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Inspired by the precision and high level of automation of modern CNC machine tools, Reifenhäuser Cast Sheet Coating has developed MIREX MT, a new polishing stack technology that outperforms by far all state-of-the-art polishing stacks with regard to reproducibility and sustainability. The new patent pending polishing stack technology is the first and only system in the market that combines modern digital technique with sophisticated mechanical engineering.
The MIREX MT product range allows film producers to adjust the polishing nip more precisely by a factor of 10. In contrast to other polishing stacks, nip adjustment of MIREX MT can be effected fully automatically, even during running production. In the past, the line had to be stopped for manual adjustment of the correct nip on a trial and error basis. MIREX MT works at the push of a button and the set data are 100% reproducible.
The high level of automation has a positive effect both on the film quality and production cost. Due to the uniform thickness profile over large web widths, producers are able to obtain film of considerably improved precision while saving raw material. Thanks to the automatic adjustment, set-up times are only a quarter of the time needed in the past. The amount of waste can be reduced by 75%, depending on the production conditions.
When it comes to sustainability, the new MIREX MT technology outperforms all other polishing stacks available in the market. Hydraulic systems are completely dispensed with so that the polishing stack developed by Reifenhäuser Cast Sheet Coating is suited for clean room production. Film producers can benefit from triple savings in energy: no need for hydraulic pumps in permanentoperation, improved efficiency of roll drives, no energy-intensive adjustment of the nip.
As Helmut Meyer, responsible developing engineer, puts it: “Forget what you know about polishing stacks. With MIREX MT we have completely changed the current state-of-the-art technology and chosen a different approach. Our courage paid off: In the past, it was hardly conceivable what the new polishing stacks are able to accomplish with regard to precision, automation, and reduction of production cost.”
MIREX MT combines the roll set-on system and the nip adjustment system forming a mechatronic drive unit. The angular position of the first polishing roll can be varied by 30 degrees using a X-Y adjusting device. Individual drives arranged on both sides of the roll facilitate axle crossing of the first two rolls – a prerequisite for a uniform film thickness profile. Reifenhäuser Cast Sheet Coating has optimized the existing roll drives by combining several low-backlash planetary gearboxes with servomotors and torsion-resistant couplings.
MIREX is available in three designs, depending on application, film thickness and production capacity: Smart, Standard and High Quality.
·Smart: Less challenging applications (PS/PP) and low to medium output of maximum 1.200 kgs per hour
·Standard: Medium to higher capacities selectable in three steps from 1,000 to 3,000 kgs per hour.
·High Quality: Ensures high performance for specific applications in terms of output, speed and different film thicknesses and film properties.
Reifenhäuser Cast Sheet Coating will be presenting the new MIREX MT polishing stack for the first time on booth C22 at the K show to be held in Düsseldorf from October 16 to 22, 2013.