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GEMINI FLAVOUR SYSTEM
For Twin track and single track Cigarette and Filter Makers
The new Gemini flavour application system provides a solution for every type of on-line flavour application in cigarette and filter manufacturing. Twin track or single track application from a single unit. Mobile for transfers between different making lines. Choice of 7 application points. Innovative with pulsing application.
Available as either single or twin track variants.
Kaymich's 'Gemini' products have been designed to apply an extensive range of liquid flavours through various in-line application points in the cigarette manufacturing process including paper, filter, tobacco rod and packing foil via a rewinder.
The twin track unit can be configured for either single or twin track application.
A single track unit can be upgraded to a twin track unit via a twin track upgrade kit.
Flavour outlets are independently controlled and monitored to enable consistent flavour delivery.
The system is capable of supplying up to 300ml of flavour per track per minute, with delivery proportional to making machine speed.
Kaymich's 'Gemini' product range is compatible with menthol and other flavours.
CE compliant
Accurate to within 1% or min 0.2mg/rod of target dosage. Gemini employs fully sealed gear pumps to deliver accurate consistent flow.
The "Gemini" system provides:
- Accurate and consistent application
- On-line monitoring
- Clean application
- Production versatility
"Gemini" offers many new benefits and features aiding today's demanding production requirements.
Features
- Two independently controlled flavour outlet ports (twin track variant)
- High capacity twin sealed tanks. 50 litres per tank
- Intelligent configurable control system
- User configurable flavour temperature
- Choice of application points
- Pulsing (intermittent) application (optional)
- Data Collection and Data Logging (optional)
- Automatically controlled, built-in agitation system)
- Drain facility
- Easy access to aid servicing and maintenance
- Multi-lingual user interface
- Quick release self-sealing connections)
Benefits
- Twin track application from one unit
- Versatile application
- Rapid melt
- 300ml/min per track pumping capacity
- Easy access panels for servicing and maintenance
- User configurable open- or closed-loop flow control
- Process and product traceability
- Mobile, versatile unit can be moved from maker to maker
- In-builr heating system enables application of pure menthol, eliminating the need for carrier fluids
- Backward compatible with existing Kaymich applicators
- Integrated flow meter verifies the application dosage is within tolerance
- Large touch screen HMI provides user friendly animated icons and clear optional settings.
- In- built multi-lingual display assists easy operation
- Integrated trouble shooter aids maintenance
- User configurable units of measurement provide ease of operation and compatibility
- On screen keyboard for convenient entry of text or numeric values
- Flavour application proportional to machine speed
- Rapid brand change reduces set-up time
- Two tank design enables continual flow whilst replenishing flavours
- Accommodates a wide range of flavours.
- Wide choice of application points provides production versatility and accommodates product design.
Performance Characteristics
- Maximum capacity: 50 litres per tank
- Temperature control range: Ambient to 70°C
- Standard flow rate: 300ml/minute
- Gemini dimensions: H=1000mm,W=1400mm, D=650mm
- HMI Dimensions: 420mm x 375mm x105mm
Services Required:
- Air: Dry, filtered non lubricated - 60 to 100 psi (4 to 7 bar)
- Electrical: 415Vac 50/60Hz (three phase with neutral and earth
Flavour specification
- Typical flavour application could include Menthol (crystal or solution), Mint, Fruit, Clove, Vanilla, Liqueurs flavouring.
- Menthol crystals, natural or synthetic
- Viscosity, not critical
- Other flavours may also be applied. Please contact Kaymich to confirm compatibility.
Paper Applicator
Application onto the paper on the cigarette maker is generally acceptable for dosages up to 6mg per cigarette. Up to this dosage the tobacco is capable of absorbing the flavour directly from the paper.
Tobacco Applicator
For higher dosages (above 6mg per cigarette) Kaymich recommends application is made into the tobacco stream. A unique applicator design ensures that an accurate dosage of flavour is distributed evenly across the stream, allowing the effective absorption of the full flavour dosage.
Into the tobacco on the cigarette maker (Suction Chamber) (for above 6mg/cigarette)
For higher dosages (above 6mg per cigarette) Kaymich recommends application is made into the tobacco stream. A unique applicator design ensures that an accurate dosage of flavour is distributed evenly across the stream, allowing the effective absorption of the full flavour dosage.
Filter applicator
Gemini' uses the manufacturer's stuffer jet with the flavour applicator mounted on the tow funnel. Flavour is dispensed through a hollow needle into the heart of the filter tow. When the machine receives a stop signal, the needle is retracted from the tow and rests within the valve body. The application point is positioned directly in the centre of the moving tow where the filter paper and tow are rolled forming the rod. This ensures that liquid flavour is completely encapsulated, maximising flavouring efficiency and minimising making machine and atmospheric contamination
Onto thread on the filter
The filter thread option is a heated applicator, designed to allow flavour loading of a textile yarn (thread) for direct incorporation into the Filter Tow. Simply enter the end of the thread into the receptor and press the red button on the front of the applicator. The thread will be transported through the nozzle, ready for use.
The adjustable-height feed nozzle allows the thread to be placed centrally in the tow. Once set-up, the fine adjustment can be locked off to ensure consistent and repeatable positioning.
Onto foil Rewind Unit for pre-mentholated foil
Option to apply pure flavour to foil on a re-wind unit to enable manufacture of pre-flavoured foil
Options
Data Collection
Data Collection is a software feature providing remote access via Ethernet to 'Gemini' and the making machine's "live" information.
'Gemini's Human Machine Interface (HMI) is fitted with an Ethernet socket enabling connection to an existing network or stand alone PC. 'Gemini' and maker data is transferred over the Ethernet (TCP/IP) using an OLE for process control (OPC) communication protocol. The HMI acts as an OPC server while the factory network's PC/servers act as OPC clients.
Data Collection allows the user to access a wide range of 'Gemini' information from a remote location. Typical parameters that can be monitored include temperature settings, heated zone temperature measurements, dosage, tank levels, brand selection, maker speed, stop and start times, reasons for last stop and many more. In fact, all settings and machine status parameters are published via the OPC link.
Using the 'Data Collection' feature, users owning a number of Kaymich flavour systems have the advantage of managing several production lines from one remote PC.
Requirements
- OPC client configured to collect and store data from 'Gemini'
- One available Ethernet network connection per 'Gemini' flavour unit
- Network security configuration
Pulsing Or Intermittent Application
Quick pulsing applicator output for example can be used to provide flavoured and unflavoured sections at regular positions within a rod.