FILM, FOIL AND FOAM FOIL

It is a matter of common sense. A good start always increases the chance of success.
Our extrusion system has been designed to achieve the highest output and the smallest waste. For you, this means controlling the process in order to obtain the best quality. For us it is an exercise in rational technology.

The feeding system, the cleanliness of raw materials and dosing are critical to the production of high optical quality sheets. Thanks to years of research focused on this process phase, Omipa can offer you the best technology available.
Extruder feeding is accomplished through a dosing system controlling the loading, mixing and colouring of the raw material, ensuring it is free from any contamination. In order to guarantee the best level of accuracy, we opt for an integrated gravimetric dosing unit with more components.

The extruder incorporates a screw whose special profile, a perfect example of Omipa’s know-how and experience, always ensures homogeneous and constant mixing and plasticization.
The barrel has a special wear-resistant coating and is provided with venting hole with high vacuum suction.
The molten material is filtered through a filter changer.

The installation of a polymer feed pump group from the OMP series in an exclusive Omipa design, assures total control of material flow, as it maintains constant pressure under every working condition.
Omipa proposes coextrusion systems to process the various materials.
You can choose among different coextrusion blocks for multi-layer applications. In any case, you can be sure you will always obtain a perfect and homogeneous distribution across the entire sheet surface.

Our configured dies will enable you to cover the entire production range in all thermoplastic materials.
This is much more than a promise. It is our experience, integrated by the most advanced CAD/CAM design methodologies, that allows us to guarantee the most precise and controlled distribution of internal flows.

The calender plays an important role in an extrusion line. It determines the thickness of the sheet and its surface finishing. In high quality productions, this is the most delicate phase. We have been working hard on this, by testing and trying out.
We have proven that the smallest details actually have an influence on the final result. And we have taken care of every small detail, by applying the best mechanical and electronic technologies available, and by using the most advanced materials.

Omipa is always synonymous with excellence in calendering technologies.

• Total control of vibrations and perfect motion transmission
  This objective is achieved by mixing solid construction with the choice of highly precise motors and transmissions. In addition, ST gearboxes with slack taking-up, specially manufactured by Omipa, eliminate any risk of shutter marks. These are designed to eliminate any vibration (possible source of distortion) and to guarantee perfect uniformity of rotation (to reduce tension in the sheet).
• Powerful but delicate closure of the rolls
  Controlled by high strength oleodynamic unit for perfect and constant positioning.
• Micro-adjustment of the gap between the rolls, with automatic computerized control
  High optical quality sheet extrusion necessarily requires a calender designed to offer the possibility of varying the position of the outlet roll. Omipa calenders allow you to change the contact arch in a completely automatic and absolutely simple way, with extreme accuracy.
• Constant temperature control
  The temperature of each roll is controlled through a newly conceived thermoregulation unit. The thermoregulation fluid can be water or oil, as needed.
• Quality of the rolls
  Every single detail of the calender rolls is aimed at optimizing efficiency. Internal circuit design with peripheral holes is studied to guarantee a high thermal exchange combined with easy cleaning. The hardness of the roll construction material, as well as its surface finishing, guarantee the best surface properties of the finished product.

Stabilization of the sheet is fundamental to relieve stress once the sheet has left the calender.
The different combinations between longitudinal trimming systems and cross cutting systems offered by Omipa are all geared towards a total respect for the product thereby adding to the utmost final quality, the advantage of eliminating every possible reject due to inaccuracy. With the same attention, Omipa takes care of the stacking phase, which is the definite end of the entire process. Accuracy and speed here play a fundamental role. Here too, Omipa will be at your side, helping you to design the best configuration for your own and your product’s needs.

1. Roll plane and film coupling unit.
   After the roll plane, a take-off group with one or more couples of rubber-coated rolls is provided. In this phase, applying a PE film on the upper and lower sheet sides protects the sheet surface.
2. Longitudinal trimming.
   An automatic and independent circular saw trimming system, with more saws and with rotation speed control. Depending on the material to be processed, knives can be applied as an alternative to saws. A regrind unit can also be included, if required. The unit is equipped with soundproof protections in compliance with the most rigorous safety standards. Complete with scrap winder for PE film, if required.
3. Cross cutting unit and fully or semi-automatic winder.
   Depending on the product, we opt for a cross cutting unit, guaranteeing high accuracy and cleanliness of cut combined with flexibility given by variable speed motors, or for a special fast mechanical shear. All the systems are equipped with safety protections. The sheets are stacked with vacuum suckers in different configurations: unilateral, bilateral, or with central cut for stacking more than one sheet simultaneously. As regards foil, we offer automatic or semi-automatic winders, perfectly integrated with the line.

When you choose Omipa you are sure you will always have the best process qualities: stability, simplicity and customisation.
All Omipa lines are supplied with a supervision system controlled by PLC.
The software, produced internally, is always tailored to individual needs.
The use of a PLC allows you to record and monitor all the line process parameters: speeds, revolutions, temperatures, absorptions, outputs, pressures and alarms.
Designed for the central control of the entire line and of each single equipment, the system guarantees precious advantages as it makes line management more practical and functional.
Each alarm (the system can manage up to 400) can be connected with a control procedure, enabling the operator to solve problems by consulting stored instructions.
Codified recipes can be stored and recalled in real time, whenever necessary, thereby making it possible to modify line parameters easily and quickly, with the possibility of immediately repeating the desired production, without slowing it down in any way.

All the data provided during line operation are, in turn, stored to create an overall historical record of all the production parameters, such as:

• graphs of pressures, motor speeds, line output trends
• automatic starts
• line values
• alarms (date, time etc.)
• product management, stacking systems etc.

In addition, the software will allow you to manage:

• automatic start-ups
• pre-heating by means of a timer
• line maintenance program.

Although this is a complex system, it was studied to offer the operator extreme simplicity of use. The entire line management is concentrated in a single work station, and a graphic display of all the functions allows direct action at every point of the line from a single control site.
The system can be interfaced with the main corporate data management software, for global and integrated control of production (orders, purchasing, stocks).
The digital control system is the “mind” of every Omipa extrusion line.
For the operator, everything becomes easier, safer and more manageable. For the company, practical advantages result in better overall control of production with a consequent higher profitability of the line.