
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The mixing cycle is
decided by the certain set temperature. Normally batch time
is 10- 15 minutes depending upon grade, quantity and formulation
of material to be mixed. After cycle time is over, the the material
is being discharged and collected in to silo. The final material
is uniformly and homogenized mixed which is ideal to use as
for Rotomolding process. |
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Third Process
:Rotational Molding |
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In the other Plastics
processes like Injection Molding, Blow Molding & Extrusion
Process ,the plastics material is being melt at certain higher
temperature and conveyed forward in to die or mould by special
designed Screw. Unlike such processes ,Rotational molding is
a very simple process. In which it is easy to produce hollow
and seamless products of all the sizes and profiles. Since Rotational
molding is a very simple and economical process alongwith low
cost Moulds , it is very popular in India especially to produce
the water storage tanks. |
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It comprises of mainly
four steps as per following. |
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Material Loading: |
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The polymer powder
is being loaded in to two parts Rotational Mould as per size
and shape of product. After loading material manually in to
mould , the mould is closed. According to type and shape of
Mould , some times the mould are also closed by insulating covers. |
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Rotational Molding: |
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The closed Moulds mounted
on to Arm are swinged in to closed heating chamber where Hot
and forced Air is circulating. The moulds are already rotating
in two perpendicular axis at certain low speed as per size of
the mould. The moulds are in Rotation in two axis so as to distribute
the loaded powder uniformly inside surface of the moulds. The
moulds are heated by forced hot air in to chamber up to certain
heating time. The material in to moulds fuses after heating
and it forms a uniform layer inside the mould. |
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Cooling: |
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Now the moulds are
taken out form heating chamber and swinged to cooling station.
The moulds are cooled at cooling station by means of forced
air or by spraying water where the moulds are in rotation mode
in both axis. After certain cooling period, the raw material
gets solidifies in to shape of the mould. |
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Unloading the finished product: |
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The mould is taken
to unloading/ loading part where the mould is opened to get
the finished product. After getting the finished product, again
fresh polymer powder is being charged in to mould so as to keep
ready for next cycle. |
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