mall//herlan as general contractor
A genuine one-stop solution! mall//herlan supplies complete lines as well
as single machines for the production of monoblock packagings made of
aluminium for aerosol cans and beverage bottles. The production line is
complemented by the highly developed container and manufacturing process
technology.
The production line
for impact-extruded
monoblock aerosol cans
wifag//polytype group – brilliance on top
The ”workhorse“ of the
mall//herlan production lines
Mall + Herlan GmbH
Wöschbacher Straße 33
DE-76327 Pfinztal/Germany
Phone +49 721 946 010
Fax +49 721 946 01 99
[email protected]
www.mall-herlan.com
mall//herlan is a part of the swiss Wifag Polytype Group.
Technical data
CMC 200 and 250 production lines
CMC 200
CMC 250
Length x Height x Width
88 x 6 x 8 m
94 x 6 x 8 m
No. of machines
19
19
No. of cycles
200
250
No. of mandrels per mandrel wheel
12
18
No. of transfer units in the machine
2
3
Transfer motions per minute
100
84
No. of operators
4
4
Connected load, electricity
730 KW
730 KW
Connected load, gas
55 Nm³/h 65 Nm³/h Annual container production volume
60+ Mio
75+ Mio
SWITZERLAND
GERMANY
TURKEY
WIFAG-Polytype Holding AG
Fribourg/Switzerland
Mall + Herlan GmbH
Pfinztal/Germany
WIFAG Maschinenfabrik AG
Fribourg/Switzerland
Mall Herlan MB GmbH
Neuhausen ob Eck/Germany
WIFAG POLYTYPE MIDDLE EAST
MAKiNE TiC. VE PAZ. A.Ş.
Istanbul/Turkey
Polytype AG
Fribourg/Switzerland
Pagendarm BTT GmbH
Hamburg/Germany
Polytype Converting AG
Fribourg/Switzerland
ITALY
PolyMan AG
Fribourg/Switzerland
Mall + Herlan Schweiz AG
Pfyn/Switzerland
Mall + Herlan Italia S.r.l.
Seriate (BG)/Italy
OMV MACHINERY S.R.L
Parona-Verona/Italy
SWEDEN
Solna Offset AB
Järfälla/Sweden
Solna Group AB
Kalmar/Sweden
ASIA
WIFAG-Polytype China Ltd.
Hong Kong/China
Wifag-Polytype India
Marketing Private Ltd.
New Delhi/India
Polytype Asia Pacific Co., Ltd.
Chachoengsao/Thailand
NORTH AMERICA
Polytype America Corp.
Mahwah, NJ/USA
SOUTH AMERICA
Polytype South & Central
America Comercial Ltda.
Cotia - SP/Brazil
Monoblock aerosol cans:
a modern lifestyle packaging
to meet the highest standards
in the area of personal care
The CMC 200/250 production lines from
mall//herlan produce aerosol cans made of
aluminium. Aluminium slugs enter at the front, and
cans ready to be filled are the finished product at
the end of the line. These lines produce 200/250
aluminium cans per minute in a continuous process.
The CMC 200/250 is the ”workhorse“ among the
production lines. With an effective production speed
of 200/250 cpm, it boasts an annual production
volume of more than 60+/75+ million containers.
The CMC lines are mature machines known for their
reliability. This reliability and the expertise of
mall//herlan are underpinned by over 100 years of
experience in the field of mechanical engineering.
Dozens of installations on all continents – proven
and reliable technology
Turn-key lines with customized design – fit to all
plant layouts
Strong and stable extrusion process performed
by the press during each stroke movement –
production safety guaranteed
Precision cutting and high-gloss brushing in the
trimming and brushing machine – top-quality
can output
Reliable transfer systems – smooth operation
and high production output guaranteed
Energy-saving features of the decoration
process/drying oven – cost-effective
High-quality premium decoration unit with up to
9 colours – widest possible decor variety
Necking machine with variable stroke and
40 processing stations – variety of product shape
Automatic High-Speed Line
CMC 200 and 250 for the production
of Monoblock Aluminium Packages
at 200/250 pcs./minute
Operation:
Aluminium slug enters at the front and cans ready to be filled are the finished
product at the end of the line – in a single continuous process. The line consists of
three modules: The Front end produces the cylinder. In the Deco area protective
coatings and the label are applied to the can. The Back end is for necking and quality
checks, including packaging.
16
12a
12b
19
18
17
9
11
14
1
10
13
15
19 / Leak detector
Detects microleaks as
small as 50 microns. The
detector checks the bottles
in two steps:
1. The lacquer on damaged
spots is removed by
compressed air.
2. The photocell detects
when rays of light fall
into the cans. Quality
control guarantees
100 % perfect cans.
17 / Necker
In the necker, the cylindrical can body is tapered
step by step by means
of die necking. The final
step is curling of the
1" opening.
18 / The neck check
is another quality control
step: special attention is
paid to the curl.
12b / Flexstore
The accumulator ensures
non-stop production
operations by synchronising the machine speeds
and emptying the curing
ovens in the event
that the machine stops.
16 / Ovens – Dryer
Lacquers and inks are
cured in ovens, which
gives them their perfect
optical appearance and
makes them resistant to
environmental influences.
15 / Overvarnish O/V
The third machine in the
Deco area applies the
overvarnish. The O/V is
the visible finish of the
can. Next to the fact that
the O/V can give shiny
surfaces, it ensures high
output in fillers conveying
systems.
14 / Decorator
The second machine in the
Deco area is the printing
unit, which can apply up to
nine colours, ensuring the
widest possible decoration variety for monoblock
packagings made of
aluminium. The decorator
is also equipped with a
QA system for a perfect
and stable print finish.
13 / Base coater
The first machine in the
Deco area is the base
coater. This is where the
cans receive the base coat,
which is needed to protect
the can, but also serves
as a substrate for a subsequent brilliant printing.
7
12 a / Two Flexstore
accumulators
are the main components
in the Everline concept
(patent pending). If the
decoration assembly stops,
the Front end of the line
can continue to operate,
and all finished cans are
buffered in the Flexstore
12a. The area behind the
decoration assembly (Back
end) can also continue
to operate, as it receives
its cans from the filled
Flexstore 12 b. This means
that the Front end and the
Back end of the line are
never at a standstill, even
during a label change.
11 / IBO – Inside bake oven
The IBO creates the
temperatures required
by the lacquer manufacturers for interior lacquer
hardening and therefore
guarantees product safety.
10 / Inside spray machine
The inside spray machines
applies lacquer to the
inside of the can. Spray
lances are dipped into the
cans and, as the lance is
pulled out, the cans are
sprayed with internal
coating and sealed. Then
they are dried again. The
cans are now ready for
decorating.
4
6
20
20 / Packaging machine
Only cans which are
100 % fault-free are
allowed to proceed to
the packaging station. At
this machine, cans are
packed for shipping to the
filling locations. Cans can
be bundled in hexagonal
packs for subsequent
manual handling at the
filling plant.
2
8
9 / Accumulator
The accumulator ensures
non-stop production
operations by synchronising the machine speeds
and emptying the dryer
in the event that the
machine stops.
7 / Washer
In the washer, the formed
cylinders are washed
using water with a
temperature of 80° C and
a detergent additive. The
washing water is applied
in an environment-friendly
cascade.
8 / Dryer
The cans are dried inside
and outside in a dryer,
which can operate on gas
or electricity.
6 / The MHB – trimming
and brushing machine
In the trimming and
brushing machine, the
can is shortened to the
specified length. What
is important is that the
mall//herlan machine
prevents the formation of
burrs. The trimmed can
is pushed onto a mandrel
in the machine and the
surface then matt-finished
by rotating brushes.
5
5 / Pick-up system
A Pick-up system removes
the cans from the conveyor
and pushes them onto a
pin chain conveyor. The
system has a small buffer
section to decouple the
Front end from the rest of
the line.
3
4 / Ironing machine
The cylinders coming out
of the extrusion press
enter the ironing press,
where the wall thickness is
optimised and the bottom
of the cylinder is formed.
This can body shape
permits more uniform and
more lightweight cans.
3 / Impact Extrusion Press
The extrusion press turns
the slugs into cylinders
by pressing a punch into
the slug with a force
of up to 400 tons. The
aluminium becomes plastic
and flows back along the
wall of the punch.
1 / Material infeed
The raw material is a
circular blank, a so-called
slug, made of aluminium.
The slugs are filled into the
conveyor and forwarded
to the lubrication drum,
where they are lubricated,
separated and aligned for
further processing.
2 / Slug infeed
The slugs are reliably
forwarded in the direction of the press via an
adjustable active conveyor
system and a patented
chute system.