Bürkle Short-Cycle Throughfeed Press Line ODW 1433/60 for laminating chipboards with customer-specific material (vinyl)and balance paper from the roll (good side at top) and laminatescut to size

Main data of the plant:Size of heating platens 1400 x 3300 mmMaximum press surface 3,93 m2Specific pressure on themaximum pressing area 60 N/cm2Total pressure 2356 kNHeating medium hot water Maximum pressing temperature (mylar foil) 130 deg.C.Heat required with 120 pressings/h 80 000 kcal/h.Total electric connected load approx. .. kW Operating voltage 400 voltControl voltage 24 volt, DCFrequency 50 cyclesRequired suction volume with aspeed of the air of 30 m/sec. = 5 200 m3/h.Required air pressure minimum 6 bar

The precise connections will be advised on completion of the design works.

Paint finish: Machines light gray, RAL 7035Switch cabinet light gray, RAL 7035Safety devices orange, RAL 2003

Dimensions of boards:Length 2015 - 3050 mm**) Width 600 - 1300 mmThickness of boards 8 - 60 mm

Note:Boards of a thickness of more than 30 mm do not pass through the laminating station.The maximum width of boards for laminating is 1270 mm.

**) For the manufacture of doors (without laminating station) the hardboards of 3-4 mmthickness are transported up to the core transfer and are then assembled on theacceleration belt transport. They are fed manually.

Substrates:

ChipboardsSpecific weight 650-700 kg/m3Relative humidity 6-8%Thickness tolerance +/- 0,15 mm

Surface sanded

Hardboards which can be laminated, similar to DIN 68750Specific weight 800 kg/m3Relative humidity 4 - 5 %Thickness tolerance +/- 0,15 mmSurface free from impurities

Fibreboards of medium density (MDF boards)Specific weight 650 kg/m3Relative humidity 6-10 %Thickness tolerance +/- 0,15 mmSurface sanded

Cores for doorsLaminated on both sides with fibreboards

Note:The substrates being used must be heated to room temperature of at least 16 deg.C. prior to their use.

Surface material:

Customer-specific material (vinyl)To be used from the roll.Weight of foil 200 - 300 g/m2Note:The quality of the material must allow cutting in the laminating station by means of the swinging knife. The elasticity must be so that the material does not splinter during cutting.

Balance papers:Sodium paper with a slight resin coating.Processing from the rollWeight of paper from 70 g/m2

Veneers:Strips of veneer which are joined to the size of the substrate.Relative moisture of the wood 8-12 %Thickness of veneer 0,4-1,2 mm

Decorative laminated sheets (DKS): CPL/HPLsimilar to DIN 16926Processing in sheets cut to sizeThickness 0,6-1 mm

Overhang of foil when laminating:Overhang in lengthwise direction approx. 10 mm per sideOverhang in direction of feed: maximum 30 mm per side

Overhang of foil when using the same in sheets cut to size

approx. 5 - 10 mm all around

Diameter of rolls of foilThe maximum diameter of the roll of foils is 500 mm.

Glues:

Dispersion glue: (PVAC glue)Quantity to be applied 90 - 130 g/m²

Capacitywhen applying paper foils

Handling time with a length of the heating platens of 3300 mm:- Loading and unloading by means of circulating mylar belts- Closing of press- Pressure build-up- Decrease of pressure- Opening of press

Handling time per cycle approx. 16 seconds

The capacity of the plant depends on the materials being used.

Factors which influence the pressing time are:- Thickness of boards- Type of foil and thickness- Type of glue and quantity of application- Temperature of the materials being used as well as the ambient temperatures

Usually the pressing times range from 10 to 35 seconds (depending on the above mentioned factors

As per the information from the customer a pressing time of approx. 20 seconds anda pressing temperature of approx. 60 - 70 °C. are required for pressing vinyl.

The normal pressing times for veneering are approx. 30 to 50 seconds.

The normal pressing times for pressing laminates are approx. 60 - 120 seconds.

Stacking HeightMaximum stacking height 1000 mm when loading and unloading with protectiveboards.

Note regarding protective boards:When loading, the protective board must be removed manually. When unloading, the protective boards must be placed on manually as well.The protective boards must always have the same thickness.

Energy Supply:Placing of cables and pneumatic lines in cable ducts which are fitted to the variousmachines.

The connection cables from the various machines to the switch cabinet will be placed in*) floor channels. These floor channels are specified in the foundation drawing.

Kind of production:1) Single or double-sided lamination of substrates with either veneer or laminates (cut to size).

2) Single or double-sided lamination of substrates with paper (from the roll).

**) Manufacture of doors Assembly of the doors takes place on the acceleration belt transport. The following sequence of operations is possible: a) Single-sided glue spread and manual turning of each second hardboard (3 layers) b) Double-sided glue spread on the hardboards and assembly of the complete door (5 layers). This requires hardboards which have been sanded on both sides.

Arrangement of the Line:The press will be installed without pit.

Switch cabinet at the left-hand side of the alignment roller track, seen in direction of feed.Distance to the centre of the line approx. 3000 mm

Control desk at the right-hand side next to the acceleration belt transport.

Heating piping at the left-hand side, seen in direction of feed

Heating device at the left-hand side of the press , seen in direction of feedThe connection lines between the heating device and the press have to be placedand insulated by the customer.

Stacking to the right, seen in direction of feed of the line.

Design of the Plant:

Item 1 Hydraulic Scissor Lift Tablefor lifting and lowering the stacks(The stacks are fed on an existing roller track, transfer height approx. 300 mm).

Technical Design:- The hydraulic drive as well as the control valves are fitted within the basic frame- Safety devices with foot-contact rails at all four sides and a pipe-break safety valve.

Technical Data:Dimensions of platform 1500 x 3200 mmUseful load 3500 kgUseful stroke 1200 mm

Heavy-Duty Roller Trackmounted on the scissor lift tableDirection of feed: lengthwise

Technical Data:Length of transport 3200 mmUseful width 1400 mmDiameter of rollers 108 mmRoller jacket zinc-coatedSpacing of rollers 300 mmOverall height to top edge of roller track(inclusive scissor lift table), approx. 650 mm

Driving UnitDrive by means of a geared motor and a precision roller chain from roll to roll.

Feed speed approx. 10 m/min.Item 2Infeed Device

Technical Design:- Infeed arm with 2 infeed shoes, driven by a geared motor and a precision roller chain- Infeed arm can be swung up pneumatically for changing the stacks and for manual loading.- Infeed arm arranged at the left-hand side, seen in direction of feed.

Technical Data:Adjusting range of the infeed arm steplessly adjustable 600 mm maximumThickness of boards 8 - 60 mmInfeed speed 3 - 15 m/min.Infeed height approx. 1060 mm

Item 3

1 Alignment Roller Trackwith diagonally arranged rollersAdjustment in width of the guide rail by a handwheel and mechanical digitalindication. Transport rollers provided with a rilsan covering.Guiding rail arranged at the right-hand side, seen in direction of feed.

Technical Data:Length of transport 4000 mmWidth of transport 1400 mmSpacing of rollers 300 mmWorking height 1060 mmFeed speed 3-15 m/min.Diameter of support rollers 80 mm**) Range of adjustment from 600 to 1300 mm approx. 350 mm

Supplementary Equipment:Scraper wall at the infeed with a light barrier for the automatic height control ofthe scissor lift table (light barrier manually adjustable to the thickness of boards).

Item 4Transverse Brushing Machine Model DBM 1400for double-sided cleaning and dust removal from flat boards.Transverse brush segments which are fitted on a standard chain. Regular wear of the brush segments, thus a considerably longer servicelife. Brushes and feed driven independently of one another. Each brush chain has its own direct drive.

Adjustable brush pressure, re-adjustable brush shafts. Feed ofthe boards by pairs of rubber covered infeed and outfeed rollers. Connection pieces for connecting an available dust exhaust device. Emergency cut-out bar at the infeed side.

Technical Data:Maximum working width 1400 mmSystem of brush chainsCovering Mexican fibreSpeed of brushes 1 m/sec.Maximum passing height 120 mmFeed speed 3-15 m/min.Working height 1060 mmTotal driving power 2,1 kWNumber of connection pieces per side 1 x 200 mm diameterMinimum suction power with approx.28 m/sec. 3500 m3/hWeight approx. 700 kg

Operating side: right-hand side

Supplementary Equipment:

Machine baseto adapt the working height to the infeed height of the press.

Item 5Glue Spreading Machine Model DAK 1400for single or double-sided application of glue onto flat boards.

Technical Design:- Direct drive of the applying rollers by joint couplings- Separate direct drive of the doctor rollers by slip-on gear mechanism- Precise metering of the amount of glue to be applied by a high differential speed between doctor roller and applying roller- Fast and easy cleaning of the machine while the rollers are turning and the protective grate is open due to a safety switching

Technical Data: Maximum working width 1400 mmWidth of rollers 1516 mm2 Rubber covered, smooth applying rollers 70 shoreSurface 20 grooves/“Diameter of applying rollers 240 mm2 Hard rubber covered doctor rollers, diameter 190 mmMaximum passing height 80 mmFeed speed 3 - 15 m/min.Working height 1060 mmOperating side right-hand side

Supplementary Equipment:

Machine baseto adapt the working height to the infeed height of the press.Outfeed with 3 driven knife-edge disk rollers for thin boards.

Spraying pipes for cleaningwith flat jet nozzles in the gap protection, for automaticcleaning of the doctor roller and applying roller.Minimum required water pressure 3 bar

Doctor rollers being coolable with a rotary connection (without cooling device).

Infeed table extended by approx. 300 mm.

Item 61 Disk Transport Trackto transport the glued boards

Technical Design:

- Disks made of stainless steel, turning in a water bath which is provided with foam- Axles made of galvanized steel pipe- Water troughs made of galvanized steel plate which are removable for cleaning

Technical Data:Length of transport 2400 mmWidth of transport 1400 mmDistance between axles 300 mm**) Knife-edge disks 7 pcs. per axle**) 2 pcs. at a distance of approx. 800 mm3 pcs. distributed for the smallest workpiece2 pcs. at a distance of approx. 1100 mmDiameter of disks 100 mmFeed speed 3 - 15 m/min.

Supplementary Equipment:

Double-sided rail which is manually adjustable to the width of the boards.Adjustment in width of the guide rails by a handwheel and mechanical digitalindication.

One section of 800 mm length each being hinged at infeed and outfeed sideto facilitate cleaning of the glue spreading machine and to insert the foil in the subsequent laminating station.

Disk transport track displaceable in direction of feed.

Pallet Rack mounted on the disk transport track, of two openings,for preparing the surface material.

Consisting of:1 Basic frame with platform1 Removable platform for a second stack of surface materialWhen the laminating station is withdrawn, one section each can be retracted.Item 7Laminating Station Model EKM 1300

Height adjustment for all rollers with a handwheel and digital indication

Uncoiling StationFast introduction of the foil thanks to the good accessibility and simple guiding of the foil. One uncoiling device each at top and bottom (suspension). *) The bottom foil spool bearing can be withdrawn laterally towards the right-hand side.

Safety chucks with pneumatic disk brake.The foil is adjusted by a cross adjustment. Scales at the guide rollers to align the foil.

1 Clamping roller to draw tight the foil when starting.

2 Pcs. spool shafts with clamping cones for cardboard sleevesof 60 - 100 mm and 140 - 155 mm (3“ and 6“).

Foil breakage control at top and bottomTo stop the plant when the foil breaks and to reduce cleaning times and a loss of production.

Waiting deviceThe feed stops when no boards are fed any more, thus the loss of foil is reduced. The waiting position of the last board can be preselected.

1 Control for dischargeThe last board is evacuated from the plant after the manual trimming of the foil and without using any further foil. However, the foil rests prepared for the next charge.

Automatic trimming deviceSwinging knife driven by compressed air to cut paper and foils between the boards. The boards are fed edge to edge. The gap for trimming is generated by a difference in speed. To avoid the overriding of boards of less than 8 mm thickness, the same must be fed with a space in between.Inclusive 1 spare trimming knife.

Technical Data:2 Rubber covered laminating rollers 290 mm diameterDirect drivePneumatic pressure 9000 N2 Rubber covered pressing rollers in frontof the trimming knife 130 mm diameter2 Rubber covered pressing rollers behindthe trimming knife 130 mm diameterFeed speed 3 - 15 m/min.Working height approx. 1060 mmOperating side: right-hand side

Supplementary Equipment:

2 Wide stretching rollers (banana rollers)adjustable in bend, swivelling, with an adjusting slide to adjust contact of the foilwith the roller.

The laminating station can manually be withdrawn towards the left-hand sideon rails and wheel-flange rollers when using veneer.

Top foil roll suspension arranged at the post of the laminating station.

Item 8Acceleration Belt Transport Systemto accelerate the boards after trimming in the laminating station. This produces the distance of time required for the continuous short-cycle process between the continuously working laminating machine and the press working in cycles.

Technical Design:- Basic frame made of structural steel with belt and core transport arranged in between- Feed speed steplessly adjustable- Belts with non-skidding PVC coating

Technical Data:Width of transport 1400 mmLength of transport approx. 5000 mmDivided in 2 sectionsWidth of belts 50 mmSpacing of belts 150 mmFeed speed 3 - 15 m/min.Loading speed approx. 45 m/min.

Core Transferfor transport of the substrate on the bottom surface material which is already laid-on and for subsequently depositing the board.

Technical Design:- Transport of the substrates on disk rollers made of special steel- The disk rollers are laterally fitted to two circulating transport chains.

Technical Data:Width of conveyor belt 1400 mmLength of conveyor belt 3200 mmFeed speed 15 m/min.Speed of depositing 30 m/min.Height of depositing 110 mm

Supplementary Equipment:

Stopswhich swing-in pneumatically, to hold the boards during depositing.The complete unit can be lifted and lowered pneumatically for either the coating of paper or for using the core transfer (veneering).Item 9Hydraulic Short - Cycle Press Model ODW 1433/60

Technical Design:Press of the downstroke type of frame construction. Optimal pressure distribution thanks to the arrangement of the cylinders between the frames.

Framesburned out of solid steel plates. Bearing surfaces for the bottom heating platen and the press cylinders mechanically machined.

Press tablesare solid steel platens with a sanded surface. Drilled heating channels.

Press cylindersmade of steel with built-in guide rings made of Teflon bronze compound material. Special

grooved ring packings of polyurethane with reinforced profile at the motional side. Dust removal lip in the supporting ring of the packing.

Pistonshard chromium-plated

Parallel guidingof the mobile press table by lever compensating rods with large-sized connection shafts.Bearings maintenance-free.Roller guiding independent of temperature.

Insulationbetween frame and bottom heating platen by a means of plastic compound boards on mineral basis.

Post - suction hydraulics with oil storage reservoir and large-sized connection lines and filling valves for each press cylinder. Opening of the press by means of separate pull-back cylinders.Control by electro-magnetically operated valves. Assembly of the valves on a common hydraulic block for ease of servicing.

The hydraulic unit is fitted to the press frame. The hydraulic oil does not belong to our scope of supply.

Loading of the pressby temperature-resistant, circulating plastic foils equipped with a fast exchange system. Drive of the foils by A.C. geared motor allowing smooth starting, smooth slowing-downand creep speed to the final position.Guide rollers without paint finish.

HeatingHeating of the press is done by hot water. The heating medium is fed to the heating platens by high pressure metal hoses with stainless steel armouring and by collecting pipes.Each heating platen is heated separately.

Technical Data:Dimensions of heating platens 1400 x 3300 mmLoading side 1400 mmTotal pressure 2356 kNSpecific pressure 60 N/cm2Cylinders, 2 rows 6 x 140 mm diameterHydraulic operating pressure 255 barThickness of heating platens 100 mmDaylight between platens 150 mmMaximum operating temperature withmylar foil 130 °CElectric connected load approx. 18 kWSpecific load on foundation 25 N/cm2Weight of the press 17 000 kg

Supplementary Equipment:

Shaking deviceto remove the boards which stick to the top protective foil after opening of the press. Pneumatic cylinders release the tension of the foil after closing of the press and tension the same again after opening.

Cleaning devicefor the circulating plastic foil. Consisting of suction nozzles at the infeed side and outfeed side of the bottom heating platen.

Safety device to prevent faulty loadingto avoid damages to the mobile heating platen in case of incorrect loading of the press.Function:Limit switches of a high switching accuracy monitor the flatness of the mobile press table. In case of a minimum deviation, there is no high pressure build-up and the press opens. Each time when the press opens, the performance of the limit switches is controlled.

Air nozzles in the heating platens to detach the conveyor belt after pressing.

Multicircuit hydraulicsfor the separate pressure control of groups of cylinders in case the press is not fully loaded. In addition each circuit can be disconnected separately.

Forming of groups: 1. circuit: 2nd and 3rd transverse row of cylinders 2. circuit: 1st transverse row of cylinders

Item 102 Heating DevicesFor the separate heating of the top and bottom heating platen with hot water.

Technical Design:- Water circuit designed as closed system- Heating by means of electric resistances- Automatic regulation of the water temperature by microprocessor controlTechnical Data:Heating power 2 x 54 kWAdmissible operating temperature 140 °C.Connected load of the pump approx. 2 kWHeating medium water Water quality clean, not aggressive,

pH value 7,5 to 8,5Dimensions: length 990 mm

width 400 mmheight 1050 mm

Note:The connection lines between the heating device and the press have to beplaced and insulated by the customer.

Item 11Outfeed Roller Trackto take over the pressed boards from the press and to make them available forthe vacuum stacker.

Technical Design:*) Transport rollers covered with a felt jacket. Central pneumatic alignment.Fixed final stop

Technical Data:Length of transport 4200 mmWidth of transport 1400 mmDiameter of rollers 80 mmSpacing of rollers 300 mm*) Height of transport approx. 950 mm*) Feed speed 12/48 m/min.

*) Note:To take up the boards the clamping transverse beam goes into the roller track. Thishas been taken note of in the design.

Item 12*) Stacking Equipment without Swivelling Devicefor the continuous stacking of boards with a sensitive surface by means of*) clamps (without vacuum).

Technical Design:- Portal design- Drive of the vacuum suction carriage by *) a frequency-controlled geared brake motor- Precise positioning of the pick-up and depositing position - Without pit

Technical Data:Maximum load 100 kgNumber of cycles maximum 3 cycles/min.**) Travel approx. 2500 mm**) Number of stacking places 1**) Number of stopping places 2Required air pressure 6 bar

*) Design retractable rollers, gripping fromthe bottom, 4 pcs. per side

Clamping stroke depending on the size of the boardsOperation centrical

**)

Item 12.1Protective Fencingto protect the working zone of the stacker

Consisting of:**) Protective fence and 1 safety light barrier at the outfeed of the stacks.**) Light barriers with muting function

Item 13 by the customer**) 2 Heavy-Duty Roller Tracksfor depositing and transporting the finished boards and for making thestack available for the fork lift truck.Direction of transport lengthwiseOverall height approx. 300 mm

**) 1 Roller track for depositing the protective board and for stacking the boards; length approx. 7600 mm**) 1 Roller track for removing the stack of finished boards; length approx. 4000 mm**) Control of the roller tracks by the customer

Item 14Electric Controlfor the central control of the plant.(without the existing elements)

Technical Design:Technical design as per DIN/VDE (EN 60204/1)- Switch cabinet with all switches, control and adjusting devices- Control of the plant by a microprocessor based programmable control (PLC) make Siemens- Operating elements, light barriers and limit switches at the different plant elements- Connection lines between switch cabinet and the different plant elements of plug type.

- Automatic adjustment of pressure according to the prespecified dimensions of the boards- Telephone modem for the fast localization of errors

Control deskinstalled separately, with a sloping control area to house all operating and control elements.

Supplementary Equipment:**) Potential-free locking contacts for the control which is available with the customer for the heavy-duty roller tracks item 13.