Windsor machines training repport

1 CIT/ME/SEMINAR/020
Chapter-1
COMPANY PROFILE
1.1 Introduction
Windsor machines are the India’s largest plastic processing machinery manufacturing and
exporting company. Windsor machines have been manufacturing a complete range of
plastic processing machinery for more than decades. It has collaboration with R.H.
Windsor of U.K. In 1984 Klockner works of Germany made the company a part of its
worldwide operation and renamed it Klockner
Windsor Ind. Ltd. Then in 1994 Mr. Dilip G. Primal bought the company and the name
was again changed to Windsor machines India Ltd. Windsor machines has three state of
art plants in India at Than, Ahmedabad and Chhatral employing over 1500 employees.
1.2 Technical collaborations
For monolayer and multiplayer film plants the company has technical collaboration with
Kuhne GMBH of Germany and technical license from Rollepaal of the Netherlands for
high output RPVC pipe plants.
Fig 1.1 Windsor Machine

1.3 Staff welfare
The relationship between the company and employees is comparatively good. Staff
member works with their full efficiency and try to give their maximum for the progress
and welfare of the staff. The company gives good canteen facility which runs on the
contract basis. Company provides tea snacks lunch and dinner to the staff and workers at
subsidized rate. The company has setup water coolers with aqua guard in all the
departments which provides cool and clean water to the staff.
Company gives good salary, yearly increment and bonus to the employees. Company runs
good credit society of the staff and workers jointly. This society also gives the loans to
employees. Company gives sweets and dress to the workers on Diwali. Company also
organizes sports activities on Dashera like cricket, volleyball long jump etc. between all
departments and give prizes to the winners. Company pays travel allowance and leave
with pay to all staff member. It also pays the medical allowance to the worker.
1.4 Various Departments of the company
i. Purchase Department
ii. Sales Department
iii. Marketing Department
iv. R & D Department
v. EDC Department
vi. Assembly Department
vii. Machine and Die Department
viii. Testing Department
ix. Quality Department
x. Account & Finance Department
xi. Maintenance Department
xii. Store and Inspection department
xiii. Planning Department
xiv. Electrical Department

Chapter-2
EXTRUSION LINES MACHINES
2.1 Introduction
Extrusion is the process where a solid plastic (also called a resin), usually in the form of
beads or pellets, is continuously fed to a heated chamber and carried along by a feed
screw within.
The feed screw is driven via drive/motor and tight speed and torque control is critical to
product quality. As it is conveyed it is compressed, melted, and forced out of the chamber
at a steady rate through a die. The immediate cooling of the melt results in re-
solidification of that plastic into a continually drawn piece whose cross section matches
the die pattern. This die has been engineered and machined to ensure that the melt flows
in a precise desired shape.
Plastics are very common substances for extrusion. Rubber and foodstuffs are also quite
often processed via extrusion. Occasionally, metals such as aluminum are extruded plus
trends and new technologies are allowing an ever-widening variety of materials and
composites to be extruded at continually increasing throughput rates. This article will
focus only on the extrusion of plastics.
2.2 Process For Making Screw
i. Raw material (EN-36, EN-48, etc.)
ii. Cutting
iii. Turning (on lathe M/C)
iv. Blank grinding
v. Ruff thread milling
vi. Stabilizing / Normalizing
vii. Stratning
viii. Grinding
ix. Centering
x. Finish thread milling
xi. Polishing
xii. Nitriding

xiii. Stratning
xiv. Finish grinding
xv. Buffering
xvi. Nose making
xvii. Inspection
xviii. Store
2.3 Types of Extrusion Lines Machines
i. Single screw pipe extrusion lines machine
ii. Twin screw pipe extrusion lines machine
2.3.1 Single Screw Pipe Extrusion Lines Machine
In this machine single screw is used in extruder as shown in fig.
Fig 2.1 Single Screw
There are three section in feed screw:
(1) Feed Section
(2) Compression Section
(3) Metering Section

Table 2.1 Technical Specification of Single Screw.
2.3.2 Features
1. 4th generation energy efficient extruder
2. European Proven Technology ensures excellent linearity of specific output
3. L/D ratio of 37 : 1 ensures excellent melt homogeneity
4. Direct coupled design ensures minimum transmission loss
5. Wear resistant coating ensures long screw life at high rpm
2.3.3 Different Types of Raw Material
1. PE- Polyethylene
2. PPR- Polypropylene
3. HDPE- High Density Polyethylene
2.4 Twin Screw Extrusion Line Machine
In this machine Twin screw is used in extruder as shown in fig.
Fig 2.2 Twin Screw Extrusion Line Machine
Models Unit LX 40 LX 50 LX 65 LX 75 LX 90 LX 120
Screw Diameter Mm 40 50 65 75 90 120
L/D Ratio - 26:1 26:1 26:1 26:1 26:1 26:1
Main Motor Kw 7.5 15 30 37.5 60 110
Max Throughout
(HDPE)
kg/hr 18-20 36-40 90-100 120-130 170-190 300-
320

2.4.1 Different Types Of Raw Material
a) PVC - Polyvinyl Chloride
b) CPVC - Chlorinated Polyvinyl Chloride
2.4.2 Features
a) Minimizes energy inputs
b) Achieves uniform pumping
c) Front barrel with HSS sleeve offered for selected models
d) Minimizes wear & tear
e) Economic replacement option
f) High accuracy of ±1 C
g) Hard face coating on selected models
2.4.3 Application
a) Supplying potable water for rural and urban places
b) Casing and column pipes for bore well
c) City sewage Pipes
d) Domestic plumbing
e) Effluent discharge lines
f) Electrical conduits
g) Sprinkler irrigation system
h) Inside housing telecom connections

Table 2.2 Technical Specifications of Twin Screw.
Models Unit KTS
110
KTS
140e
KTS
170
KTS
200
KTS
250
KTS
300e
KTS
350
KTS
450
KTS
550
KTS
900
KTS
1500
Screw
Diameter
Mm 52 52 65 65 65 71 71 91 91 110 135
Screw
Speed
Rpm 5-50 5-52 4-45 5-53 5-53 5-53 5-53 4-40 4-45 3-30 3-26
L/D
Ratio
- 20:1 25:1 18:1 18:1 22:1 22:1 28:1 22:1 25:1 28:1 28:1
Main
Motor
kW 11.2
5
11.2
5
15 22.5 22.5 30 30 45 60 90 160
Max.
Output
kg/h
r
100-
110
130-
140
150-
170
180-
200
230-
250
280-
300
330-
350
420-
450
520-
550
850-
900
1300
-
1500
Pipe
Range
(Single
Die)
Mm 20-
110
20-
110
20-
200
20-
200
63-
250
63-
250
110-
315
110-
400
110-
400
160-
400
250-
630
Pipe
Range(T
win)
Mm 19-
50
19-
50
19-50 19-
50
20-
110
20-
110
20-
110
20-
110
63-
200
75-
200
110-
250

2.5 Difference Between Single & Twin Screw Line Machines
2.6 Working of Extrusion Line Machine
In basic extruder machine Plastic pellets or beads (also referred to as resin) are fed from
the hopper along a feed screw through a barrel chamber.
As the resin travels along the barrel, it is subject to friction, compression, and heated
zones. The result is that the resin melts and further travel at the exit end of the screw
serves to mix the melt homogeneously. The melt enters a chamber designed to ensure an
evenly distributed flow to the die. In many machines, a melt pump is used to prevent any
pressure surges.
Also, breaker plates serve to prevent any solid particles or foreign objects from passing
through the die, then it passes from the vacuum unit where it cool down and get proper
shape and it prevents bending of pipe and then it goes to traction unit it pull to cutting unit
where pipe is cut down as per required length.

2.7 Components of E.L.M.
2.7.1 Extruder
Fig 2.3 Extruder
In The Extruder Raw material is Feed through hopper in barrel and goes to feed screw
which is driven by the external device like motor and it forward the material .During
travelling the material it is heated by the heater at required temperature for melting
purpose then this melt material pumped to the die.
 Molding of plastic by continuous extrusion is not unlike ordinary extrusion
methods.
 The extrusion machine can make solid rods, pipe or tubing, U, J,Y, or other
sections.
 Granular material is fed by hopper into a heating cylinder (chamber) through
which it is forced by a screw into a heated (shape) die.
 After leaving the die the polymer material swells appreciably, the amount of
swelling depending
 Upon the shear rate (due to the screw) and the molecular weight distribution of the
polymer.
 Therefore, designing and making of dies require a lot of trade know-how.
 Continuous length of extruded sections are produced at a rate of 150 to 300 metre
per hour, the hot material after being extruded through the die cools and hardens
on the take-off belts.

 For colouring of the plastics, dry colour may be added to the screw extruder.
 Generally, thermoplastic materials are the only ones extruded.
2.7.1.1 Parts Of Extruder
Feed screw
Fig 2.4 Feed Screw
As the only moving part in many extruders, feed-screws must do the job of moving the
resins through the barrel chamber in a steady and predictable manner. As a result, and the
feed-screw is critical to the design.
2.7.1.2 Die and Die Head
Dies can take on a variety of shapes and have adjustable openings. In the case of filament
extrusion and others, multiple duplicate die patterns to extrude many strands in parallel
can be found on a single die.Dies are designed to compensate for effects of shrinkage
when a melt re-solidifies, two dimensioned size adjustments, and varying rates of
solidification. Dies must be free from defects and scratches, otherwise the melt could
show the defect's pattern.
Fig 2.5 Single die head Fig.2.6 Multiple die head

Table 2.3 Single Head Die
Models P 63 P 110 P 200 P 250 P 315 P 400
Pipe Range (mm) 20-63 20-110 63-200 90-250 110-315 110-400
Output Capacity(Kg/hr) 100 200 320 425 550 700
Table 2.4 Multiple Head Die
Models TDH 50 TDH 63
(Dual)
TDH
110(Du
al)
TDH
200(Du
al)
QDH
32(Quadrupl
e)
QDH
46(Quadru
ple)
Pipe Range (mm) 19-50 20-63 20-110 63-200 19-32 32-46
Output Capacity
(Kg/Hr)
200 200 400 850 280 400
Table 2.5 Die Specifications
Models SM 50 SM
110
SM
200
SM
315
SM 450 SM 630
Pipe Range
(mm)
12-50 20-110 63-200 110-
315
160-450 225-630
Output Capacity 100 250 350 500 700 1000
2.7.1.3 Barrel chamber
The barrel is also heated to facilitate melting of the resin. Although the major contributor
to melting is friction, the heat as conducted through the barrel can serve as a "fine adjust"
or vernier in temperature control and energy input. Electrical resistance heating is a
common method employed. This thick-walled steel chamber that is expected to withstand
high pressures (~ 20,000 psig), is precisely machined for a tight fit with the feed screw,
and has a hardened steel alloy on its inside wall to prevent wear and corrosion. Some
barrels will also have a grooved feed zone to increase the frictional forces on the resin.
2.7.2 Cooling Unit
a) Intensive cooling provided to ensure high production ratio
b) Easy cleaning bayonet type spray nozzle provided

c) Accurate vacuum control, water level & temperature control provided
d) Additional vacuum chamber and axial movement provided from VST-250
and above for quick startup and less wastage
e) Manual slide rail arrangement for Axial transverse movement of the tank
f) Dual vacuum spray tanks on common frame for dual pipe extrusion line
g) Imported filters for online cleaning
h) Air operated solenoid values optionally
i) Cyclone separator for vacuum pump
Fig 2.6 Cooling Unit
Table 2.6 Cooling Tank Specifications
Models Unit VST 110 VST 200 VST 250 VST 450 VST 630
Pipe Range Mm 16-110 20-200 25-250 75-450 110-630
Cooling Length Mm 4000/6000 6000 6000 6000 6000/8000
No. of Chambers - 1 1 2 2 2
2.7.3 Traction Unit
a) Up to 6 belt tracting device to suit pipe diameters
b) Different line speeds can be changed through change of sprockets
c) Track adjustment by pneumatic control
d) Self adjustment track suspension provided
e) Counter balance pressure to balance track weight for thin pipes offered

f) Encoder for length measurement & feed back arrangement offered optionally
g) Easy accessibility for maintenance of all components
h) Dual twin-track traction units for dual pipe extrusion line
Fig 2.7 Traction Unit
Table 2.7 Traction Unit Specifications
Models Unit TTU
75
TTU
110
TTU
200
TTU
315/3
TTU
315/4
TTU
450/4
TTU
630/6
Pipe Range Mm 12-75 16-110 20-200 32-315 40-315 75-450 110-
630
No. of
Tracks
Nos. 2 2 2 3 4 4 6
Max. Line
Speed
Mtrs./Mi
n
16 15* 15* 10.6 10.6 7.20 4.36
Contact
Length
Mm 540 800 1200 1200 1200 1600 1600

2.7.5 Cutting unit
Fig 2.8 Cutting Unit
a) Carbide tipped rotating circular saw for longer life
b) Pneumatically operated carriage movment
c) Clamping force adjustable depending upon the wall-thickness of the pipe
d) Swarf removal system optionally offered
e) Trolley movement on linear motion bearings
Table 2.8 Cutting Unit Specifications
Models Unit TCU
110
TCU
200
TCU
250
TCU
315
TCU
110/2
TCU
200/2
Pipe Range Mm 20-110 20-200 50-250 90-315 20-110 50-200
Cutting Speed
(Max.)
Mtrs/Min
.
15 10 10 6 12 15
Clamping
From
- Top Top Side Side Top Top

2.7.6 Planetary Cutting Unit (PCU)
Fig 2.9 Planetary Cutting Unit (PCU)
 Salient Feature
a) Mechanical actuator instead of hydraulic or pneumatic
b) 6 Jaw universal clamping
c) On line chamfering provided
d) Chamfering without replace ring

Chapter-3
BLOWN FILM LINES MACHINES
3.1 Introduction
Blown film extrusion is one of the most commonly used thin-gauge fabrication processes
in the world. The process of producing film by extruding molten resin into a continuous
tube is simple.
A simple blown film line consists of an extruder, die, air ring, iris or bubble cage,
collapsing frame, and a winder.
3.2 Types of Blown Film Lines Machines
a) Monolayer Blown Film Lines Machine
b) Three layer Blown Film Lines Machine
c) Five layer Blown Film Lines Machine
3.3 Monolayer Blown Film Lines Machine
3.3.1 Introduction
Monolayer Blown Film Lines Machine is one type of Blown Film Line machine which is
used to produce a one layer film. One layer film generally used for packing purpose but it
consist only one layer so it can’t be used for packing a costly material.
Monolayer Blown Film Lines Machine consist only one Extruder and one type of raw
material to produce a Mono layer film.
3.3.2 Different Raw Material Used
a) LDPE- Low Density Polyethylene
b) LLDPE- Linear Low Density Polyethylene
c) HDPE- High Density Polyethylene

Fig 3.1 Monolayer Blown Film Line Machine
Table 3.1 Technical Specification Of Monolayer Blown Film Line Machine
Description Unit Mono Layer - Blown Film Plant
CROW
N 650
CROW
N 800
CROW
N 1000
CROW
N 1250
CROW
N 1500
CROW
N 1700
CRO
WN
2500
PROCESSING DATA
Film layflat
width range
m
m
300-650 350-800 500-
1000
650-
1250
900-
1500
1000-
1700
1600-
2500
Film thickness
range
LL/LD/HD
mi
cro
n
8 – 150

MAXIMUM OUTPUT
LD Kg/hr 28-32 65-75 80-100 100-120 100-120 110-130 250-
280
LLD Kg/hr 25-28 50-55 70-90 80-100 80-100 90-110 200-
240
HDPE Kg/hr 40-45 75-85 100-120 120-140 120-140 130-150 240-
260
No. of
Extruders
1 1 1 1 1 1 1
L/D Ratio 26:1 30:1 30:1 30:1 30:1 30:1 30:1
Extruder mm 40 50 55 60 60 60 90
Motor
Rating
kW 11 30 37 56 56 56 132
Gauge
Randomisati
on
By Rotary Die (Optional)
FIXED DIE (Option of Rotary Die)
Die lip size
for LD/LL
mm 150 200 250 300 350 400 600
Die lip size
for HDPE
mm 90 110 150 175 - - -
TAKE OFF
Roller width mm 750 900 1100 1350 1600 1800 2600
Main nip
motor
kW 0.75 1.5 1.5 2.2 2.2 3.75 3.75
SURFACE WINDER
Type mm Semi
Auto
Semi
Auto
Semi
Auto
Semi
Auto
Semi
Auto
Semi
Auto
Semi
Auto
Roller width mm 750 900 1100 1350 1600 1800 2600
Additional
nip motor
kW 0.75 1.5 1.5 1.5 1.5 1.5 1.5

Winder
drive motor
kW 0.75 1.5 1.5 1.5 1.5 1.5 1.5
Max. wound
diameter *
mm 500 600 600 600 600 600 600
Line speed mtrs /
min
8-80 8-80 8-80 8-80 8-80 8-80 8-80
Option of single station or double station
OPERATING REQUIREMENT
Total
connected
load
kW 30 72 83 112 120 125 210
Total Space
requirement
(L x W x H)
m 5x5x5 11x4x7.
5
11x6x7 14x7x7 14x8x10 15x7x13 22x8x1
2
3.3.3 Application
a) Shopping bags, Grocery bags, T-shirt bags etc.
b) Liners & lamination film for Aluminum foil, jute paper and board
c) Liner for woven sacks, Cans and other industrial needs
d) Refuse bags, diaper films, packaging of diary product
3.4 Three layer Blown Film Lines Machine
3.4.1 Introduction
Three layer Blown Film Lines Machine is one type of Blown Film Line machine which is
used to produce a Three layer film.
3.4.2. Different Raw Material Used
d) Nylon

Fig 3.2 Physical view of Three layer Blown Film Lines Machine
Fig 3.3 Stationary multi-layer die

Fig 3.4 Nomenclature of Three layer Blown Film Lines Machine
Table 3.2 Technical Specification Of Three Layer Blown Film Lines machine
Description Unit 3 Layer Non IBC
DUKE
1250
DUKE
1500
DUKE
1700
DUKE
2100
PROCESSING DAT
Film layflat width range Mm 600 - 1250 900 - 1500 1000 -
1700
1400 –
2100
Film thickness range LL/LD/HD Micron 20 – 150
MAXIMUM OUTPUT
LD-LD-LD Kg/hr 180 - 200 200 - 220 220 - 240 220 – 240
LLD-LLD-LLD Kg/hr 160 - 180 180 - 200 200 - 220 200 – 220
HD-LD-HD/LD Kg/hr 170 - 190 190 - 210 210 - 230 210 – 230
No. of Extruders 3 3 3 3
L/D Ratio 30:1 30:1 30:1 30:1

3.4.3 Application
a) Milk film
b) Rice packaging
c) Tomato catch up packaging
d) Liquid packaging
Extruder Options 1 Mm 50/50/50 55/55/55 55/55/55 55/55/55
Extruder Options 2 Mm - 50/60/50 50/60/50 50/60/50
Extruder-Motor Rating for
Option 1
kW 22/22/22 30/30/30 30/30/30 30/30/30
Extruder-Motor Rating for
Option 2
kW - 22/45/22 22/45/22 22/56/22
Gauge Randomization Through Oscillating Table / Reversing Haul off
DIE
Die lip size Mm 300 350 375 425
TAKE OFF
Roller width Mm 1350 1600 1800 2200
Main nip motor kW 2.2 2.2 2.2 2.2
TWO STATION SURFACE WINDER - XTRA FLEX
Type Mm Semi-Auto Semi-Auto Semi-Auto Semi-
Auto
Roller width Mm 1350 1600 1800 2200
Additional nip motor kW 1.5 1.5 1.5 1.5
Winder drive motor kW 1.5 1.5 1.5 1.5
Max. wound diameter * Mm 600 600 800 800
Line speed mtrs/min 8-80 8-80 8-80 8-80
Total connected load for Option
I
kW 146 172 175 194
Total Space requirement
(L x W x H)
M 16x10x12 15x10x13 16x10x12 18x10x14

3.5 Five layer Blown Film Lines Machine
3.5.1 Introduction
A Five layer Blown Film Lines Machine consist five Extruder and five type of raw
material to produce a five layer film.
Five layer Blown Film Lines Machine is one type of Blown Film Line machine which is
used to produce a five layer film. One layer film generally used for packing purpose but it
consist only five layer so it can be used for packing a costly material.
3.5.2 Different Raw Material Used
d) NYLON
e) MLLDPE- Metallocene Linear Low Density Polyethyle

Fig 3.5 Five layer Blown Film Lines Machine

Table 3.3 Technical Specification Of Extruder
Description Unit 5 Layer Non IBC
– PLANT
5 Layer IBC –
PLANT
BARON 1500 BARON 1500
(IBC)
PROCESSING DAT
Film layflat width range Mm 900 - 1500 1050- 1500
Film thickness range LL/LD/HD Micron 25 – 150 25 – 150
Film thickness range with PA Micron 50- 150 50- 150
MAXIMUM OUTPUT
LD-LD-LD Kg/hr 180 – 200 300 – 330
LLD-LLD-LLD Kg/hr 160 – 180 290 – 320
HD-LD-HD/LD-Tie-PA or EVOH-Tie-
LD*
Kg/hr 170 – 190 260 – 280
No. of Extruders 5 5
Screw Dia Mm 55G/40/50/40/55G 60G/40/55/40/60G
Extruder-Motor Rating Kw 30/11/30/11/30 56/11/30/11/56
Gauge Randomisation Reversing Haul Off
DIE
No. of film layers 5 5
Die lip size (HM) / (LL/LD) Mm 350 400
TAKE OFF
Roller width Mm 1600 1600
Main nip motor kW 2.2 2.2
SURFACE WINDER
Type Mm Semi Automatic Semi Automatic
Roller width Mm 1600 1600
Additional nip motor kW 2.6 2.6
Line speed mtrs/min 8 – 80 12 – 120
Total connected load for option I kW 265 343

Fig. 3.6 view of five layer die
3.5.3 Application
a) Frozen meat and fish packaging
b) Edible oil packaging
c) Coffee packaging
d) Almond oil packaging
3.6 Working of Blown Film Lines Machine
A typical film blown film machine consists of the following five major units:
a) Extruder unit—converts the solid pellets into hot melt.
b) Die unit—forms the hot melt into tube.
c) Cooling unit—cools down and solidifies the hot melt.
d) Take-off unit—pulls and flattens the tube at constant speed.
e) Winding unit—winds-up the flattened tube into finish rolls

Fig 3.7 Working of Blown Film Lines Machine
Blown films are created by feeding plastics pellets into an extruder where they are melted
and homogenised before they are pumped through a circular blown film die.
The melted plastics form a continuous tube which is drawnfrom the die. It is inflated and
simultaneously cooled by rapidly moving air.
The tube, also called a ―bubble,‖ is then flattened as it passes the collapsing frames and
drawn through nip rolls and over idler rolls to a winder which pulls and winds the
finished rolls of film.
3.7 Components of Blown Film Lines Machine
3.7.1 Extruder
In The Extruder Raw material is Feed through hopper in barrel and goes to feed screw
which is driven by the external device like motor and it forward the material .
During travelling the material it is heated by the heater at required temperature for
melting purpose then this melt material pumped to the die.

Fig 3.8 Extruder
3.7.2 Air Cooling Rings
Blown film air rings are used primarily to stabilize the bubble and secondarily to cool the
melt. In plastics forming, a circular manifold distributes an even flow of cool air into a
hollow tubular form passing through the manifold.
An air ring is installed just above the die in an upward air cooling blown film machine.
The air outlet called a lip (or slit) has an annular shape that surrounds the molten resin
extruded from the die. Air is introduced into the ring by the blower, and the air is turned
into a uniform flow inside the air ring. Then the air is blown through the lip against the
molten resin for cooling
If the flow of air blown out of the lip is not uniform, it leads to non-uniform cooling. As a
result, film thickness will be uneven. To prevent this, the air ring is designed to ensure
uniform air flow over the entire lip.As the molten resin is cooled, it becomes ―frosty,‖ or
less clear (transparent), and a solidification border appears. This borderline is called a
frost line.

Fig 3.9 Air Cooling Ring
3.7.3 Die Unit
Use: Die is used to produce required dimensional bubble.
Feature:
a) Universal spiral mandrel die designs
b) Stream lined flow path to ensure faster change over
c) CNC machining to ensure highest precision
d) All flow surfaces mirror polished to eliminate
e) degradation of plastic melt
f) A Unique designed flow path to achieve differential
g) Low profile die design with spiral mandrel, easy assembly and cleaning
h) Single to dual melt channel distribution
i) Fully open die center, maximize Internal Bubble Cooling(IBC) cooling capacity
j) Strong self-cleaning, shortest purging time
k) No port lines, no layer leakage
l) Low pressure drop

3.7.4 Calibration Baskets-Options
Use: it used to calibrate the bubble dimensional
Feature:
a) Standard cage for Duke lines
b) 9 point contact type motorised cage for IBC standard lines
c) Scissor design multipoint contact cage
d) Universal spiral mandrel die designs
e) Stream lined flow path to ensure faster change over
f) CNC machining to ensure highest precision
g) All flow surfaces mirror polished to eliminate degradation of plastic melt
h) A Unique designed flow path to achieve differential layer ratio effectively
Fig 2.10 Calibration Baskets
3.7.5 Take Off Assembly
Use: it used to take off the bubble to haul off unit.
 Reversing Haul Off
a) For all standard lines, reversing haul off forms am integral method for gauge
randomization
b) Horizontally designed take off available up to 3000 mm roller width
c) Variable frequency A.C. drive for nip
d) Synchronized drives
e) Water cooled nips(Optional)

 Features
a) Rigid structure & longer support guides the bubbles at higher output & line speed
b) Operator friendly frame setting
c) PBT bushes as standard
d) Option of Aluminum rollers available for specific application
e) Option of motorized adjustment of slats
Fig 3.11 Take Off Assembly
3.7.6 Haul Off Unit
Use: it used to control the gauge variation of film.
 Features
a) For all standard lines, reversing haul off forms an integral method for
gauge randomization
b) Horizontally designed take off available upto 3000mm roller width
c) Variable frequency A.C. drive for nip
d) Synchronized drives
e) Water cooled nips (optional)

Fig 3.12 Haul off assembly
3.7.7 Film Winders
Use: it used to wind the produced film.
 Fully automatic winders
a) Winding capacity - 1000 mm /1000 Kg
b) Line speed – Max. 150 m/min
c) Automatic reel change over and automatic web cross-cutting mechanism
d) Pneumatic Shaft (4 nos)
e) Expander roller – Poly band /Banana
f) European gear drives
g) Load cell for tension control
h) Vector flux drive in closed loop
i) Hydraulic lowering of wound roll

Fig 3.13 Winders
3.7.8 Semi Automatic Winders
a) Two station semiautomatic surfacewinders.
b) Online reel changeover withoutany wastage
c) Bow roller provided as expanderroller
d) Option of Auto-tension control
e) Ultra sonic sensors for IBC control
f) Gravimatric dozing or batch blending with yield control
g) Fully automatic thickness and measurement

Fig 3.14 Winders

Chapter-4
DIE SHOP
4.1 Type’s of die for film
(1) Side feed die.
(2) Center feed die.
(3) Spiral die.
4.2 Main parts of film die
1. Inner mandrel:-
It manufactured on CNC machine. It is placed inside the die body. Its function is to
maintain the uniformity of material. It also maintains the flow and quantity of material. It
makes material to flow with equal speed and distribution.
2. Middle mandrel:-
It joins outside of the inner mandrel and inside of the die body. It also maintains flow and
quantity of material. It makes material to flow with equal speed and distribution.
3. Outer mandrel:-
It joins outer side of outer mandrel and inside of inner mandrel. And maintains flow and
quantity of material. It makes material to flow with equal speed and distribution.
4. Die body:-
It comes after the die elbow top. It acts as the outer cover of the die. It is based on which
all the components are supported. On its outer surface the ceramic heaters are mounted.
5. Die body extender:-
It comes after the die body. Its functions are to provide. The extra projection for the die
cover. Heaters are provided on it.
6. Inner mandrel extender:-
It is provided on the other side of inner mandrel. No heaters are provided on its surface.
HRC finishing i.e. High resistances chroming provided to achieve smooth surface.

7. Mandrel lip:-
It comes on the inner mandrel extension flow passes on the of the mandrel lip so it is
necessary to provide the smooth surface on the outer surface so the material passes
smoothly.
8. Mandrel lip extender:-
It comes on the mandrel lip. The smooth surface is provided on this surface also.
9. Die ring:-
It comes over mandrel lip and after the die body extension. It forms the outer surface of
the pipe extruded. And ceramic heaters are provided on it.
10. Die elbow:-
It joins on inner mandrel degree of holes are provided on it. It provides material to Inner,
middle & outer mandrel by degree holes and grooves on it.
11. Elbow:-
Elbow top joins on it. It consists of degree holes. It provides material to elbow top. And
extruders are connected on the degree holes on the elbow.
12. Plug:-
Plug joins inside the elbow it converts the horizontal flow of the material coming from
the extruders to the vertical direction.
4.3 Main parts of blow die
1. Die body:-
It comes after the die elbow top. It acts as the outer cover of the die. It is based on which
all the components are supported. On its outer surface the ceramic heaters are mounted.
2. Spiral mandrel:-
It is inside the body its function is to maintain the uniformity of the material. It maintains
the flow and quantity of the material. It makes the material flow with equal speed and
equal distribution.

3. Plunger:-
Its functions are to rise under the pressure of the material trapped. Before assembling the
plunger it is nitrated. It comes inside the spiral. And connected to the bottom plate.
4. Shaft:-
Its function is to support the plunger its bottom part is thread and the top part is connected
with top plate.
4.4 Die assembly
The parts of die are assembled with special precautions. For each part following
procedures is carried out to assemble:-
a) First the parts which to be assembled are clean with the cloth and then this parts
are cleaned with the help of kerosene.
b) If the holes and spiral is there it is polished. For polishing air cooled tools are used
with different grade papers the polishing is done some times small grinding
wheels are also used.
c) After the parts are cleaned they are sent for other nickel coating or the hard
chrome coating.
d) After the plating parts are once again cleaned with cloth and once again cleaned
with kerosene.
e) After this on matting surface the lapping process is carried on as the lapping
material used is silicon carbide is used. As after this one part is rotated under
pressure on another.
f) After this the link is applied on the surface and once again rotated under pressure
to ensure the leak proof joints of the parts.
g) After this the silicone gel is applied on the matting surface
h) Then the blots are taken and on there surface copper paste is applied and they are
used for assembling purpose.
i) The filler gauges are used to measure the gap between the die. And the bolts are
tightened in such manner that the gap is automatically maintained. And controlled
easily.

Chapter-5
NORMALIZING
5.1 Introduction
Normalizing or air quenching consists in heating steel to about 40-50 C above its upper
critical temperature and, if necessary, holding it at that temperature for a short time (570
C temp. upto 5 to 7 hours) and then cooling in still air at room temperature.
Normalizing differs from full annealing in that the rate of cooling is more rapid and there
is no extended soaking period. The type of structure obtained by normalizing will depend
largely on the thickness of cross section as this will affect the rate of cooling. Thin
sections will give a much finer grain that thick section.
Normalizing produces microstructures consisting of ferrite (white network) and pearlite
(dark areas) for Hypocutectoid (i.e., up to about 0.8% C) steels.
Fig 5.1 Normalizing process

5.2 Purpose of Normalizing
a) Produces a uniform structure.
b) Refines the grain size of steel
c) May achieve the required strength and ductility in a steel that is too soft and
ductile for machining,
d) Reduces internal stresses.
e) Improves structures in welds.
f) Produces a harder and stronger steel than full annealing.
g) In general, improves engineering properties of steel.

Chapter-6
NITRIDING SHOP
6.1 Nitriding shop
 In this mainly two process are carried no which, are as follows:-
a) Electrodes nickel plating.
b) Nitriding process.
 Brief description on this is as follows:-
6.1.1 Elecrodes nickel plating
In this process the nickel plating is done without passing any current. In this only air is
passed.
6.1.2 Advantages:-
Electrodes is the process in which the plating is take place equally on each and every part
which is immersed in the solution.
Solution:-
 Nickel sulphate(820n)
 Composition:- -> Nickel 92%
 Sulphur 7%
 Other impurities 1%
6.1.3 Purpose of the process:-
 The main purpose of this surface to get mirror polish on the component through
which the plastic material passes.
 All flow surface mirror polish to eliminate the degradation of plastic material.
6.1.4 Procedure:-
First the components are cleaned with the help of degasser.
a) After this the parts are put in to liquid bath.

b) In this jobs are heated at 75 c.
c) During this D.C.current is passed through the solution and the
d) component.
e) After that the parts are cleaned with the help of water.
f) Then they are dipped into milled HCL for sometime.
1. Above two processes are repeated for three times and after those parts are
cleaned with distilled water.
2. Now the parts are dipped in to the solution. The air is passed through the solution.
The temperature is kept 70-90 c. for 45u plating it takes 4hours and 30minitues.
3. After this part are sent for the inspection and check finishing as well the thickness
which is in the microns.
6.2 Nitriding process
6.2.1 Definition :-
Nitriding accompanies the introduction of nitrogen into the surface of certain type of
steel (e.g. containing Al & Cr) by heating it and holding it at a suitable temperature in
cintact with partially dissociated ammonia or other suitable medium.
6.2.2 Process characteristics
o Case depth is about 0.381 mm.
o Extreme hardness (Vickers 1100).
o Growth of 0.025-0.050 mm occurs during nitriding.
o Case has improve corrosion resistance.
o 56 to 61 HRC.
Nitriding process
Before being nitride, the components are heat treated to produce the required properties in
the core.
The normal sequence of operations are:
(i) Oil quenching from between 850 and 900 C temp. followed by tempering at
between 600 and 700 C.
(ii) Rough machining followed by a stabilizing at 550 C for five hours to remove
internal stresses.

(iii)Finish machining, followed by nitriding.
(iv)40 hours for 0.25 mm and 100 hours for 0.75 mm case depth, (approximate
values).
The components are placed in a heat-resistant metal container which is then filled with
ammonia whilst cold. When it is completely purged, it is sealed, placed in a furnace and
raised to a temperature of approximately 500 C.
Parts are maintained at 500 C for between 40 to 100 hours depending upon the depth of
case required; after which the parts are allowed to cool in the container.
6.3 Advantages of Nitriding
a) Very high surface hardness of the order of 1150 VPN may be obtained.
b) Good corrosion and wear resistance.
c) Good fatigue resistance.
d) No machining is required after nitriding.
e) Some complex parts which are not carburized satisfactorily can be nitride without
difficulty.
f) The process is economical when large number of parts are to be treated.
g) Since nitride parts are not quenched, this minimizes distortion or cracking.
6.4 Disadvantages of Nitriding
a) Long cycle time (40 to 100 hours).
b) The brittle case.
c) Only special alloy steels can be satisfactorily treated.
d) High cost of nitriding prosses.
e) Technical control required.
f) If a nitride component is accidentally overheated, the surface hardness will be lost
completely and the component must be nitride again.

6.5 Typical Uses
* Extrusion machine screw. * Bushing.
* Extrusion dies. * Journals.
* Gears. * Mandrills.
* Guides * Some basic parts/components etc.
6.6 Purpose of nitriding process:-
a) To obtain high surface hardness,
b) To increase the wear resistance.
c) To improve fatigue life.
d) To improve corrosion resistance

CONCLUSION
So this is all about the learning’s at WINDSOR MACHINE within 45 DAYS. To do my
summer training in Windsor machine was a phenomenal learning experience for me. This
one month was a joy ride for me in the mechanical field, and now on completion of my
training I can say that I have gained very sound knowledge in mechanical field.

SAFETY MEASURES
a) Always wear helmet for protection of head.
b) Always wear spectacles for protection of dust
c) Wear dust mask to protect dust from entering nose.
d) Wear gloves while doing oily work.
e) Always wear shoes to protect our self from electric shock.

REFRENCES
a. www.windsormachines.com
b. www.wikipedia.org
c. www.techno.net
d. www.nitrex.com
e. www.grahamengineering.com
f. www.rockwellautomation.com

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