Infrastructure

Extrusion plants at Simplex – the manufacturing process, is state-of-the-art Starlinger. This ultimate extrusion technology comes alive in the experienced hands of our workforce to process over 25,000 kgs. of virgin polymer everyday. Producing impeccable high tensile strength tapes with optimum elongation – a pre requisite for perfect fabric. Precision winding being the key to weave fine fabrics, all tapes are wound by new generation inverter controlled winders to produce even bobbins. Quality checks begin from the very initial stages of Tape-making. Every lot produced is checked for its Denier, Strength, Elongation and Color.If Liner plant is a luxury, Our buyers deserve this luxury. This over qualified plant ensures that we produce liners with zero pinholes, fish eyes or any other extrusion flaw.

At SimplexChemo, microprocessor controlled Form-fit Liner Machine cuts, seals and form-fits the liner in a dust-free clean room environment conforming to ISO Level-7 (< 10,000 PPM). Be it Glued, Tabbed or Flanged-in, well executed process eliminates liner twisting inside the bag.

The vital facility of coating – the essential prerequisite for making FIBCs is a 1.5 meter wide coating plant laminating both circular and flat fabric in thicknesses ranging from 15 to 80 microns. A unique fabric cleaning device, designed and developed in-house, is mounted on the coating machine to avoid any foreign particle going in-between fabric and the coating.

Fine and consistently fabric is the face of our FIBCs. Over 3 million square feet of high quality fabric is woven everyday on an array of wide width Starlinger looms. Computerized weaving machines with the help of skilled hands produce consistent quality fabric. At the end what you have from this state-of-the-art facility is an amazing collection of poly woven fabric, ranging from 60 GSM to 300 GSM ready to be turned into burly jumbo bags for stringent end applications.

SimplexChemo’s R&D initiatives are amply reflected in its ultrasonic slitting and sealing technology which makes our fabric comparable to tuck in fabric of a Sulzer loom. SimplexChemo recognizes for a critical food contact application, it’s not enough to mere make a high quality fabric, the fabric also needs to be contamination-free, carrying no foreign particle or even a speck of dirt. To achieve this high level of fabric cleanliness, fabric is stretch-wrapped on looms itself. Raising the bar on cleanliness, the stretch sealed fabric rolls never touch the ground. 4 color printing – a rare facility with others is pass at SimplexChemo. This excellence finds it’s match in the fabric’s evenness to create sharp, non-fading prints – repeats after repeats.

The company has an annual capacity to convert almost 8000 tons of virgin polymers, weave almost 100 million mtrs of fabric, resulting in a final production of more than 100 million stitched and printed woven sacs.

Simplex has the 2 state of the art tapeline from lohia Starlinger to make Quality Tapes and then convert it to woven bags and fabric with over 100 looms. The lamination plant with width coverage of 1.5 mtr. from Taiwan and we also have 7 printing machines with a capability of 6 colours in flexographic printing machines and 10 colours in Rotogravure printing machine.

Ultrasonic machining, or strictly speaking "Ultrasonic vibration machining", is a subtraction manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm (0.002 to 0.005 in.).[1] The fine abrasive grains are mixed with water to form a slurry that is distributed across the part and the tip of the tool. Typical grain sizes of the abrasive material range from 100 to 1000, where smaller grains (higher grain number) produce smoother surface finishes.

Ultrasonic vibration machining is typically used on brittle materials as well as materials with a high hardness due to the microcracking mechanics.

An ultrasonically vibrating mill consists of two major components, a transducer and a sonotrode, attached to an electronic control unit with a cable. An electronic oscillator in the control unit produces an alternating current oscillating at a high frequency, usually between 18 and 40 kHz in the ultrasonic range. The transducer usually consists of a cylinder made of piezoelectric ceramic. The oscillating voltage is applied to electrodes attached to the transducer, which converts the electrical energy into mechanical vibrations. The transducer then vibrates the sonotrode at low amplitudes and high frequencies.[2] The sonotrode is usually made of low carbon steel.[1] A constant stream of abrasive slurry flows between the sonotrode and work piece. This flow of slurry allows debris to flow away from the cutting area. The slurry usually consists of water (20 to 60% by volume) and boron carbide, aluminum oxide and silicon carbide particles.[1] The sonotrode removes material from the work piece by abrasion where it contacts it, so the result of machining is to cut a perfect negative of the sonotrode's profile into the work piece. Ultrasonic vibration machining allows extremely complex and non-uniform shapes to be cut into the workpiece with extremely high precision.

Machining time depends on the workpiece's strength, hardness, porosity and fracture toughness; the slurry's material and particle size; and the amplitude of the sonotrode's vibration.[2] The surface finish of materials after machining depends heavily on hardness and strength, with softer and weaker materials exhibiting smoother surface finishes. The inclusion of microcrack and microcavity features on the materials surface depend highly on the crystallographic orientation of the work piece's grains and the materials fracture toughness

Standardised tests to demonstrate the UV resistance of FIBC have been in existence since 1989. The UV resistance test according to Annex A of ISO 21898:2004 is currently the prevailing standard. However, standardised test conditions inevitably vary from the reallife conditions that FIBC are exposed to during use. Not only does the spectrum and intensity of UV radiation vary in different climate zones, but also other weather factors like temperature, humidity or frost play a role. Furthermore, substances in contact with the polymer, like pigments and even the goods filled into the FIBC, may also have an influence on the UV stability of the bag.

The combination of these elements will influence the speed of photochemical degradation of the polymer fabric of FIBCs in real life. This has led to voices from the industry questioning how well the laboratory tests set out in ISO 21898:2004 correlate to real-life conditions and can predict the life-time of FIBCs used in different climate zones around the world. Ultraviolet light is harmful to plastics because it attacks the carbon bonds in the chemical structure, releasing free radicals that in turn react with oxygen in the air, destabilising the plastics’ chemical structure and degrading it. Improving protection The most obvious way to mitigate the degradation of an FIBC due to UV radiation and other weather impacts is physically to protect the bags from the elements. Although FIBC handling instructions routinely advise against outdoor exposure, this is not always practical for users and certainly not controllable by FIBC producers and traders.

Chemical alternatives are available and widely used to help polymers like polypropylene maintain their properties longer against degradation through environmental influences. To counter the harmful effects of UV light on FIBCs, two main methods are used: UV light absorbers, eg, Triazine or Benzotriaole, and light stabilisers, ie, HALS (Hindered Amine Light Stabilisers). These additives, which absorb or stabilise UV light respectively, are often introduced to the base formula for the polypropylene material out of which the FIBC are woven. Both methods can retard the damaging effects of UV light but cannot stop it altogether. Either way, photochemical degradation remains a reality that must be taken into consideration. The question becomes how well we can predict the lifespan of the FIBC given that it will be exposed to environmental stress.

This is the job of the testing system. Figure a: protection against photochemical degradation March/April 2015 FIBCs & Bagging BULKDISTRIBUTOR 31 Best quality-to-price ratio FIBC (Flexible Intermediate Bulk Container) to increase the profitability our customers’ products. Tisza Textil is the European supplier of quality bags that unites best costto-quality ratio with innovation. Thanks to our excellent on-site service we can develop the ideal solution for our customers, whether it is a new high-tech innovation for the pharma industry or an economical standard FIBC single-loop bag for the fertilizer business. Our manufacturing locations in Estonia, France and Hungary are perfectly set across Europe, to serve our customers with quality bags with short transportation distances and can provide backup in case of emergencies. Tisza Textil is a fully vertically integrated producer of Big Bags for various ndustries. Since we have the supply chain under control, we can help our customers to reduce costly storage on their site. Our customers value the dedication of Tisza Textil to deliver bags that meet their needs exactly.

Whether it is the chemical modification of the outer bag to improve mechanical or chemical resistance or special constructions for the inliner, Tisza Textil can make changes at short notice. Our R&D and technical department in Europe offers extensive knowledge of customer requirements and can turn these into products in a very short time. We are very pleased to offer you our broad portfolio of products and services. Please contact us on our website on www.tiszatextil.com Laboratory limits The aim of testing is to recreate environmental strains in a controlled laboratory environment and examine the durability of samples against a battery of tests. In this way, accelerated laboratory UV tests allow quality control on FIBC without performing extended outdoor tests.

Ideally, the results confirm the load-bearing capacity of the FIBC upon which decisions on usage of the FIBC are based. Specific mention of UV resistance requirements had already emerged in European regulations for polypropylene sack used for transporting food aid in 1989. Since then the governing international regulation is the UV resistance Annex to ISO 21898:2004. The regulation lays down rules for laboratory tests using UV B lamps (based on ASTM – G154-98). In a cycle that alternatively subjects samples to 8 hours of UV light at 60degC at a time and then 4 hours of condensation at 50degC at a time for at least 200 hours, the weathering strain on FIBC is simulated. Once the exposure is complete, the samples are to be tested for their breaking force and the elongation of the fibre at the breaking point. The results are then compared to a control sample.

The UV resistance tests under ISO 21898:2004 give a common set of accelerated laboratory testing procedures that are repeatable and require the results of the tests to be expressed in terms that are comparable. Still, the International Standards Organisation concedes that “a number of factors of uncertainty are inherent in the procedure, so comparisons should be available between the method used and exposures in the environment in which the product is to be used”. This caveat in the preamble of Annex A of ISO 21898:2004 hints at a central shortcoming of the accelerated UV resistance test with UV-B lamps at 60deg – it does not adequately represent real outdoor conditions. Therefore we cannot predict how well that test correlates to real life exposure to light, temperature and other environmental influences in different climates from the arctic to the tropics where FIBCs are being used. Finding a solution Committed to providing a forum to discuss and inform about known and emerging topics affecting the FIBC community, EFIBCA hosted a UV Workshop in October 2014 for its members.

A panel of experts spoke to the assembly about the technical, legal and practical aspects of photochemical degradation and weathering. EFIBCA UV Workshop delegates reached a consensus that improved life-time estimations of FIBCs are of vital interest for the industry. That would not only help mitigate UV-related risks, but also allow cost savings through better adapted polymer formulations and more specific handling advice. “We debated a wide range of UV-related issues, from the influence of various factors on UV stability to the shortcomings of the UV testing standards, but the group decided that understanding the correlation between different test standards and outdoor weathering is central to progress in other areas,” said Dr Amir Samadijavan, EFIBCA vice president for technical matters.

TENSILE TESTS are performed for several reasons. The results of tensile tests are used in selecting materials for engineering applications. Tensile properties frequently are included in material specifications to ensure quality. Tensile properties often are measured during development of new materials and processes, so that different materials and processes can be compared. Finally, tensile properties often are used to predict the behavior of a material under forms of loading other than uniaxial tension. The strength of a material often is the primary concern. The strength of interest may be measured in terms of either the stress necessary to cause appreciable plastic deformation or the maximum stress that the material can withstand.

These measures of strength are used, with appropriate caution (in the form of safety factors), in engineering design. Also of interest is the material’s ductility, which is a measure of how much it can be deformed before it fractures. Rarely is ductility incorporated directly in design; rather, it is included in material specifications to ensure quality and toughness. Low ductility in a tensile test often is accompanied by low resistance to fracture under other forms of loading. Elastic properties also may be of interest, but special techniques must be used to measure these properties during tensile testing, and more accurate measurements can be made by ultrasonic techniques. This chapter provides a brief overview of some of the more important topics associated with tensile testing.

    These include:
  • Tensile specimens and test machines.
  • Stress-strain curves, including discussions of elastic versus plastic deformation, yield points, and ductility.
  • True stress and strain
  • Test methodology and data analysis It should be noted that subsequent chapters contain more detailed information on these topics. Most notably, the following chapters should be referred to:
    • Chapter 2, “Mechanical Behavior of Materials Under Tensile Loads”
    • Chapter 3, “Uniaxial Tensile Testing”.
    • Chapter 4, “Tensile Testing Equipment and Strain Sensors”.

Tensile Specimens and Testing Machines Tensile Specimens. Consider the typical tensile specimen shown in Fig. 1. It has enlarged ends or shoulders for gripping. The important part of the specimen is the gage section. The cross-sectional area of the gage section is reduced relative to that of the remainder of the specimen so that deformation and failure will be

KNOW ABOUT EXTRUSION:

Extrusion is an apparatus and a process that is used to create objects of a fixed cross sectional profile. A material is pushed or drawn through a die of the desired cross section. The two main advantages of this process are the ability to create very complex cross sections and work on materials that are brittle. The extrusion process can be done with both the hot or cold materials. Materials that are commonly used for extrusion are polymers, metals, ceramics and food stuffs.

EXTRUSION COATING:

Extrusion coating use a blown or cast film process to coat an additional layer on existing roll stock of paper, cotton cloth, woven fabrics, jute fabric, aluminum foil, Bopp film or polyester film. This process can be used to improve the characteristics of paper by coating on it with polyethylene to make it more resistant to water. The extruded layer can also be used as an adhesive to bring two other materials together.

EXTRUSION LAMINATION:

Extrusion lamination is a process that is used to combine two different substrates using molten polymers. The process of extrusion lamination includes both the characteristics of extrusion and lamination. Our extrusion lamination plant is said to be versatile as it can provide lamination for various substrates including metal, paper and mainly plastic films. It can provide lamination of different thicknesses with level of quality.

Our Extrusion Lamination Plant is an ideal solution for all the plastic manufacturing and processing industries.

Professional extrusion lamination plant manufacturer in India offer superior quality extrusion coating as well as extrusion lamination plant for their efficient use on IDPE thin layer coating and PP thin layer coating on substances like paper, cotton cloth, woven fabrics, jute fabrics and aluminum foil applications. The equipment supplied by us can able to meet different packaging and lamination needs of all your plastic processing industries.

We manufacture extrusion lamination plant by using distinctive and most modern technologies and we assure that they can meet the International standard specifications. The technology of extrusion lamination plant includes upgraded quality of extrusion system with high productivity, long durability, maximum efficiency and outstanding performance.

    Luminous features of our extrusion coating and extrusion lamination plant include:
  • It can be used on various substrates as paper, cotton cloth, woven fabrics, jute fabric, aluminum foil, Bopp film or even a polyester film.
  • Can perform either extrusion coating or extrusion lamination.
  • Highly efficient and durable lamination.
  • Ideal for Circular Woven Fabric materials
  • Two stage auto tension control DC winder