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Contact: +44 (0)114 2446071

Success through innovation

Product:

Foil Mentholator System.

Application:

The Off-line application of flavour onto reels of foil or other materials.

Overview:

The Kaymich Foil Mentholator Unit is designed to unwind reels of aluminium foil and apply an accurate dose of molten menthol or cold flavour to the tissue side of the foil, before rewinding the foil onto a reel, ready for the packing process.

This new system is designed to be faster, cleaner and easier to use than traditional rewind systems, without sacrificing quality or accuracy.

This self-contained device is capable of processing high volumes of tissue backed foil, primarily intended for the application of menthol, from both crystals and alcohol suspension

Modular design with many optional features resulting in bespoke system to meet the end user needs.

The flavour is applied to suit the substrate and flavour dosage requirements and capable of applying flavour across a variety of widths. The Mentholator Unit has an optional traceability output system that comprises a display on the control panel and label printer; this provides live information and a printed record of machine data for the operator.

The Mentholator Unit features includes high capacity tank to provide long production runs between re-fills and the unit is available with heated or cold application options, depending upon the application requirements.

The applicator head is positioned at approximately head height and is configurable. Variable width and variable flow control across the width of the paper can be provided for.

Mid-height bobbin positioning eliminates un-necessary bending by the operator and the optional mechanically assisted loading feature makes bobbin loading and unloading easy.

The unit itself is fully enclosed, with a large viewing window enabling everything to be seen internally. The large easy access panels at the front and rear of the unit provide easy access for operation, cleaning and maintenance.

KEY FEATURES

STANDARD COLD SPECIFICATION

The concept behind the system is a modular unit that can be configured to precisely meet the needs of the individual customer. The following features are standard to each unit:

  • SYSTEM • Modular design. • Easy maintenance. • Fully safety interlocked. • Emergency stop switch. • Extraction and positive air displacement.
  • PUMP/FLUID PATH • Cold flavour application, including alcohol based mediums. • Variable flow / dosage rate. • Accurate flow, giving an application tolerance of +/– 3% mg/mm. • Liquid is dispensed proportionally to machine speed. • Self-cleaning feature. • Flow control. • Sensors to detect problems with flavour delivery. • Tank level sensors.
  • APAPER PATH/BOBBIN HANDLING • Rewind speeds up to 300m/min. • Automatic tensioning. • Servo drives and take up with automatic tensioning / clutch. • Automatic chuck. • Variable foil widths. • Variable bobbin lengths. • Variable process speed. • Soft ramp up and ramp down. • Compact paper path. • Minimal paper wastage. • Anti-vibration system, including speed fall off / shutdown if outside of safe limits. • Ability for user to manually input bobbin parameters. • Bobbin diameter measurement on out feed and take-up spools. • Easy loading and unloading. • Easy brand change. • Manual foil-splice station.
  • APPLICATOR • Fully configurable application pattern, not just width but different amounts in different areas.
  • ATEX • ATEX compliant. • Separate ATEX zone. • Alcohol Gas sensors (for cold application of alcohol based flavour).
  • CONTROL • Touch screen computer control. • Audible process warnings. • Visual process status, three colour totem, mimicked on computer screen. • Process status available as isolated switched outputs..

 

STANDARD HEATED SPECIFICATION

The concept behind the system is a modular unit that can be configured to precisely meet the needs of the individual customer. The following features are standard to each unit: SYSTEM • Modular design. • Easy maintenance. • Fully safety interlocked. • Emergency stop switch. • Extraction and positive air displacement..

 

PUMP/FLUID PATH

  • Heated flavour application, from heated tanks for flavour preparation throughout fluid path to applicator.
  • Variable flow / dosage rate.
  • Accurate flow, giving an application tolerance of +/– 3% mg/mm.
  • Liquid is dispensed proportionally to machine speed.
  • Flow control.
  • Sensors to detect problems with flavour delivery.
  • Tank level sensors.

 

PAPER PATH/BOBBIN HANDLING

  • Rewind speeds up to 300m/min.
  • Automatic tensioning.
  • Servo drives and take up with automatic tensioning / clutch.
  • Automatic chuck.
  • Variable foil widths.
  • Variable bobbin lengths.
  • Variable process speed.
  • Soft ramp up and ramp down.
  • Compact paper path.
  • Minimal paper wastage.
  • Anti-vibration system, including speed fall off / shutdown if outside of safe limits.
  • Ability for user to manually input bobbin parameters.
  • Bobbin diameter measurement on out feed and take-up spools.
  • Easy loading and unloading.
  • Easy brand change.
  • Manual foil-splice station.

 

APPLICATOR

• Fully configurable application pattern, not just width but different amounts in different areas.

 

CONTROL

  • Touch screen computer control.
  • Audible process warnings.
  • Visual process status, three colour totem, mimicked on computer screen.
  • Process status available as isolated switched outputs.

 

OPTIONAL FEATURES TO BE SPECIFIED AT TIME OF ORDER (subject to additional cost)

  • Label Printing – basic level. Black and white printer for the production of labels to apply to bobbins on completion. An entry level system that enables the printing of basic labels to mark and identify bobbins, post flavour application.
  • Label printing - advanced. Upgraded black and white printer with hand held barcode reader. A higher specification system that utilises barcode technology to identify bobbins, retain brand settings and run production through the Foil Mentholator.

The use of barcode technology can significantly reduce downtime during brand change over, as well as facilitating the stock handling of flavoured bobbins.

  • Auto Recognition for Foil Width A fail safe option to ensure correct brand setting with materials.

The width of foil is constantly checked during operation and compared against brand settings. This checks that the correct bobbin has been loaded for the programme in use.

Disparity results in machine stop.

The potential for machine contamination due to incorrect brand settings and manufacture of out-of-specification bobbins is eliminated.

  • Easy Load, Mechanically Assisted bobbin load and unload procedure.

A manually operated, mechanically assisted mechanism to reduce physical stress or strain during the loading and unloading procedure. The system provides a means of transport of bobbins around the factory and mechanical assistance for removing flavoured bobbins/loading unflavoured bobbins to the Mentholator.

  • Tank Agitator In-built agitation system for blended liquids. The agitation system will maintain a homogenous mix and ensure that there is no separation of flavour solids from the carrier solution due to settling. 

 

ADDITIONAL OPTIONAL FEATURES AVAILABLE ON REQUEST (subject to additional cost).

 

SYSTEM

  • Standalone oven for either pre-heating bobbins prior to processing or for heating prior to use on packer.
  • Vacuum sealing device for processed bobbins.
  • Paper storage for pre or post process.

 

PUMP/FLUID PATH

  • Feedback monitoring of applied flavour verses amount consumed as a process safeguard.

 

PAPER PATH/BOBBIN HANDLING

  • Bobbin diameter measurement on out feed and take-up spools.

 

APPLICATOR

  • Post application drying.
  • Application sensor.

 

CONTROL

  • Wired and Wi-Fi network capable.
  • Data logging of all process / operational parameters.

The Kaymich Foil Mentholator