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Helen Lesley Wells
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1 2 3 4 5 6 7 Layers MES presence in more than 16 countries ल म क स त भप रज तकस र धन वन त रश चन द रम ग व क मद ह स र श वरगज रम भ दद व ङ गन अश व सप तम ख वष ह रधन शङ ख म त च म ब ध रत न न ह चत दर श प र त

Historical Milestones 1 st 3 Layer Line Export to North America 2013 MES has evolved itself as a global player by adding a country almost every year during the last fifteen years Mamata Extrusion

2 Layers MES presence in more than 16 countries ल म क स त भप रज तकस र धन वन त रश चन द रम ग व क मद ह स र श वरगज रम भ दद व ङ गन अश व सप तम ख वष ह रधन शङ ख म त च म ब ध रत न न ह चत दर श प र त दन क य र त सद मङ गलम Customisation is a long process like Churning of the milky Ocean for 14 Gems which ultimately delivered a pot containing Amrita, The heavenly nectar of universal happiness. Historical Milestones 1 st 3 Layer Line Export to North America 2013 MES has evolved itself as a global player by adding a country almost every year during the last fifteen years Mamata Extrusion Systems Pvt. Ltd. (MES) is focused on manufacturing state of the art co-extrusion blown film lines. MES was a Joint Venture Company established in 1997 as 50:50 equity partnership with Brampton Engineering Inc. Canada. It is now a fully owned company of the Mamata Group since Over Last Decade & Half MES Has Evolved Itself as a Company which Set New Standards in Blown Film Technology by Offering Customised Blown Film Solutions for Sustainability. MES Offers Customised Solutions as under : High quality Monolayer Blown film lines. Pre-optimised, basic automation, entry level Non IBC blown film lines up to Three Layers offering competitive conversion costs without compromising Film Quality and Outputs. State Of The Art, Customised & Fully Automated Three Layer Blown Film Lines with Internal Bubble Cooling (IBC) System for High Outputs for Critical application requirements. Barrier Blown Film Lines up to Seven Layer. Mamata becomes sole owner of JV Launched at PLASTINDIA th Barrier Film Plant with Brampton s SCD / Die Technology Line installed in India st Wider width 2895 mm Ultra High output 800 kg/hr 3 Layer Line Installed th Line Installed 1 st Line supplied to Australia st 3 Layer Line Exported to Europe st Wider width 2375 mm higher output 500 kg/hr 3 Layer Line Installed th Line Supplied st 3 Layer Line export to Far East & Middle East st Ever 7 Layer Line installed in India 1 st 3 Layer Line Export to West Africa & Russia th Vegaflex concept Line sold within one year of launch 2002 Introduction of Vegaflex concept line - A new standard of excellence for Industry to follow st Ever 5 Layer SCD Line Manufactured & Installed successfully in India st Line delivered :50 Joint Venture Between Mamata Machinery Pvt. Ltd., India & Brampton Engineering Inc., Canada

3 Optimal Performance With Customised Blown Film Line You Choose Applications... We Deliver Solutions! Layers Lamination Films Surface Printed Films Non Printed Films Why Customisation With ever increasing applications of Blown Films for variety of uses and ever increasing competitive pressures, it has become mandatory to derive optimum results from your blown film line. Only way to do this is to critically analyse your requirements and insist on a line configuration that is tailor made for your needs of today and tomorrow. Tomato Ketchup Milk Mineral Water (Shrink Film) Coffee Powder Edible Oil Soft Drinks (Shrink Film) How to Rice Salt Stretch Film With over 15 years of experience solely in co-extrusion blown film Atta Soft Drinks (Shrink Film) Mulch Film technology we can help you critically analyse your needs and deliver a optimal solution that is custom made. Lamitubes Soft Drinks (Shrink Film) Meat 04 All photographs are shown as a illustration only to understand blown film applications. 05

machines etc. The quality of film roll will decide the succsess of end products.

4 The flatness of the film rolls will be decided by quality of gauge randomization. The right selection of width of the post extrusion equipment of the Blown Film Line will take care of matching widths of converting equipment like Printing, Lamination, Slitting, Bagging / Pouching machines etc. The quality of film roll will decide the succsess of end products. Surface Winders u Fully automatic roll change over u Variable surface pressure between the wound roll and the drum allows roll hardness to be precisely controlled u Full width, knife guard, incorporating safety interlocks with the cut off knife u Surface drum driven by (Field oriented control) Encoder feed back, load cell / Dancer feed back AC drive for Tension control u Digital Length counter for warning u Cut over sequence monitored through a PLC u Full emergency stop system u Dual-knife slitting station u Side slitting cutter is dual type u Longer Guide Beds to un-load wound roll u Ultra light weight, horizontal Dancer roller / electronic load cell mechanism for web tension control, ensures constant tension through out web width and wound roll diameter Optional Features : u Expanded Poly bend roller u Static Eliminator bar u Taper Tension controls u Full- roll unloading allows roll to be lowered to floor level hydraulically u Trim re-winder unit Haul Offs - Vertical & Horizontal MES offers two choices for Haul Offs - Vertical or Horizontal type for gauge randomization each having their own advantages. Vertical Oscillating Haul Off : Provides the provision to make film path vertical through set of turn bars & idler rollers mounted on platform for full 360º oscillation for uniform gauge distribution & excellant roll geometry. u Uniform gauge distribution u No wrinkles u No scratches on the film u Excellent roll geometry u Perfectly flattened films through full 360º oscillation Horizontal Oscillating Haul Off : Keeps the film path horizontal & achieves differential oscillation of set of turn bars to complete the gauge randomization process. u Gauge randomization by turning the film at 0º to 180º in both directions to achieve full 360º Oscillation u Economical System as compared to Vertical Oscillating Haul Off u Compact system u Uniform gauge distribution through the product rolls 06 07

In line with width of the post extrusion equipment system elements selected, one has to

We have 3 type of dies which will be customised as per customers requirements. 1.

Five / Seven Layer Dies For best in class assured lowest film thickness variations.

right quality steels with in house computer aided machining with due attention given at

gauge tolerances, right gloss and desired mechanical properties.

Steel u The Taper Lock Body & Mandrel Assembly Design ensures excellent concentricity

$outer lip temperature controls to avoid melt fractures Three Layer Die Mono Layer Die Five$ / Seven Layers Co-extrusion Dies The co-extrusion stack die offers most modular and

/ Seven Layers Co-extrusion Dies The co-extrusion stack die offers most modular and

5 In line with width of the post extrusion equipment system elements selected, one has to decide on die size as per blow up ratio (BUR). We have 3 type of dies which will be customised as per customers requirements. 1. Monolayer Dies 2. Three Layer Dies 3. Five / Seven Layer Dies For best in class assured lowest film thickness variations. Mono & Three Layer Spiral Mandrel Dies Our Die Heads are characterised by selection of the right quality steels with in house computer aided machining with due attention given at each stage of die manufacturing, to ensure production of high quality films with tight gauge tolerances, right gloss and desired mechanical properties. Customised die design as per applications u Manufactured from AISI 4340 Alloy Machine Steel u The Taper Lock Body & Mandrel Assembly Design ensures excellent concentricity between the spiral mandrels and the die body u Streamlined Polymer Flow having No Stagnation and Dead Points u Capability to handle Critical Layer Ratios u Separate inner & outer lip temperature controls to avoid melt fractures Three Layer Die Mono Layer Die Five / Seven Layers Co-extrusion Dies The co-extrusion stack die offers most modular and versatile die design to allow processors to harness the characteristics of a wide range of resins to make structures with the required properties. u Temperature isolation between layers u Streamlined melt distribution u Easy upgrades due to modular design 08 09

Once die size is decided we have to match the cooling capacity available with combination of Air Ring & IBC.

The Eliminator Air Cooling Ring offers : u Improved Cooling efficiency u Ease of operation u Better Lock-In over a wider range of operating conditions which results in significant improvement in

The primary orifice air flow provides pre-cooling of fragile melt and stabilizes the bubble as it is drawn upwards along the forming cone.

u Creates a powerful Venturi effect that draws the partially cooled bubble radially outwards to the tip of the forming cone u This will thin the melt to improve the thermal conductivity as well as

holes and collar height, the operator can fine tune and lock in the bubble shape.

Provides precise air distribution and minimizes blower pressure requirements.

6 Once die size is decided we have to match the cooling capacity available with combination of Air Ring & IBC. The Eliminator Air Ring The air ring technology for the cooling of polymers at its exit and its orientation area to achieve targets for gauge uniformity, out put and physical properties of blown film. The Eliminator Air Cooling Ring offers : u Improved Cooling efficiency u Ease of operation u Better Lock-In over a wider range of operating conditions which results in significant improvement in gauge consistency even at higher out put rates Method of Operation : The Eliminator Air Ring delivers two air streams from a common chamber to the exterior blown film bubble. The primary orifice air flow provides pre-cooling of fragile melt and stabilizes the bubble as it is drawn upwards along the forming cone. Adjustment to the primary orifice can suit a wide range of material melt strength. The secondary orifice provides a high volume and high velocity air stream which has dual function. u Creates a powerful Venturi effect that draws the partially cooled bubble radially outwards to the tip of the forming cone u This will thin the melt to improve the thermal conductivity as well as provide the main cooling effects by means of its high velocity The Eliminator s collar provides additional bubble support and increases the cooling efficiency, by simply adjusting the three rows of holes and collar height, the operator can fine tune and lock in the bubble shape. u Four adjustments : Lower Lip, Upper Lip, Collar & Blower speed optimizes Air ring performance for wide range of polymers, Structure, thickness and blow up ratios u Advanced Chamber Design : Provides precise air distribution and minimizes blower pressure requirements. Unique design requires no baffles or screens u Adjustable primary orifice : Suits wide range of material melt strength u Adjustable upper lip and collar : Allows fine tuning of the air stream for optimum stability and cooling over the wide range of blow up ratios Collar with independently adjustable vents allows for maximum flexibilities in controlling bubble stability u Compound Teflon Seals : Improves film gauge uniformity by eliminating air leaks and reduced maintenance u Bronze Thread : Eliminates wear in critical thread area maintaining accuracy over extended life u Cooling Ring, Manifold, Cooling coil etc. are all insulated 4+1 IBC System offers film processors maximum cooling efficiency while maintaining ease of operation. The combination of the Eliminator Air Ring and 4+1 Pancake IBC System helps to handle virtually any bubble without compromising cooling efficiency. 4+1 Pancake IBC System Method of Operation : 4+1 Pancake IBC System Air flow adjustments maximize the system s efficiency. The Lower orifice pre-cools and stabilizes weak melt as soon as the polymers exist the die. The adjustable air flow through each set of the four pancakes allows for a gradual increase in air velocity for maximum heat transfer. The Air flow regulator plate acts as a by-pass valve allowing greater over all air exchange rate while maintaining optimum air velocity through each pancake. A Supervisory Microprocessor based control system uses Ultra sonic non contact sensors to sense the bubble position related to the bubble cage and adjust the flow of the cooling air or / and the hot exhaust air in order to maintain the proper bubble size. Two separate blowers provide the energy into and out of the bubble. u Five independently adjustable orifices to regulate the amount of air flow through each pancake from fully open to fully close u The blower systems with variable frequency AC drives u Control system to allow the operator to precisely control the air exchange to maintain balanced bubble u Easy installation and removal with new quick release that facilitates positive positioning of stack assembly and easy quick release u Ultra sonic sensing technology has no dependency on the colour or thickness of the film 10 11

In today s competitive environment the line configuration is not complete without much needed automation.

Single / Multi Component Gravimetric Blending & Dosing u The system functions independent of the bulk density variations of the material to be metered guarantying constant quality and repeatability u

Online Thickness Measurement System u Online rapid and accurate measurement of film thickness allows the film production process to be tightly controlled.

7 In today s competitive environment the line configuration is not complete without much needed automation. Automations for Enhanced Efficiency MES can offer a wide variety of automation options starting from resin handling to finished roll handling. Single / Multi Component Gravimetric Blending & Dosing u The system functions independent of the bulk density variations of the material to be metered guarantying constant quality and repeatability u The accuracy considerably reduces the raw material costs, in fact and the ingredients are metered without any wastage. Online Thickness Measurement System u Online rapid and accurate measurement of film thickness allows the film production process to be tightly controlled. Thickness can be measured by capacitive / nuclear based devices, contact or non-contact devices, prior to collapsing frame or post primary nip depending upon non-barrier / barrier film nature. The pumping capacity of extruder should match the line output & Layer thickness ratio requirement. Extruders For All Blown Film Applications Blown Film Extruders : The challenge for blown film extruder is to deliver constant torque in a given dynamic situation. MES uses the latest AC close loop vector flux technology along with rugged design Gearboxes to meet this challenge. The customised screws with plain barrel, ceramic finned heaters and high efficiency blowers help in getting best possible quality melt at lowest possible temperature for better quality film at higher outputs. Feed Screw : MES specifically selects each screw to match a particular process to provide high extrudate quality at optimum throughput rates. u Low melt temperature increases system throughput rate and provides less thermal degradation u Melt Channel Screws provide balanced feed and melting rates u The melt channels are sized to flush easily u It can deliver high throughput without increase in energy consumption for lower operating costs u Improved dispersive and distributive mixing permits a wide blending range Control : u Barrel temperature zones are regulated by a microprocessor-based controllers for accurate temperature control u Full PID programs and alarms u Available supervisory control packages include remotely programmable and fully integrated line control systems Gear Boxes : u Rugged design gearboxes provide horsepower and torque ratings that surpass the usual standards u Hardened and precision-ground gears feature a helical design to ensure years of non-stop production u Integrally-mounted thrust bearing assures precise alignment to ensure that the bearing achieves a long working life Drives : u AC vector flux closed loop drives provide optimum energy efficiency and precise control Auto Gauge Control Systems u In Segmented Air type system the gauge is controlled through air flow from Segmented Air Ring. u Heated Lip gauge control system is an accurate and easy to use system to reduce gauge variation in blown film. Based on feed back of film thickness measurement profile, the individual heaters of heated Die Lip correct the gauge variation and control the profile continuously. Auto Width Control u Provides an instant readout of the actual layflat eliminating the need to wait for the film to reach the winder. Reduces the time required to get bubble on size and helps reduce layflat changes from long term process variations. It helps to make trimless film winding. Supervisory Control & Data Acquisition System (SCADA) u The SCADA system facilitates the total line control from a single point giving the operator the flexibility of easy control and monitoring the complete line performance. Auxiliaries / Utilities List of some of the out sourced Auxiliaries / Utilities which can be offered by MES along with the line to facilitate supply of entire line as a package. u Web Guides u Corona Treaters u Chilling Plants u Electrical Distribution panel u Testing Equipments etc

your line from the Range of System Elements we offer No of Layers : 1 to 7 Film Width : 600 mm (24 ) to 3000 mm (124 ) Output Range : 50

UNI-FLO Eliminator Air Ring IBC : 4+1 Pancake IBC Auto Gauge : Heated Die Lip Type / Segmented Air Type Control Systems Cage : Roller type

Winders up to 3125 mm width Structure : Prefabricated tower Controls : Panel type line controls / SCADA controls Others : We can also offer

From Concept to Commissioning We have a specially designed Application Based Critical Analysis tool M-CAT to derive the best configuration

Call Our Experts To Have A Dialogue And Know The Solution!

8 your line from the Range of System Elements we offer No of Layers : 1 to 7 Film Width : 600 mm (24 ) to 3000 mm (124 ) Output Range : 50 kg/hr to 800 kg/hr Extruders : 50 mm to 150 mm Die : 100 mm to 800 mm - Spiral Mandrel / Streamlined Co-extrusion Dies Cooling Ring : The UNI-FLO Eliminator Air Ring IBC : 4+1 Pancake IBC Auto Gauge : Heated Die Lip Type / Segmented Air Type Control Systems Cage : Roller type Haul Off : Horizontal Oscillating Haul Off / Vertical Oscillating Haul Off with discharge nip & PLC controlled operation Winder : Surface Winders up to 3125 mm width Structure : Prefabricated tower Controls : Panel type line controls / SCADA controls Others : We can also offer turnkey solutions All other automations / auxiliaries / utilities upon request. From Concept to Commissioning We have a specially designed Application Based Critical Analysis tool M-CAT to derive the best configuration for your new blown film line based on your Needs, Wants, Expectations, Concerns & Budgets. Call Our Experts To Have A Dialogue And Know The Solution!!! Infrastructure MES has well designed large Assembly area with Special high ceiling bay, for assembly of towers and set up to complete lines for demonstration and testing spread across 1,40,000 Sq.feet. A full CNC machining facility for manufacturing of critical components including dies. Configure a Line to produce what you want to sell

MAMATA EXTRUSION SYSTEMS PVT. LTD. (Formerly known as Mamata Brampton Engineering Pvt. Ltd.) 5/1/1A/1, Phase-1, G.I.D.C.

9 The details mentioned here by are for reference purpose only and the technical data and specifications given are subject to change without prior notice. Kindly refer your customised offer for scope of supply and other details. MAMATA EXTRUSION SYSTEMS PVT. LTD. (Formerly known as Mamata Brampton Engineering Pvt. Ltd.) 5/1/1A/1, Phase-1, G.I.D.C., Vatva, Ahmedabad , India. Phone : Fax : sales@mamata.com Website : 10/2013 marg

Coextrusion system for the production of 3 layer blown film FLEXIBILE MODULAR EFFICIENT

Coextrusion system for the production of 3 layer blown film FLEXIBILE MODULAR EFFICIENT Film coextrusion is becoming more and more widespread in the packaging industry and is quickly replacing monolayer