1. GENERAL OVERVIEW Tubes and laminated tube making process MECHATRONICAMECHATRONICA

2. Tubes MECHATRONICAMECHATRONICA Usage / markets served: - Oral care products (toothpaste…) - Cosmetics (creams,shampoo…) - Pharmacy (ointments,gels,lubricants…) - Chemicals (sealants,paints,silicones,adhesives...) - Food (ketchup,mayonese,paste…)

3. Tubes Types of tubes & technologies for tube making: - Al tubes – from 1841 Al slug is fed into a set of tools in the die which extrude it. Next step – trim to specific length on both ends and from one end it is threaded to screw on the cap. - Laminated tubes – ABL & PBL Placing a laminate pre-printed flat material which is gently formed into cylinder. High-frequency and hot air heat is necessary to fuse the sides of the material together to form a solid cylindrical tube body. Then the boy is cut into various lengths. The tube body is transferred to heading operation. Heading may be with preformed plastic shoulder or with injection or compression moulding of shoulders. Then cap is applied and torqued to the desired requirement. - Extruded tubes – single and multi layer The seamless tube body is formed into an extruder (extrusion). A mixture of resin and colour concentrate is placed into an extruder hopper. The extruder is temperature controlled to melt the mixture and the tube body is formed; heading; decorating; capping MECHATRONICAMECHATRONICA

4. Advantages  Al (metal) tubes Air tight and impermeable and have “no suckback”. These poperties give superiour protection to contents, keeping it fresh and uncontaminated through long periods. Seamless.  Laminated tubes With barrier properties close to those of metal tubes. They have a good “feel” and “memory” and maintain their attractiveness throughout the life of their content. First used for package of high-volume products, but now used for many other products.  Extruded tubes Seamless. The tube body and the cap are 100% polypropylene. 360° printed design. MECHATRONICAMECHATRONICATubes

5. IMPORTANT! Raw materials with good quality improve our chances to make good quality tubes; to maintain the nominal speed of the machine; to have minimum wastage MECHATRONICAMECHATRONICA Raw materials for laminated tubes KOMBIS technology RAW MATERIALS: Pre-printed ABL or PBL laminate/web Pre-moulded plastic shoulders Pre-moulded plastic caps Al membrane

6. KOMBIS 8003 machine MECHATRONICAMECHATRONICA Machine is designed on modular principle

7. Application techniques of each mechanism Unwinding mechanism: to unreel the foil web and maintain it in proper position at proper tension to deliver it to the body maker Body maker: to form a continuous tubular body bending and overlapping both ends of the foil, heating and pressing them; cutting smaller tube bodies to specified length Connecting transporter: to transfer the cut smaller tube bodies to the heading unit MECHATRONICAMECHATRONICA KOMBIS 8003 machine

8. Application techniques of each mechanism HEADING UNIT Rotating table: holding 12 cylindrical or oval mandrels serves as a base to allocate the duties for several operations Shoulder welding and capping: to supply shoulders and caps in specific order and to feed them to the mandrel and wind the cap and to torque to the desired requirement PBL module: to provide hot air, necessary for shoulder welding of PBL foil Top sealing module: to feed Al band and stick it onto the shoulder hole Ejection: to eject the ready-made tubes from the machine onto a conveyor or a box MECHATRONICAMECHATRONICA

9. Input parameters EXTREMELY IMPORTANT! For machine long life; smooth work and for good quality side and shoulder seams, input parameters should be strictly monitored: 1. Cooling water: Temperature: 13°C-15°C; Flow rate: 30 l/min; P max : 4bar. 2. Compressed air Pressure: 8bar; Air flow rate min 500 l/min. Supplied pressure must be 8bar, but main air valve must be set on 7 bar (never set to a maximum supplied pressure). This will prevent supplied air fluctuations. Fluctuations in supplied air affect BADLY tubes quality!!! MECHATRONICAMECHATRONICA KOMBIS 8003 machine

10. General knowledge FRICTION Definition: Friction is the force resisting the relative motion of solid surfaces, fluid layers and material elements sliding against each other. Friction force is opposite the driving force and friction force tries to stop the movement. Friction forces depend on the type of the material, roughness, cleanness, etc. as well on the force that two bodies press to each other. - Dry friction resists lateral motion of two solid surfaces in contact: Static – between non-moving surfaces and Kinetic – between moving surfaces - Fluid friction – between layers within a viscous fluid that are moving relative to each other - Lubricated friction – where fluid separates two solid surfaces - Skin friction – the force resisting the motion of a solid body through a fluid - Internal friction – the force resisting motion between the elements making up a solid material while it undergoes deformation MECHATRONICAMECHATRONICA

11. General knowledge Training Program - General section COMPRESSED AIR Extensively used in industry – motive power in a cheaper, safer, more flexible and reliable way Using compressor, sustainable supply is made by compressing atmospheric air. Air contains: Moisture – has to be removed and small quantity of oil added at the compressor to avoid corrosion of mechanical components and to lubricate them. MECHATRONICAMECHATRONICA Pneumatic circuit Pneumatic logic – reliable and functional control method for industrial processes Advantages -Simplicity of design and control ¤ machines are easily designed using standard cylinders & other components ¤ machines operate by simple ON-OFF type control - Reliability ¤ long operating lives and require very little maintenance ¤ Because gas is compressible, the equipment is less likely to be damaged by shock. The gas absorbs excessive force -Storage ¤ compressed gas can be stored, allowing the use of machines when el. power is lost -Safety ¤ Very low chance of fire FLOWSPEED PRESSURESTRENGTH

12. Training Program - General section General knowledge COOLING Water cooling is a method of heat removal from components and industrial equipment. As opposed to air cooling, water is used as the heat conductor. Two properties that matter the most: thermal conductivity and specific heat capacity Thermal conductivity describes how well a substance transfers heat. The thermal conductivity of liquid water is about 25 times that of air. Specific heat capacity is the amount of energy it takes to heat a substance by one degree. The specific heat capacity of water is about 4 times that of air, which means it takes four times the amount of energy to heat water than it does to heat air In Kombis 8003 machines water is used for: cooling the body mandrel, inductors and generators some parts in the PBL module. MECHATRONICAMECHATRONICA

13. General knowledge INDUCTION HEATING A process which is used to heat with an aim to bond, harden or soften metals or other conductive materials. For many modern manufacturing processes, induction heating offers an attractive combination of speed, consistency and control. In the most common heating methods, a torch or open flame is directly applied to the metal part. Induction heating, is unique, because heat is actually "induced" within the part itself by circulating electrical currents. Important: The efficiency of an induction heating system for a specific application depends on several factors: - the characteristics of the part itself, - the design of the inductor - the capacity of the power supply (high-frequency generator power and its operating frequency) - the amount of temperature change required for the application METAL OR PLASTIC Induction heating works directly only with conductive materials, normally metals. Plastics and other non-conductive materials can often be heated indirectly. MECHATRONICAMECHATRONICA

14. MAGNETIC OR NON-MAGNETIC It is easier to heat magnetic materials. In the ferromagnetics the heat is produced also by the induced eddy currents and by the hysteresis losses. This is useful under the Curie point – the temperature at which the ferromagnetic transforms to paramagnetic. In addition the ferromagnetics often has high electrical resistivity and respectively high electrical losses. By this reason the iron parts require less power than copper or aluminum in practice. THICK OR THIN Because of skin effect at high frequencies (electromagnetic field diminishes in depth), the heating generates directly on the surface. It is more effective to heat small parts or thin layers (foil, membrane, etc.) at high frequencies. RESISTIVITY As was noted – the metals with high specific electrical resistance heats quicker. The temperature increases the resistance and in practice the heating process is strongly non-linear and complex because of the effects combination. This is the reason to use systems for automatic control of the generator and the heating process. Inductor Design Inductor design is one of the most important aspects of the overall system. The flow of alternating current causes the electromagnetic field emission from the inductor, which is necessary for induction heating. A well-designed inductor provides the proper heating pattern for your part and maximizes the efficiency of the induction heating power supply, while still allowing easy insertion and removal of the part.nductor design MECHATRONICAMECHATRONICA General knowledge