Torninova Plastic Machinery

2

PLASTIC MACHINERY?TORNINOVA DOES IT BETTER!

3

4

Plastic, Passion and Technology, together.

The experience of the Mencarelli family in the mechanical field begins.

1925 19931969

Birth of Torninova “Costruzioni Meccaniche”

Our First Air Bubble FilmMachine

Milestones

5

2005 2010 Today

Our new Headquarters

Over 250 working machines over five continents

We go Globalwith Torninova Corporation

The experience of the Mencarelli family in the mechanical field began early in the last century, in 1925. At the time of its foundation in 1969, Torninova’s experience had already developed, leading the company to specialize in technical support for flexographic printing machines and extrusion lines.

Later, in 1993, Torninova started designing and manufacturing air bubble film machines and stretch film machines.

The company has always been highly involved in research and development in order to offer its customers versatile and flexible systems that combine the most innovative electronic and mechanical technologies.

A commitment to meeting the highest possible standards has led the Torninova Corporation to design its complete range of air bubble film machines, stretch film machines and to acquire top know-how in the field available to its customers.

About Us

8

Market Leaders for nearly 40 years Torninova has been providing technologythat expands the possibilities of your company and your life.

Global Markets

9

STRETCH AND SHRINK FILM

Europe

IPACK IMA

Milan / Italy

INTERPACK

Dusseldorf / Germany

PLAST

Milan / Italy

K

Dusseldorf / GermanyConferences& Fairs

10

Torninova provides technology that expands the possibilities of your company and your life.

Production

December 2012: Torninova begins production at its new hi-technology 13.000 m2 Plant in Bastia Umbra.

The Plant provides 746 KWp from its own solar power system.

New Plant

11

Torninova Corp. - located in Bastia Umbra (Perugia) in Italy - is a company which specializes in designing, developing and manu-facturing machines for air bubble and stretch film production as well as converting machines for each market.

Thanks to our patented systems and our technicians with over 40 years of experience, Torninova Corp. provides the best solutions in a demanding market and guarantees a high-tech end product.

Continuous technological advancement and ever increasing commitment enables Torninova Corp. to operate all over the World efficiently, professionally and more importantly, effectively.

Supporting its young, dynamic yet experienced staff, the company is able to produce machines tailored to customer needs, paying particular attention to production versatility.

Innovative design ideas, manufacturing precision, highly reliable components and the constant support of our technicians, ensure our customers receive a solid, long-term service.

These features mean that our company has become a market leader, with hi-tech machines all over the World.

Italy, Qatar, Spain, India, United States, Japan, United Kingdom, Germany, Canada, Russia, France, Argentina, Australia, Saudi Arabia, China, Indonesia, South Africa, Mexico,Turkey, South Korea, Brazil.

12

Technical Assistance

13

Torninova Corp.’s integrated use of pionee-ring mechanics, electronics and information technology is the company’s real strength and guarantees efficient after-sales service. The diagnostic software and display panels on the machines ensure the operators mantain high levels of efficiency.

With the development of new technologies and its skilled staff, Torninova Corp. can provide its customers with an Internet remote supervisory support system which carries out machine dia-gnostics and required software modifications.

TELESERVICE

Our technicians perform scheduled maintenance on our machines.

SCHEDULED MAINTENANCE

Torninova Corp. guarantees its customers rapid supply of spare parts that may be needed during a machines’s entire life-cycle.

SPARE PARTS

Open during working hours (8 am - 12 pm and 2 pm - 6 pm GMT+1, Monday to Friday), the call center offer immediate assistance and provides guidance throughout the process putting you in direct contact with a qualified engineer always able to resolve your particular issue.

CALL CENTER

The company is constantly attentive to cu-stomer needs, so specialized technicians are available to provide assistance at the machine installation site. Torninova Corp. is able to ensure rapid intervention.

ON SITE SERVICE

14

15

StretchFilmMachinery

16

Torninova Corporation brings to market the very best in stretch film production technology thanks to its thorough research and deve-lopment in collaboration with Italian and Ame-rican University professors, renowned European manufacturers of extruder components and experienced figures from the field of extruded stretch film (Eng. Vander PROVERA).

Some of our Client partners (Italian and foreign) have also supported our research and development phases by purchasing prototype systems to scientifically test and continuously monitor each single component and process.

During such tests, appropriate adjustments were made in response to real time controlsunder actual production conditions. The result is a perfectly integrated system of cutting edge components, calibrated and arran-ged into a compact, high performance cast line that provides maximum flexibility with minimum energy consumption.

Consider some hallmark components of the COMPACT STRETCH system:

The LLPOWEREX™ extruder series with screw profiles (AC motors and infrared heaters ensure limited maintenance and low energy consumption) has been specifically developed to guarantee perfect LLDPE extrusion.

The SWIFTCOOL™ chill-roll unit’s dual cooling rollers guarantee total material stabilization. A dual-chamber vacuum box with automatic die adjustment and an integrated x-ray device to measure material thickness (guaranteeing accuracy even with coloured stretch film) offers the finest and fastest control features for the film extrusion process.

Customers can choose from three different winding systems:

The fast and reliable QUICKSILVER-4S™ winder (rewind cycle time of 10 seconds) directly rewinds stretch film into rolls on 2-inch or 3-inch cores (suitable for hand and machine use), in formats ranging from 100 mm to 250 mm, 450 mm and 500 mm.

The QUICKSTANDARD-2S™ winder is the best solution for production of machine and jumbo rolls up to a maximum diameter of 500 mm, on 3-inch cores.

The QUICKgOLD-4S™ is Torninova’s patented, universal, all-in-one evolution of hand and machine roll winders. Maintaining the same characteristics, it can also produce jumbo rolls up to a maximum diameter of 420 mm. The win-ding cycle still remains extremely fast (around 15 seconds) without compromising the produc-tion of hand rolls even at very high speed.

Optional roll handling features can be integra-ted into each winder to assure steady, high-speed cast stretch film production. For instance, the automated packaging system packs hand rolls in a 6-unit cardboard box.

Another component which sets the machine apart from others is the FULLFEED™ trimming system with a force-feed device specifically designed for the type and quantity of trimming required by a stretch film machine. A suc-tion device completely recovers all chopped trimmings for re-use by the main extruder line, thus preventing variations in pressure and film thickness even in the event of frequent changes in production and operating speed.

The FULLFEED system eliminates potential non-uniformities in film thickness, including those in longitudinal sections.

On request, instead of the flake re-feeding system, it is possible to equip the COMPACT STRETCH with a recycling machine that comple-tely re-granulates edge and bleed trims.

PERFECTLY INTEGRATED, HIGHLY FLEXIBLE SYSTEM

17

The new COMPACT STRETCH series is not a simple combination of standard components from various processes but, on the contrary, is a well-developed, well-tested, made-to-measure integrated system affording maximum simplicity and flexibility in the production of high-quality rolls of co-extruded cast stretch film.

INTEGRATEDSOLUTIONS

Everyday, producers of stretch film have to face the increasing cost of raw materials, labour and energy. Producers thus find themselves in an increasingly competitive market in which prices are constantly driven down.

In these circumstances, profitable production is only attainable with a system that guarantees elevated and continuous production, 24 hours a day. Torninova Corporation has focused all of its attention on this aspect, developing and designing affordable systems for high-output production. The result has been an increase in sales and satisfied Clients in a very competitive market.

FAST AND RELIABLESOLUTIONS

All machines are equipped with a PLC-managed control system which runs touch-screen opera-ted supervisory software for programming and managing the entire system.

The operator can use customized formulas to manage production according to the required percentage of co-extrusion and the needed production speed.

Via Internet, the machine can be remotely diagnosed to provide immediate customer assistance.

AUTOMATED SOLUTIONS

18

The COMPACT STRETCH 2.000 series, characterized by an incredibly compact design, is a powerful cast co-extrusion line for the pro-duction of excellent, multi-layer PE stretch film.

Various co-extrusion configurations and produc-tion outputs can be chosen according to specific customer needs (3, 5, 7-layer and multi/nano layer configurations). An auto-adjusting flat die, a double chill-roll system with inner axial “torque”motors, an integrated thickness measu-ring device and super compact gear motors on the extruders are only a few of this machine’s special features.

The COMPACT STRETCH 2.000 is an “integra-ted-system” developed to ensure maximum production reliability, minimum energy con-sumption, a user-friendly automation interface and extensive control of the winding process. The results are excellent rolls of stretch film (in-cluding “down-gauged” film) in hand, machine and jumbo formats.

COMPACT STRETCH 2.000™

Cast stretch film machinery.

OPTIONAL EQUIPMENT

QUICKSILVER-4S winderhand and machine rolls

QUICKSTANDARD-2S windermachine and jumbo rolls

AUTOMATIC HAND-ROLL packaging systemFor the production of:

- hand wrap film - machine wrap film

- jumbo wrap film - cling film

19

TECHNICAL DATA

RAW MATERIALSLLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend and PP pellets

WEB WIDTHS2.000 mm (production of rolls in widths: 125, 250, 450, 500 and 1.000 mm)

NET OUTPUTUp to 1600 kg/h

MECHANICAL SPEEDMax. 800 m/min

LAYER CONFIGURATIONS3, 5, 7 and multi/nano layer

FILM THICKNESS RANGE7 - 50 µm

ACTUAL POWER CONSUMPTION< 0,40 kW/kg

RAW MATERIALS HANDLING By pneumatic loaders or gravimetric dosing system of up to 6 ingredients for each extruder

EXTRUDERSDiameters: 55, 70, 100, 120 and 160 mmL/D ratio: 32 D

Barrel:- standard grooves- helical grooves for high extruder output (+30%)

Drive:gearbox and AC motor or internally cooled gear motor with a compact layout of either 2 or 4 three-phase, asynchronous motors for each gear motor

CHILL-ROLLS GROUP1.200 mm diameter, matted or polished chro-med-surface primary chill-roll; 450 mm diameter chrome-surfaced secondary chill-roll.

EDGE TRIMMINGDouble-blade, in-line cutting of edge and bleed trims. Granulator and extruder force-feed recycling or dedicated regranulation unit.

WINDERShafted double-turret systems for 2-inch or 3-inch cores- QUICKSILVER-4S for hand and machine rolls- QUICKSTANDARD-2S for machine and jumbo rollsAutomatic loading of cores and automatic unloading of finished rolls with balanced weight control; automatic packaging system for hand rolls available on request.

AUTOMATIONSIMATIC WinCC; Three user-friendly touch screens.

20

The COMPACT STRETCH 1.000 series is the World’s smallest and most reliable 1-meter stretch film machine. All components of this extremely compact, cast co-extrusion system (occupying less than 75 m2) have been spe-cifically developed to enhance the flexibility offered by the machine’s specific dimensions as well as to ensure production of the highest quality stretch film with the utmost reliability and energy efficiency.

The COMPACT STRETCH 1.000 produces rolls of stretch film in hand, machine and jumbo formats at surprisingly high outputs (850 kg/h), all without compromising product quality (available in 3, 5, 7-layer and multi/nano layer co-extrusion configurations). An auto-adjusting flat die, a double chill-roll system with inner axial “torque” motors, an integrated thickness measuring device and super compact gear motors on the extruders, are only a few of this machine’s special features.

COMPACT STRETCH 1.000™

Cast stretch film machinery

OPTIONAL EQUIPMENT

QUICKSILVER-4S winderhand and machine rolls

QUICKSTANDARD-2S windermachine and jumbo rolls

QUICKGOLD-4S winderhand, machine and jumbo rolls

AUTOMATIC HAND-ROLL packaging system

TECHNICAL DATA

RAW MATERIALSLLDPE (C4-C6-C8), mLLDPE, VLDPE pellet blend and PP pellets

WEB WIDTHS2.000 mm (production of rolls in widths: 125, 250, 450, 500 and 1.000 mm)

NET OUTPUTUp to 850 kg/h

MECHANICAL SPEEDmax. 800 m/min

LAYER CONFIGURATIONS3, 5, 7 and multilayer

FILM THICKNESS RANGE7 - 50 µm

ACTUAL POWER CONSUMPTION< 0,45 kW/kg

RAW MATERIALS HANDLING By pneumatic loaders or gravimetric dosing system of up to 6 ingredients for each extruder

EXTRUDERSDiameters: 55, 70, 100, 120 and 160 mmL/D ratio: 32 D

Barrel:- standard grooves- helical grooves for high extruder output (+30%)

Drive:gearbox and AC motor or internally cooled gear motor with a compact layout of either 2 or 4 three-phase, asynchronous motors for each gear motor

CHILL-ROLLS GROUP1.200 mm diameter, matted or polished chromed-surface primary chill-roll; 450 mm diameter chrome-surfaced secondary chill-roll.

EDGE TRIMMINGDouble-blade, in-line cutting of edge and bleed trims. Granulator and extruder force-feed recycling or dedicated regranulation unit.

WINDERShafted double-turret systems for 2-inch or 3-inch cores- QUICKSILVER-4S for hand and machine rolls- QUICKSTANDARD-2S for machine and jumbo rolls- QUICKGOLD-4S for hand, machine and jumbo rollsAutomatic loading of cores and automatic unloading of finished rolls with balanced weight control; automatic packaging system for hand rolls available on request.

AUTOMATIONSIMATIC WinCC; Three user-friendly touch screens.

For the production of:

- hand wrap film - machine wrap film

- jumbo wrap film - cling film

21

QUICKGOLD-4S™

Hand, machine and jumborolls winder

TECHNICAL DATA

• Web widths: from 1 to 3 m• Mechanical speed: 800 m/min• Film thickness range: 7 - 50 µm• Core diameters: 2 and 3 inch• Min. winding tension: 30 N• Min. cycle time: 15 s• Automatic core loading and

unloading of finished rolls• Max. diameter for jumbo rolls:

420 mm (50 kg/each)

QUICKSILVER-4S™

Hand and machine rolls winder

TECHNICAL DATA

• Web widths: from 1 to 3 m• Mechanical speed: 800 m/min• Film thickness range: 7 - 50 µm• Core diameters: 2 and 3 inch• Min. winding tension: 30 N• Min. cycle time: 10 s• Automatic core feeder and

unloading of finished rolls

The patented Quickgold-4S winder is the most advanced turret winder for cast stretch film machines.

This single-module universal winder includes all the characteristics of the Quicksilver-4S but is capable of producing rolls of stretch film in all 3 possible formats: hand, machine and jumbo (2 and 3-inch cores).

This winder is suitable for widths of up to 3 meters and can be installed on any new or existing stretch film machine another value-added upgrade.

The genuine, completely automatic Quicksilver-4S winder is the fastest stretch film turret win-der capable of winding both hand and machine roll formats (2 and 3-inch cores).

The specially developed automatic system for core loading and roll extraction ensures a very short cycle time (10 seconds) and perfect-quality film rolls. Very sophisticated electronic controls and algorithms, customized mechanical components and unique materials used on the contact and satellite rolls, allow winding of very thin film onto very thin cores with flat edges and no wrinkles nor entrapped air.

A precision scale also checks the production weight of each roll. The result is high-output of perfect, ready-for-sale rolls, even for the most demanding markets.

This winder is suitable for widths of up to 3 meters and can be installed on any new or exi-sting stretch film machine a truly value-added upgrade.

AUTOMATIC HAND-ROLL PACKAGING SYSTEM

OPTIONAL

TECHNICAL DATA

• Output: approx. 6 boxes/min• Carton storage capacity: 100 pcs.• Adjustable carton magazine• Boxes opend and moved by vacuum• Automatic box filling station with

interchangeable groups• Quick production changes with mini-

mum adjustment• Box closure by means of self-adhesive

taping group

OPTIONAL OPTIONAL

The automatic packaging system is the ultimate downstream accessory for stretch film machi-nes.

With the addition of this packing station, any stretch film machine can achieve fully automa-tic (no operator), “granules-to-box” production of stretch film hand rolls.

The automatic procedure builds the cardboard box, fills it with 6 finished rolls, and lastly, tapes the package shut.

The closed box is then delivered to the end of the line for stock handling. This system can be implemented in any size machine and can manage rolls coming from 2 or more lines simultaneously.

22

23

Air BubbleFilmMachinery

24

Torninova Corporation is today synonymous for Hi-Tech Air Bubble Film Machinery all around the World.

For over 20 years Torninova has been enga-ging in the production of top-level equipment, presenting state-of-the art technology applied to lines for the production of air bubble film: all of this has been possible and realized thanks to the Company’s constant engagement in finding innovative, better performing and cost-saving processes and solutions.

Torninova know-how is also based on the wil-lingness to listen to the reccomendations and suggestions provided by the daily experience of our Clients, who have been helping us to enhance and adapt every single installation, making them suitable for each project’s specific necessity and technical guideline.

Completely focused on this specific line of equipment, Torninova strives to take the best possible advantage of market feedback and requirements, updating its equipment to comply with the newest regulations; every component of our lines is perfectly connected and homo-geneous to the others, resulting in a perfectly integrated vanguard installation for the produc-tion of air bubble film.

All machines are modular and for this reason the whole Torninova system is easy to upgrade, based on every Client’s specific needs, and ap-plicable on existing machines even if supplied by other companies.

Amongst Torninova’s outstanding specialized equipment for the production of bubble foil, the following lines deserve a mention for their very special features:

The COEX BUBBLE (10)™, an authentic master-piece, represents the most advanced available technology for the production of high-perfor-mance air bubble film. In fact the special co-extrusion configuration allows the production of a symmetrically structured (ABCBA+ABCBA), multilayer air bubble film containing an integrated air retention barrier of Nylon-PA6 (layer C). The result is the production of an ultra-light bubble foil with enhanced cushioning and protective properties, far superior to the same-weight mono-extruded bubble wrap film. In practice, better results are ensured with less material and this means an unbeatable compe-titive edge in the film market.

HI-TECH AIR BUBBLE FILM MACHINERY

25

The AIR BASIC™ belongs to the family of the off-line process, and it is the patented system based on hot-air thermoforming process, which processes LDPE rolls to produce air bubble film both for technical packaging and reflective in-sulation. The specialty of this line compared to traditional off-line systems, is that it significan-tly reduces energy consumption and provides maximum production-plan flexibility with its “stop-on-phase” procedure. The AIR BASIC™ series is still one of the most purchased lines for the production of air bubble film for techni-cal packaging and reflective insulation.

The TWIN BUBBLE™ is the answer to a new profitable sector which uses air bubble film as building thermo reflective insulation . In answer to the requests from Customers involved in such specific markets, has brought Torninova to design and realize a new patented extrusion system, called TWIN BUBBLE™.

This machine allows the production of multi-layer compound (sandwich) bubble foil, PE-foam and aluminum foil, all in one-single process. The TWIN BUBBLE™ system can even produce flame-retardant materials certifiable for all different Worldwide Standards.

Other ultimate air bubble film production lines POWER BUBBLE™, POLYBOLL™, MAC BUBBLE™ complete the Torninova range. All Torninova lines of equipment are designed and built to include highly developed electronic solutions, mechanical parts especially designed and created in the Company workshop and a 24/7 teleservice assistance.

Torninova, a journey of quality and tradition in plastic machinery which continues through ge-nerations and stands as a guarantee for Clients Worldwide.

A solid technical base, constant focus, conti-nuous development, customized solutions, all of these make Torninova the reliable partner in air bubble film production, ensuring the most effective and worthy results.

26

The World’s largest packing corporations use the COEX BUBBLE (10) as it represents the most advanced technology for in-line production of air bubble films containing an integrated air retention barrier.

The COEX BUBBLE (10) is a cast co-extrusion system with three extruders. It processes LDPE, TIE and Nylon-PA6 pellets to produce high-performance, symmetrically structured (ABCBA+ABCBA), multilayer air bubble film.

The 10-layer structure allows for integration of an air-tight, Nylon-PA6 barrier for longer bubble-air-retention, thus improving the film’s cushioning and protective properties, even at reduced thicknesses.

For example, a 35 g/m2 of coex film has the same resistance of a 60 g/m2 mono film a definite competitive advantage!

Especially suitable for technical packaging and envelopes, the COEX BUBBLE (10) series is fully automatic and includes touch screen controls for custom configuration of production recipes. Thanks to an on-board network connection, machine function can be remotely monitored via Internet.

The modular configuration of COEX BUBBLE (10) lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc...

COEX BUBBLE (10)™

high-speed/high-output,in-line co-extrusion.

TECHNICAL DATA

RAW MATERIALLDPE, TIE and Nylon-PA6 pellets

THERMOFORMING PROCESSWith three cast extruders

WEB WIDTHSFrom 1,25 to 3 m

FINISHED AIR BUBBLE FILM WEIGHTmin. 25 g/m2 - max. 600 g/m2

MAX. PRODUCTION SPEED90 m/min

FORMING ROLLER DIAMETERØ 450 mm

STANDARD BUBBLE SIZEØ 10 x 3 mm spherical

CAST DIETwo separate dies with feed-block for variable geometry co-extrusion

CO-EXTRUSION GEOMETRYbase (ABCBA) + bubbles (ABCBA)


air bubble film packaging - reflective bubble foil

insulation - bubble solar pool cover - air bubble film

laminated with PE-foam - air bubble film laminated with

LDPE film - air bubble film laminated with HDPE film - air

bubble film laminated with coated kraft paper - air bubble

film laminated with coated aluminium foil - air bubble film

laminated with MPET film - air bubble film laminated with

printed film - air bubble film laminated with non-woven -

bubble wrap - etc...

27

REFERENCE Machine2,5 m - two layers

STANDARD PRODUCTION SIZE750 kg/h (75 g/m2)

STANDARD PRODUCTION SIZE13.500 m2/h (35 g/m2)

DIAMETER OF SCREW EXTRUDERS: A= Ø 130 mm L/D=30 (LDPE) B= Ø 45 mm L/D=30 (TIE) C= Ø 45 mm L/D=30 (Nylon-PA6)

AVERAGE POWER CONSUMPTION170 kW-h

OPTIONAL EQUIPMENT

- TRIPLEX winder- DUPLEX PLUS winder- VIR winder- Third layer extrusion lamination unit- Third layer diathermic oil lamination unit- Third layer hot-air lamination unit- Fourth layer unwinder- Perforation unit- Forming cylinders- Chiller unit

WHY COEX BUBBLE (10)?

Better film performance ensured with less material means an unbeatable competitive edge in the film market.

Tie

Polyethylene

Polyethylene

Nylon

Tie

Air Air

Single-layerPolyethylene

5% thickness lost after 14 days

1 kg

50% thickness lost after 14 days

1 kg

CO-EXTRUSION AIR BUBBLE FILM MONO-EXTRUSION AIR BUBBLE FILM

Note: Independent Comparison

28

The POWER BUBBLE system is the pinnacle of standard mono-extrusion technology. Thanks to its power and flexibility, this machine produces a vast array of air bubble films.

Starting from an appropriate formulation of LDPE pellets with HDPE, PP, hexene - octene LLDPE and mLLDPE, the universal single-screw extruder produces high-performance, low thickness materials.

A single operator can fully control the entire POWER BUBBLE manufacturing process with the system’s fully integrated touch screen controls. Using its on board network connec-tion, the machine’s operation can be remotely monitored via Internet. The system’s modular configuration is adjustable for any production output and lends itself to many useful upgra-des, such as a 3rd layer lamination unit, a perforation unit, etc…

POWER BUBBLE™

high-speed/high-output, in-line mono-extrusion










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALLDPE pellets

THERMOFORMING PROCESSWith cast extruder





STANDARD BUBBLE SIZEØ 10 x 4 mm

CAST DIETwo separate dies

REFERENCE Machine2,5 m / two layers

Standard production size650 kg/h (75 g/m2)

Standard production size11.250 m2/h (40 g/m2)

Diameter of screw extruderØ 130 mm L/D=30

Average power consumption125 kW-h

29

POLYBOLL is Torninova’s authentic entry-level in-line extrusion system. These machines process LDPE pellets to produce a wide range of excellent-quality air bubble films at mode-rate outputs. With its simplified structure and no-frills finishing, the POLYBOLL is the most suitable solution for medium-to-small market necessities. The POLYBOLL production process is completely automatic and fully controllable by a single, un-skilled operator. This machine allows a new bracket of customers (e.g. air bub-ble film distributors and converters) to enter and learn the production market while substantially containing their up-front investment costs.

The POLYBOLL system is also ideal for air bubble film manufacturers intending to relocate production facilities directly in distant, but pro-fitable, new markets, while drastically reducing transport costs and writing off, in the short-term, the initial investment. The POLYBOLL system’s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc…

POLYBOLL™

in-line mono-extrusion, medium/low production speeds and outputs










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALLDPE pellets

THERMOFORMING PROCESSWith cast extruder

WEB WIDTHSFrom 1,25 to 2,5 m





CAST DIEone die with double delivery




Diameter of screw extruderØ 95 mm L/D=30


30

MAC BUBBLE is a traditional off-line system which processes LDPE rolls for high-output air bubble film production. A thermoform process laminates two individual films using Teflon -co-ated cylinders heated by a diathermic oil circuit connected to electric heating units.

The result is high-speed air bubble film pro-duction with superior lamination quality, even for films of larger widths. In some cases, the production speeds achieved by MAC BUBBLE machines are much higher than those of an extrusion-based machine, even when starting from very high thickness films.

The MAC BUBBLE system also has an on-board network connection which allows machine fun-ction to be remotely monitored via Internet and the system’s modular configuration lends itself to many useful upgrades, such as a 3rd layer lamination unit, a perforation unit, etc…

MACBUBBLE™

high-speed/high-output, off-line processing










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALRolls of LDPE pellets and coated materials

THERMOFORMING PROCESSBy diathermic oil cylinders










31

AIR BASIC is Torninova’s patented off-line sy-stem which processes LDPE rolls to produce air bubble film of various bubble sizes for technical packaging and reflective insulation. A thermoform process laminates two individual films using a special heating bar to blow hot-air over the films. Compared to traditional off-line systems, this process significantly reduces energy consumption and provides maximum production-plan flexibility with its “stop-on-phase” procedure. Such special features serve to significantly reduce inventory, transportation and energy costs.Because the AIR BASIC system is so versatile and easy to use, a single, un-skilled operator can quickly perform production changeovers without wasting material at restart. The on-board network connection allows remote monitoring of machine function via Internet and the system’s modular configuration lends itself to many useful upgrades such as a 3rd layer lamination unit, perforation unit, etc. The AIR BASIC series is still one of the most purchased lines for production of air bubble film for techni-cal packaging and reflective insulation.

AIR BASIC™

medium output/medium speed, off-line processing










etc...

OPTIONAL EQUIPMENT


TECHNICAL DATA

RAW MATERIALRolls of LDPE and coated materials

THERMOFORMING PROCESSBy hot air *(or by hot air + diathermic oil cylinders)



MAX. PRODUCTION SPEED35 m/min *(65 m/min)




Standard production size190 kg/h (75 g/m2) * 360 kg/h (75 g/m2 )

Standard production size3.350 m2/h (40 g/m2) * 6.250 m2/h (40 g/m2)

Average power consumption50 kW-h* 65 kW-h

32

TWIN BUBBLE is a patented in-line system with an extrusion line specifically developed to produce reflective bubble foil insulator for construction applications. The TWIN BUBBLE series uses LDPE pellets to produce multi-layer compound (sandwich) bubble foil, PE-foam and aluminium foil, all in a single process.

The system basically consists of two “twin” bubble lines producing two bubble foils (lami-nated with coated aluminium film) in opposite directions; in the middle there is a lamination station that welds the components together. The final multilayer product is then collected on the winder at the end of the line.

The TWIN BUBBLE system can even produce flame-retardant materials certifiable for all different Worldwide Standards.

TWINBUBBLE™

in-line processing for reflective insulation materials with double bubble layers


reflective bubble foil insulation - air bubble film lamina-

ted with coated aluminium foil - air bubble film laminated

with MPET film - air bubble film packaging - bubble solar

pool cover - air bubble film laminated with PE-foam - air

bubble film laminated with LDPE film - air bubble film

laminated with HDPE film - air bubble film laminated with

coated kraft paper - air bubble film laminated with printed

film - air bubble film laminated with non-woven - etc...

OPTIONAL EQUIPMENT

- DUPLEX PLUS winder- VIR winder- Lamination unit by hot air- Forming cylinders- Chiller unit

TECHNICAL DATA

RAW MATERIALLDPE pellets, flame retardand addivitive, coated aluminium rolls

THERMOFORMING PROCESSWith cast extruders


FINISHED AIR BUBBLE FOIL WEIGHTmin. 80 g/m2 - max. 625 g/m2 (double bubble)




CAST DIESTwo dies with double delivery+ one with single delivery

REFERENCE Machine1,6 m / five layers double bubble



Diameter of screw extruderstwo (Ø 80 mm L/D=30)+ one (Ø 55 mm L/D=30)


33

OPTIONALS

Equipement for Air Bubble Film and PE-Foam Machinery

TRIPLEX™WINDER

fully automatic winder with very short cycle time

Torninova’s patented TRIPLEX winder is the fa-stest automated tapeless and glueless winder for air bubble film and PE-foam machines. This turret winder is based on a three-cantilever-shaft configuration that allows extremely fast cycle changes (< 40s). The automatic loading of new cardboard cores (whole or split) and extraction of finished rolls is synchronized with a roller-table at the final collection station. The new transversal cutting system allows film to be wound without glue or adhesive tape on the core. Thanks to its advanced technology, the TRIPLEX winds various types and thicknesses of air bubble film and PE-foam, into very short roll lengths, at a speed of over 100 m/min. The TRIPLEX can also be installed on existing production lines.

DUPLEX PLUS™WINDER

flexible automatic winder

The DUPLEX PLUS is Torninova’s traditional, highly reliable tapeless and glueless turret winder consisting of two cantilever air expan-sion shafts with automatic inflation/deflation. Extremely reliable and powerful, the DUPLEX PLUS winds perfect quality rolls to extremely accurate lengths and widths, even when divi-ded in-line into sub-formats. The DUPLEX PLUS can be configured to wind external bubble, internal bubble or double-system films. The DU-PLEX PLUS is available with an automatic FAST LOADING system for finished-roll extraction, core loading and hot-melt application (both for initial core gluing and roll closure). The DUPLEX PLUS can wind air bubble film and PE-foam of any type and thickness and can also be instal-led on existing production lines.

VIR™WINDER

contact winder for jumbo rolls

The VIR is an in-line contact winder for assem-bly on air bubble film and PE-foam machines. With its guaranteed speed performance and finished roll quality, the VIR produces rolls up to two meters in diameter and is thus recommen-ded for all customers converting air bubble film or PE-foam through a second manipulation pha-se (bags, envelopes, formats, sheets, etc.). The larger diameter rolls (longer) are automatically unloaded onto the floor to reduce finished-roll replacement times during the conversion pro-cess. The VIR can also be installed on existing production lines.

CORELESS READY (patented)

CORELESS READY (patented)

TECHNICAL DATA


MAX. WORKING SPEED90 m/min

REFERENCE50 m length roll at 70 m/min of working speed

MAX. WINDING DIAMETER1.100 mm

Bubbles on inside or outside

TRIPLEX™ CAN WORK WITH:

air bubble film - reflective bubble foil insulation -

bubble solar pool cover - air bubble film laminated with

PE-foam - air bubble film laminated with LDPE film - air

bubble film laminated with HDPE film - air bubble film la-

minated with coated kraft paper - air bubble film laminated

with coated aluminium foil - air bubble film laminated with

MPET film - air bubble film laminated with printed film - air

bubble film laminated with non-woven - PE-foam packaging

- reflective PE-foam insulation - etc...

TECHNICAL DATA



REFERENCE50 m length roll at 40 m/min of working speed


Bubbles on inside or outside or booth

DUPLEX PLUS™ CAN WORK WITH:










TECHNICAL DATA




Bubbles on inside

VIR™ CAN WORK WITH:










THIRD LAYEREXTRUSIONLAMINATION UNIT

This lamination module can be retrofitted to any new or old extrusion-based machine for the production of air bubble film or PE-foam in net widths of up to 3 meters. It laminates, in-line, a 3rd film of LDPE or HDPE over the bubble layer. The melted film from the single flat die adheres directly to the heads of the bubbles which are rapidly cooled. The result is a surprisingly low-cost, three-layer LDPE air bubble film.Additionally, the same melted film can be used as an adhesive layer for perfectly smooth, high-speed lamination to other rolled materials (PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc). The finished product is an air bubble film with two flat faces, one of which can be optionally characterized by a different material.

THIRD LAYER DIATHERMIC OIL LAMINATION UNIT

This fast and powerful in-line lamination modu-le is easily retrofitted to any new or old machi-ne for high-speed production of air bubble film or PE-foam in net widths of up to 3 meters. The 3rd film layer to be laminated is supplied from the unit’s double-station film unwinder (with no-stop changeover). Teflon-coated cylinders heated by a diathermic oil circuit connected to electric heating units, laminate the 3rd film layer over the bubble layer. This lamination process guarantees the highest production speeds of any main line and ensures best-qua-lity lamination with all kinds of material (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc.). The main advantage of this lamination unit is its ability to laminate film directly on top of the air bubble film, with no additional adhesive layer.

THIRD LAYER HOT-AIR LAMINATION UNIT

This in-line, hot-air lamination system is easily retrofitted to any new or old machine for air bubble film or PE-foam production in net widths of up to 1,6 meters. The 3rd film layer is supplied from rolls on the unit’s double-station film unwinder (with no-stop changeover) and is laminated over the bubble layer using hot air. Thanks to this air-based heating system, the unit is especially suitable for lamination of delicate materials such as PE-foam, coated alu-minium foil, printed film, etc. This unit is further distinguished “stop-on-phase” procedure and very low energy consumption.

TECHNICAL DATA



STACK UNWIND WITH AUTOMATIC ROLL CHANGEmax. Ø 1.200 mm

CAN WORK WITH:










TECHNICAL DATA




CAN WORK WITH:









PE-foam packaging - reflective PE-foam insulation - etc..

TECHNICAL DATA




Bubbles on inside

CAN WORK WITH:









PE-foam packaging - reflective PE-foam insulation - etc...

FOURTH LAYER UNWINDER

This unit laminates a 4th layer film (HDPE film, PE-foam, coated aluminium foil or kraft paper, printed film, non-woven, etc.) to the base of the air bubble film, improving or varying the finished film’s aesthetic and/or mechanical characteristics. It consists of a double-station unwinder equipped with two air expansion shafts for loading the 4th layer film rolls. While a roll is unwinding on one station, a new roll can be prepared in stand-by on the other for a no-stop changeover. This modular unit is easily retrofitted to any new or existing in-line air bubble film machine.

PERFORATIONUNIT

This useful independent module is ready for easy, in-line, retrofitting to any air bubble film machine and can possibly be used in other types of machines producing similar films (PE-foam, blow film, etc). It makes a preliminary cut on the film at desired intervals (max. 400 strokes/min) before winding, resulting in a finished film roll prepared in pre-cut sections that are quickly and easily torn-off when nee-ded. A brushless motor with encoder drives the double-blade pre-cutting device and ensures exact, consistent sheet sizes. The module is available with an optional trim-cutting unit and suction group.

FORMING CYLINDERS

These chromed cylinders for bubble moul-ding are the most distinguishing element of Torninova’s technical know-how. A mono-lithic steel cylinder, with a special internal water circuit provides perfectly homogenous thermoregulation, guaranteeing the highest production performance and maximum stability with material of any thickness. The sector vacuum system used for bubble thermoforming increases efficiency and conserves power. The push-to-connect design allows for fast cylinder changes. The cylinders can be manufactured to custom bubble shapes and dimensions and are available for all types of air bubble film machinery.

TECHNICAL DATA




CAN WORK WITH:









etc...

TECHNICAL DATA



CYCLE TIMEmax. 400 stroke/min

MIN. PERFORATION LENGTH110 mm (45 m/min)

CAN WORK WITH:

air bubble film packaging - bubble solar pool cover

- air bubble film laminated with PE-foam - air bubble film

laminated with LDPE film - air bubble film laminated with

HDPE film - air bubble film laminated with coated kraft pa-

per - air bubble film laminated with MPET film - air bubble

film laminated with printed film - air bubble film laminated

with non-woven - PE-foam packaging - etc...

TECHNICAL DATA


MOULDER ROLLER DIAMETERSFrom 270 to 500 mm

BUBBLE SHAPESSpherical, square and other shapes

STANDARD BUBBLE SIZESØ3 - Ø6 - Ø10 - Ø15 - Ø25 - Ø30 mm and other diameters

CAN WORK WITH:


insulation - bubble solar pool cover

40

ConvertingMachines

for Air Bubble Filmand PE-Foam

41

42

The MAX ONE machine produces various sizes and types of envelopes, bags, sheets, formats, tubulars and sleeves, starting from rolls of air bubble film and PE-foam.

This All-in-One system ensures ease of use for even the unskilled operator. Moreover, through its various automatic devices, a single operator can manage up to two systems simultaneously.

The entire process is controlled by the main touch screen where hundreds of recipes can be saved and/or loaded. The needles are mounted on a pneumatic unit which collects and stacks envelopes or formats into bundles.

Once completed, the bundles are transported to the collection conveyor. The palletizing system can stack several bundles at the same time, thus eliminating the need for one or more operators to perform such task a feature that is especially convenient when producing envelo-pes or large-dimension formats.

This process is completely automatic. After pre-cutting, bags can be wound into rolls on a downstream winder.

MAXONE™

bag-making and sheeter machine with needle staking

Can convert:

air bubble film - PE-foam - air bubble film laminated with






bubble film laminated with non-woven - etc...

TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films


MAX. STARTING ROLL DIAMETER1.200 mm (max. weight of 75 kg) on 3-inch cores

FILM FEED SPEEDmax. 120 m/min

NUMBER OF LONGITUDINAL BARS1, 3 or 5

NUMBER OF TRANSVERSE BARS2

NUMBER OF LONGITUDINAL KNIVES6 or more

ENVELOPE AND FORMAT FEED STEPSmin. 100 mm / max. 1.300 mm in automatic mode; for larger sizes the machine can also run in semi-automatic mode


43

The SHEETEX machine is the best solution for effortless cutting of plastic materials (such as PE-foam and air bubble film) into sheets of pre-set length.

Sheets (or multiple sheets) are cut and divided by self-sharpening razor blades which require no adjusting when varying material thickness or the number of layers to be cut.

A needle stacker collects the sheets and stacks them on a table with pivot rotation to facilitate extraction.

SHEETEX™

sheeter machine with needle staking

Can convert:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films


MAX. STARTING ROLL DIAMETER1.000 mm (max. weight of 50 kg) on 3-inch cores

MAX. THICKNESS OF MATERIALS TO BE CUT16 mm

MAX. NUMBER OF FILMS TO BE CUT SIMULTANEOUSLY4 (e.g. 4 rolls of air bubble film with 4 mm bubble height)

FEEDING LENGTHmin. 100 mm / max. 1.000 mm or more

PRODUCTION SPEEDsheet length cycles/min150 mm 23 300 mm 21 500 mm 18 1.000 mm 15

AVERAGE POWER CONSUMPTION1,5 kW-h

44

The RP machine is a fully automatic rewinder that produces coreless, small-diameter rolls (mini-rolls, max. diameter Ø 350 mm) of plastic film (air bubble film, PE-foam, EPS, corrugated paper, etc.)

Once the starting roll is inserted, the RP rewin-der automatically begins producing the small diameter rolls so the operator does nothing more than simply change the starting roll and replace the collecting box once it is full. The machine can also split the starting jumbo reel to produce 2 or more narrower rolls at the same time.

The RP rewinder is the perfect choice for entering retail markets (hardware stores, super-stores, DIY, etc.) where air bubble film rolls are not sold in standard sizes, but rather, in shorter lengths of 3 to 30 meters.

Avoiding the use of an internal cardboard core is crucial in this specific market, as its cost is excessively high in relation to the end product being sold. A compelling reason to choose the RP Coreless Rewinder.

RP™

corelessrewinder

Can rewind:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films; corrugated paper


PRODUCTION LENGTHSFrom 3 to 40 m (max. Ø 350 mm)

PRODUCTION SPEEDapprox. 180 rolls/h (length 5 m)approx. 120 rolls/h (length 10 m)approx. 90 rolls/h (length 15 m)approx. 70 rolls/h (length 20 m)

MAX. STARTING ROLL DIAMETER2.000 mm


45

In addition to producing the same short length rolls as the RP Coreless Rewinder, the RP PLUS is capable of rewinding coreless mini-rolls up to a diameter of Ø 600 mm (containing 100 meters of air bubble film).

As the diameter of the roll in production grows, automatic support devices are engaged to handle the extra weight.

This off-line rewinder can produce coreless rolls in standard sizes (50 and 100 meters) for increased savings of cost and space.

RP PLUS™

coreless rewinder

Can rewind:








TECHNICAL DATA

RAW MATERIALSTwo layer or laminated rolls of air bubble film; PE-foam rolls, laminated and non-laminated; other similar plastic films; corrugated paper


PRODUCTION LENGTHSFrom 3 to 100 m (max. Ø 600 mm)

PRODUCTION SPEEDapprox. 175 rolls/h (length 5 m)approx. 115 rolls/h (length 10 m)approx. 85 rolls/h (length 15 m)approx. 65 rolls/h (length 20 m)


AVERAGE POWER CONSUMPTION4,5 kW-h

46

The LAM machine is a hot-air lamination sy-stem which laminates the entire surface of two or more rolls of plastic materials (two or three layer air bubble film, PE coated materials, LDPE and HDPE films and PE-foam) for value-added improvement of complex, final products used in various applications.

Alternatively, by adding electrically-heated sealing wheels, the extremities of two rolls of bubble foil can be coupled with aluminium on the external side (like a “tube”).

Such coupling may also include an additional internal material (PE-foam or other). The LAM machine is therefore recommended for plastic film lamination and/or production of complex materials specific to the reflective insulation market.

LAM™

lamination machine

Can produce:

reflective bubble foil insulation - air bubble film lamina-

ted with coated aluminium foil - air bubble film laminated

with MPET film - reflective PE-foam insulation - air bubble

film laminated with PE-foam - air bubble film laminated

with LDPE film - air bubble film laminated with HDPE film

- air bubble film laminated with coated kraft paper - air

bubble film laminated with printed film - air bubble film

laminated with non-woven - all lamination with air bubble

film and PE-foam.

TECHNICAL DATA

HEATING SYSTEM Lamination with hot air or infra-red lamps; longitudinal welding with circular electric resistances


PRODUCTION SPEEDLamination from 10 to 35 m/min longitudinal welding from 5 to 15 m/min


MAX. FINISHED ROLL DIAMETER800 mm

LONGITUDINAL WELD WIDTHFrom 10 to 40 mm

LAMINATION LAYERSFrom 2 to 4

NUMBER OF LONGITUDINAL WELD LAYERSFrom 2 to 5


47

Torninova S.r.l.via dell’Artigianato 1806083 Bastia Umbra (Perugia)Italy

tel. +39.075.8000655fax. [email protected]

www.torninova.com

Torninova Plastic Machinery

Documents

working machines

hitech machines

years torninova

film production

flexographic printing

manufacturing machines

mechanical field

years of experience