1.

6 Prototype Sketch of the Machine

Concepts for designing the new shrink wrapping machine comes from the plastic surface
treatment machine shown in Figure 1.14 below.

Figure 1.14 Plastic surface treatment machine

This machine is located in the factory section of Screening and Assembly.

The function of this machine is to flame-treat plastic surfaces to lower the surface tension of
the plastic to allow for proper ink adhesion, as well as cleaning the dust and dirt on the
surface.

The type of plastic bottle used on this machine is mostly Polyethylene (PE), and
Polypropylene (PP) due to its poor bonding, because they consist of nonpolar molecules. By
rapidly applying the heat to the material surface (around 2 to 4 sec), the chain molecules are
broken and introduce the polar reactive groups and improve the wettability and adherability
of the surface.

This machine consists of slat conveyor system, with the modification of a jig fixture on top of
each slat. The movement of slats is provided by a motor, linked by belt and pulley
transmission under it. The motor for this machine is 3 phase 50Hz 380V and 220V for low
voltage and high voltage operation, respectively. Motor can provide up to the maximum
speed of 1410 RPM.

The flame is provided by an LPG tank, which moves mechanically according to the
transmission below it.

For the prototype design (AKA: Draft of Machine), it is being discussed with the Engineer to
have the heating equipment at the side of the machine. The method is tested by manually
heating the plastic film label on the surface of the bottle by two heat guns, while the bottle
surface is being rotated in the direction normal to the heat-applying direction shown in Figure
1.15 .

Figure 1.15 Concept Testing for Heating system of the Prototype

The outcome was satisfied. For the shrinkage of plastic labels, no creases occur on the upper
part of the bottle, however, some creases appear on the neck, but they are acceptable
according to the Engineer.

The quality of work for this testing, in terms of plastic label shrinking, however, depends on
the distance between the bower head and workpiece’s surface, and the speed of rotation of the
Jig fixture.

The outcome for this testing procedure is shown in Figure 1.16.

Figure 1.16 Outcome of tested product

So the heating element for the prototype design was chosen to be the heating coil in the
amount of 3 on each side of the column.
The section is separated vertically according to the shape of the sauce bottle shown in Figure
1.17 .

Figure 1.17 Section view of Heating element with bottle

Heating coils are to be mounted with the beam provided on both sides of the column at both
entrance and exit of the tunnel.

The conveyor of this machine is designed according to the plastic surface treatment machine.
Prototype is shown below in Figure 1.18 .

Figure 1.18 Isometric view of the Prototype

Heating elements are housed by the shell. Shell is to be installed at the top of the
conveyor line, connected by screw on the lateral plane.

On top of the shell is holded for the blower wheel to provide air circulation and
turbulence inside for better heat transfer, and air impinging.

Figure 1.19 Section view of the prototype

Figure 1.20 Rack and pinion

 Figure 1.21 Bottom view of the prototype

For the conveyor system. The prototype is designed to provide the rotation of the bottle as
well as moving it in the linear direction, by utilizing the rack and pinion. The rack is to be
fixed to the frame of the conveyor and remain stationary while the pinion is to be installed
and mounted on top of the jig fixture on the slats chain. The amount of pinion will be the
same as the jig fixture depending on the Engineer. This matched our concept mentioned in the
early section.

This prototype is however not on scale. The scale drawing will be applied in the next section
of designing the shrink wrapping machine parts and assemble, which would be inspected
closely with the engineer, and tested their functionality in software, and simulation to assure
that the design will give the company a solution for this work.