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Contact: +44 (0)114 2446071

Success through innovation

FAQs

CSS1000 Cigarette Side Seam System - Gravity

APPLICATOR

Can the nozzle be replaced as a single part?
No. The needle and nozzle are machined as a matched pair to ensure the integrity of the seal.

Are the nozzles available with different diameter outlet?
Yes. 0.8mm, 1.0mm, 1.5mm and 2.0mm as standard, other sizes on request

How can we determine the correct replacement needle and nozzle?
The simplest way is to provide Kaymich with the applicator serial number located in the keyway. Otherwise confirmation of the nozzle diameter and host making machine is required.

GRAVITY

How do we adjust the amount of adhesive applied to the cigarette rod?
The flow rate of the adhesive is controlled by the rear adjuster on the applicator; this determines the distance the needle retracts from the nozzle and hence, adhesive flow.

Is the application relative to machine speed?
Yes, the Venturi pressure drop principle is created by the cigarette paper and air passing over the end of the nozzle. It is therefore self-regulating.

What types of glue can be used?
Synthetic resin emulsion – PVA or EVA, viscosity range 150 – 1500 centipoise with solids content 45% to 55%.

What making machine speed can the system handle?
Depending upon materials, up to 8000cpm.


CSS1000 Cigarette Side Seam - Pump

APPLICATOR

Can the nozzle be replaced as a single part?
No. The needle and nozzle are machined as a matched pair to ensure the integrity of the seal.

Are the nozzles available with different diameter outlet?
Yes. 0.8mm, 1.0mm, 1.5mm and 2.0mm as standard, other sizes on request

How can we determine the correct replacement needle and nozzle?
The simplest way is to provide Kaymich with the applicator serial number located in the keyway. Otherwise confirmation of the nozzle diameter and host making machine is required.

PUMP

How do we adjust the amount of adhesive applied to the cigarette rod?
The amount of adhesive applied can be adjusted in the controller by inputting a value in units of cc/1000cigs or cc/1000m.

Is the application proportional to machine speed?
Yes, an optical encoder is fitted to the machine that gives 300 pulses per cigarette.

What types of glue can be used?
A wide range of PVA and Starch based adhesives.

Does the system apply more adhesive when the rod maker is accelerating to full speed?
Yes, an over feed function within the controller allows the user to specify exactly how much extra glue is required. This amount is also proportional to machine speed.

Does the system need to be calibrated?
Only when a different adhesive is used. The process takes less than 5 minutes to complete.

What making machine speed can the system handle?
The latest software can process machine speeds of up to 20,000 cpm.


Cigarette Side Seam - Mini Applicator

Can the nozzle be replaced as a single part?
No. The needle and nozzle are machined as a matched pair to ensure the integrity of the seal.

Are the nozzles available with different diameter outlet?
Yes. 0.8mm, 1.0mm, 1.5mm and 2.0mm as standard, other sizes on request

How can we determine the correct replacement needle and nozzle?
The simplest way is to provide Kaymich with the applicator serial number located in the keyway. Otherwise confirmation of the nozzle diameter and host making machine is required.

How do we adjust the amount of adhesive applied to the cigarette rod?
The flow rate of the adhesive is controlled by the rear adjuster on the applicator; this determines the distance the needle retracts from the nozzle and hence, adhesive flow.

Is the application relative to machine speed?
Yes, the Venturi pressure drop principle is created by the cigarette paper and air passing over the end of the nozzle. It is therefore self-regulating.

What types of glue can be used?
Synthetic resin emulsion – PVA or EVA, viscosity range 150 – 1500 centipoise with solids content 45% to 55%.


GFH Gravity Fed Hot Melt Systems

APPLICATOR

Can the nozzle be replaced as a single part?
No. The needle and nozzle are machined as a matched pair to ensure the integrity of the seal.

Are the nozzles available with different diameter outlet?
Yes. 0.8mm, 1.0mm, 1.5mm and 2.0mm as standard, other sizes on request

How can we determine the correct replacement needle and nozzle?
The simplest way is to provide Kaymich with the applicator serial number located in the keyway. Otherwise confirmation of the nozzle diameter and host making machine is required.


GRAVITY FED HOT MELT

How do we adjust the amount of adhesive applied to the filter rod?
The flow rate of the adhesive is controlled by the rear adjuster on the applicator; this determines the distance the needle retracts from the nozzle and hence, adhesive flow.

Is the application relative to machine speed?
Yes, the Venturi pressure drop principle is created by the cigarette paper and air passing over the end of the nozzle. It is therefore self-regulating.

What types of glue can be used?
Hot Melt Adhesive, high tack, fast setting. – Viscosity range 1000 – 5000 centipoise with solids content 45% to 55%.

What filter making machine speed can the gravity fed system handle?
Depending upon materials, up to 500 metres/minute.

What temperature hot melt does it work with?
Anything up to 200 degrees Celsius

What line combinations can we have?
One hot melt, plus one secondary PVA line, plus anything from 1 to 6 lines for tow retention. Can also be used in combination with Spray Tow system if required.

How do we ensure the flow of hot melt is correct?
The paper draws away as much of the adhesive as it can carry in a narrow defined line, therefore minimising chances of bleed through.

What services are required?
220Vac input only. 5 Bar air pressure.


FTS Filter Spray Tow Retention System

Can the FTS system be used with multi segments filter?
Yes.

Can the FTS be used with the Kaymich GFH system?
Yes the FTS system can be sold as part of the GFH system or as a stand-alone applicator.

Can the FTS system be installed by the customer?
Yes, the system is easy to install. Optimum setting is dependent upon the machine speed, adhesive and paper used.

Note: 

Application not proportional to machine speed, application pattern set for optimum operating speed only.
Minimum adhesive viscosity 500 centipoise.
Maximum adhesive viscosity 1500 centipoise.
Not to be used with lubricated air supplies.


PST Proportional Spray Tow Retention System

What does the system comprise?
• Applicator • Mounting bracket • HMI • Speed sensor/encoder • Control box including air regulators for spray air and adhesive air. • Adhesive pump Assembly • Adhesive tank

What is the minimum width pattern the system is able to produce?
We have successfully produced consistent patterns as narrow as 3mm. It may be possible to reduce this further subject to materials (adhesive and paper) and machine speed.

What is the diameter of the applicator orifice?
The applicator nozzle has an Ø0.8mm orifice.

What adhesive specification can be used?
Typically PVA adhesive between 500 – 1500 centipoise, solids content 20% - 50%. Adhesive specification is key to acheiving the desired results. HB Fullers IPACOLL LP2934B has recently been successfully used in extended tests.

Can the system be integrated into the maker controls?
No, not currently.

Can the PST system be used with multi segment filters?
Yes.


Gemini

Can I use the twin track option with a single track making machine?
Yes, the Twin track unit can be used on either single or twin track making machines.

Can I upgrade a single track Gemini to a twin track Gemini at a later date?
Yes, it is possible to do so.

Can I apply flavour onto two different making lines using a twin track Gemini?
No. This is not currently possible.

Can I apply the same type of flavour at two different points on one host machine?
The Gemini twin track option is capable of applying the same flavour and the same dosage at two different points on one making machine.

What type of control system is the Gemini supplied with?
The HMI is an Industrial PC enclosed in a compact brushed stainless steel cabinet.The Kaymich application is proprietary software that provides a visual interface to monitor process parameters and enables the user to modify control parameters. The HMI is also used to collect run time data so that all production process data may be monitored at a later date.

Can I apply two different flavours on the same maker using a twin track Gemini?
Applying two different flavours is currently not possible because of the fluid (flavour) path between tank, pump and applicator. Each flavour tank supplies the pump manifold, housing one or two pumps depending upon the Gemini configuration. Once the tank is exhausted flow is switched to the second tank. It is therefore not possible to apply two different flavours.

Is the flow meter fitted as standard?
Yes, a Coriolis type flow meter is fitted as standard.

What is the minimum amount of flow detectable by the flow meter?
The minimum flow detectable by the flow meter is 0.5 gram/min (500mg/minute).

What are the typical levels of accuracy achieved for flavour delivery in the suction chamber?
The Suction Chamber was the chosen applicator used during a six month validation process by one customer. The trial results confirmed that the dosage accuracy achieved during manufacture was within 1% after the ramp up period.

What is the Gemini response time from start?
The response time between the maker and the Gemini pump speed is approximately 350mS. This however does not account for the time taken for the hose and applicator pressure equalisation (response at the nozzle), this can be affected by a number of factors including machine speed; dosage; air in the hose.

What type of connector is used for the Data Collection feature?
Ethernet connector via OPC or by USB stick .

What modifications are made to the host machine for each type of applicator?
For all host machines, an encoder, junction box and cabling are installed.The modifications required then per host machine depend upon the type of applicator. The paper applicator is mounted upon the paper path prior to the garniture and simply requires some mounting holes drilling. The filter applicator is designed to mount upon the nozzle of the stuffer jet. Depending upon the type of stuffer jet some minor modifications may be required and these are usually carried out during installation. The tobacco applicator (garniture) requires the drilling of the tobacco plate to enable the applicator nozzle to be inserted and apply flavour to the tobacco rod. This work is usually undertaken during installation. The Suction Chamber Applicator is designed to mount upon the suction chamber rail to apply flavour to the tobacco rod. New rails are required , these are usually purchased by the end user and can be purchased either from the host maker or Spikker. A heater element is incorporated into the suction chamber rails and are controlled by the HMI on the Kaymich flavour system ( if the rails are from the host maker ie Hauni they supply the heaters, if the rails are from Spikker we supply the heaters) The applicator nozzles locates onto the rail via a precision bored hole and is attached to the suction chamber rail via two screws to enable applicator to be inserted precisely. Quick release self-sealing connections are fitted to both the applicator and hose, enabling the suction band to be replaced without removing the applicator. There are many variants of both the applicator and heater elements as they are bespoke to the type of maker it is fitted to, and the configuration of that maker.


Gemini Baby

Is it possible to apply heated flavour using the Gemini Baby
No. The Gemini Baby is an entry level version of the proven Gemini system and does not offer the heating option.

Can I upgrade a Gemini Baby to a heated version Gemini at a later date?
Yes, it is possible to do so.

What type of control system is the Gemini supplied with?
The HMI is an Industrial PC enclosed in a compact brushed stainless steel cabinet.The Kaymich application is proprietary software that provides a visual interface to monitor process parameters and enables the user to modify control parameters. The HMI is also used to collect run time data so that all production process data may be monitored at a later date.

Is the flow meter fitted as standard?
Yes, a Coriolis type flow meter is fitted as standard.

What is the minimum amount of flow detectable by the flow meter?
The minimum flow detectable by the flow meter is 0.5 gram/min (500mg/minute).

What modifications are made to the host machine for each type of applicator?
For all host machines, an encoder, junction box and cabling are installed.The modifications required then per host machine depend upon the type of applicator. The filter applicator is designed to mount upon the nozzle of the stuffer jet. Depending upon the type of stuffer jet some minor modifications may be required and these are usually carried out during installation. The tobacco applicator (garniture) requires the drilling of the tobacco plate to enable the applicator nozzle to be inserted and apply flavour to the tobacco rod. This work is usually undertaken during installation..


Bulk Melt System

How long does it take to heat 50kgs of menthol to liquid?
Less than one hour.While in the melting process a pressure sensor detects the level of the Liquefied menthol, Once this has reached a liquid level of 5% and the required time elapsed the recirculation valve will open and the liquefied menthol will be pumped back into the top of the tank to aid the melting process.

Can we save different heating profiles for later use?
Different heating profiles can be stored in the memory of the micro-processor controller to use again as needed.

How is the flavour transferred from the Bulk Melt System once ready for use?
This is optional to the user and specified at the time of order. Kaymich will supply anything from simple pipe outlet to a complete pump dispenser with heated hose.

What happens if the tank is not filled completely when the rapid melt option is started?
A level sensor detects a set height within the tank. If the crystals are below this set height the system enables a slow melting process. If the crystals are above the set height the system enables a Quick melting process.


Foil Mentholator System

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Modular Bench Mounted Application System

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SG Spray Valve

What is the maximum operating speed?
Currently under development but nominally 1,500 cycles per minute or 500 dots per minute.

What types of glue can be used?
Synthetic resin emulsion – PVA or EVA. Various adhesives with viscosity between 120 – 1200cps can be used, but the optimum adhesives have a viscosity of around 550cps..

How often and how easy are they to clean?
They only require that the air cap is wiped with a damp cloth at the end of an 8 hour shift..

How are the SG valves adjusted?
They use a ratchet mechanism that requires no tools to adjust. It also makes setting more easily defined, by closing the ratchet fully, then turning it out by a specified number of clicks. This makes noting the correct setting easy, e.g. 8 clicks open.


MV Miniaturised Spray Valve

How does the MV series valve, reduce the overspray?
The uniform flow of air inside the air cap provides a consistent spray atomization at the end of the nozzle. This gives a more consistent adhesive droplet size, therefore minimizing any very small particles that can be carried by air currents.

How does the MV2A6Q development improve upon this?
By providing greater control over the spray air and adhesive air, enabling finer application, reduced application and less overspray. The full extent of these improvements are still being refined and proven.

How can the MV valve work in any orientation?
The controlled air flow gives excellent transfer of adhesive from the nozzle to the substrate. This allows the valve to work in any orientation and still give good operation.

What is the maximum operating speed?
Currently under development but nominally 4,000 cycles per minute or 800 dots per minute.

Is the application relative to machine speed?
Yes, the Venturi pressure drop principle is created by the cigarette paper and air passing over the end of the nozzle. It is therefore self-regulating.

What types of glue can be used?
Synthetic resin emulsion – PVA or EVA. Various adhesives with viscosity between 120 – 1200cps can be used, but the optimum adhesives have a viscosity of around 550cps..

How often and how easy are they to clean?
They only require that the air cap is wiped with a damp cloth at the end of an 8 hour shift..

How are the MV valves adjusted?
They use a ratchet mechanism that requires no tools to adjust. It also makes setting more easily defined, by closing the ratchet fully, then turning it out by a specified number of clicks. This makes noting the correct setting easy, e.g. 8 clicks open.