UV offset printing ink filtration and filling machine

1、 Overview:

GZJM-1.5 filtration and filling machine is a specialized equipment for semi-automatic filtration and filling in industries such as ink and paint. Economical and efficient, easy to use, simple to maintain, especially suitable for filtering and filling UV ink. The main unit of this device is separated from the electrical control box, and the bottom is equipped with nylon rollers that can be moved to any position for easy cleaning. The motor adopts variable frequency speed regulation.

2、 Working principle:

1) The deceleration motor ① drives the screw filling pump ② to operate, sending the material in the hopper to the filter cylinder ③. After being filtered by the mesh bag, it is output through the pipeline from the filling head discharge port ④.
2) The opening and closing of the discharge port is controlled by pneumatic control ⑤, coupled with an electronic scale, to achieve the purpose of quantitative filling.
3) When the discharge port is closed, excess material in the pipeline is returned to the hopper through the return pipe ⑥.
4) For the convenience of daily maintenance, a cleaning and flushing circuit has been specially designed.

3、 Main technical parameters:

1. Drive motor power: 1.5kw
2. Inverter power: 2.2kw
3. Heating plate power: 4 × 100w
4. Cylinder: Φ 45 × 75 mm
5. Filter: 60 mesh/in2 (users can also choose)
6. Pump diameter: Φ 80mm
7. Material conveying pipe nominal diameter: Φ 32 mm
8. Filling weighing range: 0.04~6 kg (weighing error 5g)
9. Dimensions: 1600 × 800 × 1600mm (length × width × height)
10. Weight: 150kg

4、 Design features:

1. Heating device
At room temperature, UV offset ink is a viscous heterogeneous fluid. Due to the requirements for rheological and thixotropic properties of ink in printing, the flowability of ink is highly sensitive to temperature and shear rate. It is important to make good use of this characteristic for both filtration operations and filling. For example, below 0 ℃, some offset printing inks have become semi-solid and cannot flow. If the ink transfer pump is started at this time, the load on the motor will be very high, and it may even fail to start, resulting in the inability to perform filtering operations. To protect the mechanical device, a heating device is installed in the system.
Before starting the ink transfer pump, the system can be heated up (it is recommended to set the temperature at 20-30 ℃), especially when the workshop temperature is relatively low, preheating of the system is necessary. In the system design, to ensure smooth ink flow and no dead corners, a temperature upper limit has been specifically set. When the temperature reaches the upper limit, the heating will automatically stop to prevent the ink from overheating; After heating the ink to a certain temperature, start the delivery pump to circulate the ink evenly in the machine before starting the packaging operation.
2. Pressure protection device
The filter is enclosed, so information about the blockage of the filter screen by the filter residue can only be transmitted through the pressure gauge. As the filtration progresses, the degree of blockage of the filter screen by the filter residue will also increase, and the filtration resistance will also increase, that is, the value indicated by the pressure gauge will also increase. When it reaches a certain level (such as the value displayed on the pressure gauge reaching 0.7 MPa), the filtration efficiency is already in a low state, and the operator should replace the filter medium (filter screen) in a timely manner. When designing this filtration device, the protective pressure of the machine was set to 0.8 MPa. When the pressure of the filling machine reaches 0.8 MPa, the machine will automatically stop and remind the operator to replace the filter screen in a timely manner. Do not increase the protection pressure by yourself to avoid pump leakage and pressure gauge damage caused by excessive system pressure.

5、 Application features:

1. Improve filling speed
Taking 1 kg packaging as an example, the filling speed of GZJM-1.5 UV filtration filling machine is about 7 s/can, and the speed can be adjusted. According to statistics from a large ink company, filling UV offset ink (approximately 450-480 kg per batch) using the GZJM-1.5 filter filling machine can be completed within 1 hour.
2. Improve product quality
In the ink to be canned, there are usually small amounts of larger pigment particles and other mechanical impurities. During filling, these substances can be removed by filtering. Therefore, adopting the filtration filling process can improve the quality of ink production. At present, this process is widely used in the production of high-end UV ink.
3. Improve weighing accuracy
Both in terms of weighing accuracy and efficiency, electronic scale automatic feedback weighing systems are much higher than manual operations. The weight error of each can is around ± 5 g. There are two factors that affect weighing accuracy: (1) the sensitivity of the electronic scale and the induction and information feedback speed of the electronic scale system. Therefore, full consideration has been given to this in the mechanical design of the machine. The setting of advance quantity is related to the type and performance of ink, as well as the flow rate and temperature during ink filling. If the filling speed is slow, the weight error fluctuation is small; If the filling speed is fast, the weight error fluctuates greatly. Only by finding the optimal flow rate and temperature to reach a stable state can the advance amount of the electronic scale be set to ensure high-precision filling. In addition, users can also adjust the device with the help of experience and the factory.
4. Reduce costs and increase efficiency
According to actual measurements and calculations, the annual income that a large-scale ink factory can obtain from precise weighing of each filtering and canning machine is about half of the investment amount of this machine. In addition, the implicit benefits created by the improvement of product quality are also very considerable.

6、 Outline drawing:

7、 Market prospects:

According to market research, ink production plants that have long dominated the mainstream UV offset printing market in China require a filtering process for each product, resulting in a high market share for the product; However, another UV offset printing ink production factory with relatively low annual output has been plagued by excessive impurities in its products, leading to complaints one after another. It can be seen that a UV offset ink filling machine equipped with a filtering device has considerable market value.
In the future, with the rapid development of UV offset printing, filter filling will undoubtedly be a breakthrough in the quality of UV offset printing ink products.

8、 Preparation and operation:

1. Preparation:
Connect the power supply, air source (pressure 0.4-0.6MPa), and electronic scale to use
2. Operation:
(1) Close the air switch inside the electrical control box, and the power indicator light will turn on.
(2) Feed the material into the hopper. The functions of each button are shown in the table below

9、 Precautions for use:

1. The running direction of the pump is clockwise when viewed from top to bottom.
2. The electric contact pressure gauge on the pipeline next to the filter cylinder in the material channel of the filling machine is an automatic switch (Pmax ≤ 0.8MPa) set to prevent pump damage or excessive pressure inside the cylinder. Do not adjust it arbitrarily.
3. The filter screen inside the filter cartridge should be cleaned regularly to prevent excessive debris from increasing the pressure inside the filter cartridge. If the filter is clogged, the pressure inside the filter cartridge will exceed the set pressure, and the machine will automatically shut down
4. The hopper and filling nozzle should be cleaned regularly to keep them clean and free of dirt.
5. Close the 'pump stop' button after filling is complete. Cut off the automatic switch inside the electrical control box and unplug the power plug.
6. Pay attention to cleaning and maintenance after use.
7. If the electronic scale is provided by the user, the corresponding changes in circuit and operation will not be explained separately.

10、 Safety requirements:

This machine is used in the production process of chemical raw materials. Before use, users should establish appropriate safety and hygiene protection measures in accordance with relevant safety regulations and determine rules and regulations. The safety issues related to contact with chemical raw materials should be established by the user and are not within the scope of this manual.

10、 Fault analysis:

1. Open the iron door at the bottom of the machine, and the pump will run counterclockwise when viewed from the drive transmission (sprocket) side.
2. The magnetic assisted electric contact pressure gauge on the machine is an automatic switch (Pmax ≤ 0.8MPa) set to prevent pump damage or excessive pressure inside the cylinder. Do not adjust it arbitrarily.
3. If the load of the machine current is too high, the air switch inside the electrical control box will trip, and it needs to be reconnected.
4. Do not pull or tug on the signal line of the electronic scale to avoid affecting its use.

12、 Maintenance and upkeep:

1. Develop the habit of regularly checking the equipment, and periodically check whether the tightening bolts of each part are loose and tighten them.
2. The filter screen inside the filter cartridge should be cleaned regularly to prevent excessive debris from increasing the pressure inside the filter cartridge. When cleaning, open the cleaning valve (if the filter screen is clogged, the pressure inside the filter cartridge will exceed the set pressure, and the machine will automatically shut down).
3. The feeding hopper and cylinder leakage nozzle should be cleaned regularly to keep them clean and free of dirt.
4. The gearbox inside the box should be replaced with 2 # lithium grease after the first 3000 hours of operation. Before replacement, residual dirty oil should be removed. Add it every 6 months in the future.
5. The chain connecting the reducer and pump also needs to be lubricated at intervals to reduce wear.
6. If the oil in the oil-water separator inside the electric control box has decreased or disappeared, ordinary engine oil needs to be added.
7. Check if the limit switch for filling is malfunctioning, and check if all buttons on the electrical control box are malfunctioning.
8. Check if the pressure gauge on the machine can display normally. If any damage is found, it should be replaced.

13、 Configuration List:

14、 After sales service:

1. If there is a quality issue with the product and objections are raised within 7 days of sale and the product is not damaged, our company is responsible for unconditional free returns and exchanges;
2. This product comes with a nationwide warranty, with a warranty period of 1 year;
3. If there are any product quality issues during the warranty period, free repairs will be provided; Provide long-term technical support beyond the warranty period;
4. For all product after-sales issues, please contact our company directly. Our after-sales service team will respond and handle them within 30 minutes.

15、 Data download: