Team

ASSISTANT ViceMANAGER
Executive GENERAL
REPORT MANAGER
Manager President Vice President
G.CEO
MANAGER

Document No. :
Park Chul Hee Jang In Hyuk Park Seung Soon

Mixing Process Equipment

QC & Technology Team/ Naniek Octaviani

2013.04.22
 Contents

Corporate QC-Technology
Communications Team
Team 2
Confidential for internal use only
 I . Layout Machines
▶ “A” Machines

1. General Layout

4th Floor

3rd Floor

Semi 2nd Floor

2nd Floor

Semi 1st Floor

1st Floor

Corporate QC-Technology
Communications Team
Team 3
Confidential for internal use only
 2. Details Layout

∎ 4th Floor

Dust Dust
Filter Extractor

Dust
Carbon Black & Silica Daily Bin Collector

To Weighing Dust Pipe Dust Pipe

3rd Floor from B/M from 1st Floor

∎ 3rd Floor ∎ Semi 2nd Floor

Auto Chemical Oil Room

Crane
#1st Carbon
Oil Tank Auto 1 Auto 2
Weighing
Chemical Weighing Chemical Weighing

Auto Chemical Bin

#2nd Carbon
Weighing

Corporate QC-Technology
Communications Team
Team 4
Confidential for internal use only
 ∎ 2nd Floor

Wigwag Ram
Hooper
Door

Sheet Rubber Dust

Block Rubber Feeder Extractor
Feeder
Chemical Oil Weighing
Recheck
Weighing

Weighing Rubber C/V Feeder C/V

∎ Semi 1st Floor

Layout Banbury

Reducer Floating Weight

Motor

Banbury Machine Cooling Pipe

TCU

Chamber

Chasing

Rotor

Drop Door

Shut Bank

Corporate QC-Technology
Communications Team
Team 5
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 ∎ 1st Floor

Cooling
To Wigwag Water
Compound
2nd Floor Roll Die
`Pincers
Batch &
Roll
Compound
Jet Fan Calender
Jet Fan Marking
DIP Basin
Fan
Take away
C/V
Batch Off

Corporate QC-Technology
Communications Team
Team 6
Confidential for internal use only
 ▶ “Q” Machines

1. General Layout

2nd Floor

Semi 1st Floor

1st Floor

Corporate QC-Technology
Communications Team
Team 7
Confidential for internal use only
 ∎ 2nd Floor

Wigwag

Ram
Hooper
Sheet Rubber Door
Feeder Dust
Block Rubber
Extractor
Feeder
Chemical
Recheck
Weighing

Weighing Rubber C/V Feeder C/V

∎ Semi 1st Floor

Layout Banbury

Reducer Floating Weight

Motor

Banbury Machine Cooling Pipe

TCU

Chamber

Chasing

Rotor

Drop Door

Shut Bank

Corporate QC-Technology
Communications Team
Team 8
Confidential for internal use only
 ∎ 1st Floor

Cutter DIP Basin Sheet Mill Dump Mill

To Wigwag
Batch &
2nd Floor Dump Mill
Wigwag Metal Compound Compound
Under C/V
Detector Pincers Marking

Take Away
Jet Fan Jet Fan C/V

Fan

Batch Off

Corporate QC-Technology
Communications Team
Team 9
Confidential for internal use only
 II .
▶ “A” Machines

1. Main Silo

100%
92% Main Silo Main Silo
Material Capacity Material Capacity
(High Level Sensor) No. No.
1 AAC131A 6 AAC332A

2 AAC141A 7 AAC341A
Capacity :
3 AAC231A 8 AAC421A
190 m3
4 AAC241A 9 AAD241A

5 AAC331A 10 AAD342A

6%
(Low Level Sensor)

2. Daily Bin

∎ C1001 & C1002 ∎ C1003

1 2 3 4 Daily Screw
Code 1 2 3 Daily Screw
4 10 Bin No Length Code
4 9 Bin No Length
1 440 cm AAC341A
3 9
1 440 cm AAC341A
2 255 cm AAC3311A 3
2 8 2 255 cm AAC3311A
3 168 cm AAC421A 2 8
1 5 6 7 3 168 cm AAC421A
4 278 cm AAC332A
1 5 6 7
4 278 cm AAC332A
5 370 cm AAC141A
Auto
Code Auto 5 370 cm AAC141A
Chem No 6 420 cm AAC231A
Code
Chem No 6 420 cm AAC231A
1 AAY307A 7 590 cm -
1 AAD111A 7 590 cm -
2 AAD111A 8 450 cm AAD342A
2 AAD623A 8 450 cm AAD342A
3 AAD623A 9 405 cm -
3 AAY106A 9 475 cm Dust C/B
4 AAY106A 10 475 cm Dust C/B

Corporate Communications Team 10

Confidential for internal use only
 3. Online Weighing

Function : To weigh material due to compound specification

TOLERANCE
DESCRIPTION RANGE MIN MAKER MODEL NO.
(±)

Carbon Black Scale 0 ~ 150 Kg 0.1 Kg 0.3 Kg UNIPULSE F800

Middle Carbon Black Scale 0 ~ 150 Kg 0.1 Kg 0.3 Kg UNIPULSE F800

Chemical Scale 0 ~ 50 Kg 0.01 Kg 0.04 Kg UNIPULSE F800

No. 1 Oil Scale Chemical Scale
C/B Scale No. 1 Oil Scale 0 ~ 50 Kg 0.01 Kg 0.06 Kg UNIPULSE F800

Middle C/B Scale

No. 2 Oil Scale 0 ~ 50 Kg 0.01 Kg 0.06 Kg UNIPULSE F800

4. Weighing & Feeding Conveyor

Function
Weighing Conveyor : To weigh rubber due to compound specification
Recheck Scale : To recheck weigh of offline chemical
Feeding Conveyor : To prepare material that already fit specification before input to mixer
Recheck Scale

Weighing Conveyor Feeding Conveyor

TOLERANCE DIMENSION WIDTH LENGTH

DESCRIPTION RANGE MIN MAKER MODEL NO.
(±)
Weighing Conveyor 720 cm 100 cm
Weighing C/V Scale 0 ~ 450 Kg 1 Kg 1 Kg UNIPULSE F800
Feeding Conveyor 730 cm 90 cm
Recheck Scale 0 ~ 20 Kg 20 g 20 g UNIPULSE F800

Corporate Communications Team 11

Confidential for internal use only
 5. Bunbury Mixer

Function : To mixer raw materials with specific parameters to meet require compound properties

DESCRIPTION TYPE SPECIFICATION

Floating Weight Banbury Machine C1001 & C1002 : Farrel 440 C1001 & C1002,: 420 L
C1003 : Kobelco BB-320 IM C1003: 325 L
Cooling Pipe
Floating Weight Single Slope, “V” bottom type Ram position Min : 8 mm
Chamber (Ram) Ram position Max : 1609 mm
Chasing Ram press. Max : 100 N/cm2
Rotor
Rotor C1001 & C1002 : NST Speed Min : 6 rpm
Drop Door
C1003 : Intermeshing Speed Max : 60 rpm

Shut Bank
Motor Power Sensor : Yokogawa UR10000 Range : 0 ~ 5000 + 1 Kw
(Mixing Power)

Motor Ampere Sensor : Yokogawa UR10000 Range : 0 ~ 100 + 0.1 Kwh

(Mixing Energy)

Temperature Sensor : “J” Type – Min : 0.1 °C

End Frame Yokogawa UR10000 Max : 200 °C

6. Roller Die

Function : To make sheet compound from “A” process

DESCRIPTION SPECIFICATION
Motor Calender Roll Gap Min : 2 mm
Gap Max : 12 mm
Spee max : 49 m/m
Reducer

Twin Screw

Calender Roll

Left Side
Top Side

Corporate Communications Team 12

Confidential for internal use only
 7. 1st Floor Conveyor

Function
Cooling Water : To recheck weigh of offline chemical
Batch & Compound Marking : To give identity for every batch compound (Compound name, production date, group)
DIP Basin : To coat rubber surface with DIP (anti tack) solution

Batch &
DIP Basin Compound DESCRIPTION DIMENSION SPEED
Marking
Cooling
Marking Water Take Away L = 215 cm ; W = 105 cm Max : 21,3 m/m
C/V Conveyor
Take away
Marking L = 372 cm ; W = 105 cm Max : 24,28 m/m
C/V
Conveyor

DIP L = 150 cm ; W = 105 cm Max : 26,49 m/m

Conveyor

8. Batch Off & Wigwag

Function
Batch Off: To dry & cooling sheet compound after dipped in DIP solution
Fan : To make faster drying process
Wigwag : To arrange sheet of compound to pallet
Sheet Cutter : To cut sheet compound
Sheet Cutter
Wigwag DESCRIPTION SPECIFICATION
Batch Off L = 2710 cm ; W = 146 cm Speed Max : 1,8 m/m

Slope C/V L = 1440 cm ; W = 120 cm Speed Max : 32, m/m

Slope C/V
Fan
Wigwag Weight Range: 0 ~ 1500 Kg Tolerance : 1 Kg

Batch Off

Corporate Communications Team 13

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 ▶ “Q” Machines

1. Weighing & Feeding Conveyor

Function DESCRIPTION WIDTH LENGTH
Weighing Conveyor : To weigh rubber due to compound specification
Weighing Conveyor 720 cm 100 cm
Recheck Scale : To recheck weigh of offline chemical
Feeding Conveyor : To prepare material that already fit specification before input to mixer Feeding Conveyor 730 cm 90 cm

Recheck Scale

DESCRIPTION RANGE MIN (±)

Weighing Conveyor Feeding Conveyor Weighing C/V Scale 0 450 Kg 1 Kg 1 Kg

~

Recheck Scale 0 ~ 20 Kg 20 g 20 g

2. Bunbury Mixer

Function : To mixer raw materials with specific parameters to meet require compound properties

DESCRIPTION TYPE SPECIFICATION

Floating Weight Banbury Machine Farrel 440 Volume Max : 420 L

Cooling Pipe Floating Weight Single Slope, “V” bottom type Ram position Min : 8 mm
(Ram) Ram position Max : 1609 mm
Chamber
Ram press. Max : 100 N/cm2
Chasing
Rotor NST Speed Min : 6 rpm
Rotor
Speed Max : 60 rpm
Drop Door
Motor Power Sensor : Yokogawa UR10000 Range : 0 ~ 5000 + 1 Kw
Shut Bank
(Mixing Power)

Motor Ampere Sensor : Yokogawa UR10000 Range : 0 ~ 100 + 0.1 Kwh

(Mixing Energy)

Temperature Sensor : “J” Type – Min : 0.1 °C

End Frame Yokogawa UR10000 Max : 200 °C

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 3. Dump Mill & Sheet Mill

Function
Dump Mill: To make compound become sheet after processing in mixer
Sheet Mill : To make sheet compound meet thick & width specification
Sheet Mill Dump Mill
Take Away C/V
DESCRIPTION SPECIFICATION
D : 26” ; Width : 213 cm ; Speed Max : 36,5 m/m
Dump Mill
Under C/V Gap : 2 ~ 9 mm
Under C/V Length : 250 cm ; Width : 195 cm

Take Away C/V Length : 1070 cm ; Width : 200 cm

D : 24” ; Width : 106,5 cm ; Speed Max : 43,6 m/m
Sheet Mill
Gap : 2 ~ 20 mm

4. 1st Floor Conveyor

Function
Cutting Slitter: To cut sheet compound into smaller widths
Batch & Compound Marking : To give identity for every batch compound (Compound name, production date, group)
DIP Basin : To coat rubber surface with DIP (anti tack) solution
Marking Batch &
C/V Compound
DIP Basin Marking

DESCRIPTION DIMENSION SPEED

Cutting Take Away
Slitter C/V Take Away L = 245 cm ; W = 105 cm Max : 45 m/m
Conveyor

Marking L = 230 cm ; W = 105 cm Max : 44 m/m

Conveyor

DIP L = 150 cm ; W = 105 cm Max : 43 m/m

Conveyor

Corporate Communications Team

Confidential for internal use only
 5. DIP Tank 6. Metal Detector

Function Function
To mix DIP powder and water then supply to DIP basin To detect FMI in Q compound so it does not continue to next process
Motor

Size Sensitivity >16 mm2

DIP Tank

Propeller

Volume
2200 L
Capacity

7. Batch Off & Wigwag

Function
Batch Off: To dry & cooling sheet compound after dipped in DIP solution
Fan : To make faster drying process
Wigwag : To arrange sheet of compound to pallet
Sheet Cutter : To cut sheet compound
Wigwag

Sheet Cutter

Metal Detector

Slope C/V DESCRIPTION SPECIFICATION

Fan
Batch Off L = 2310 cm ; W = 146 cm Speed Max : 1,8 m/m

Slope C/V L = 1440 cm ; W = 120 cm Speed Max : 32, m/m

Batch Off Wigwag Weight Range: 0 ~ 1500 Kg Tolerance : 1 Kg

Corporate Communications Team

Confidential for internal use only
 End of The Document

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