ROTARY PRESS TRAINING
Size Change
Course Menu
- Back to Main Menu
- Lesson 1 – Introduction
- Lesson 2 – Safety Procedures
- Lesson 3 – Pre-Operational Checks
- Lesson 4 – Operating Instructions
- Lesson 5 – Glue Test
- Lesson 6 – Size Change
- Lesson 7 – Troubleshooting
- Lesson 8 – When Down,Do
- Lesson 9 – End of Shift Procedures
- Lesson 10 – Competency Quiz
- Lesson 11 – Trainer Verification
Introduction
This training module provides a detailed, step-by-step guide on how to safely and effectively change the rotary press setup for different laminate widths, typically 70mm and 90mm. You will learn how to gather the necessary tools, change the glue applicator, make mechanical adjustments, and perform a glue test to ensure everything is set up correctly for production.
Time Required:
Approximately 30-45 minutes
Setup - Gather Tools
Before beginning the size change process, ensure you have gathered all the necessary tools and components:
- New applicator head: Depending on the required laminate width, choose either the 70mm or 90mm applicator head.
- Allen keys: These will be required to loosen and tighten various bolts during the changeover process.
- Drill: Required for adjusting the laminate array height.
- Extension lead: Used to provide power to the drill for height adjustments.
Having all tools readily available will ensure the process is completed efficiently and without interruptions.
Prepare the Glue Bench
Before proceeding with the size change, the glue bench needs to be prepared. This will be your workspace for switching out the applicator head.
-
- Place a clean rag on the glue bench to keep the work area free of debris.
- Set the new applicator head on the glue bench, ready for installation.
Turn Off the Glue System
- Turn off the glue applicator via the HMI control panel.
- Turn off the “Empty Round” function to stop the auto-purge process and ensure the glue system is fully off.
Isolation
To ensure safety during the size change process, you must isolate the rotary press before performing any work on the machinery:
- Apply your lockout tag to the press, ensuring that no one can start the machine while you are working. This is a crucial safety step to prevent accidental startup and potential injury.
Remove the Glue Applicator Head
Follow these detailed steps to remove the current applicator head:
Disconnect the glue hose fitting
Your content goes here. Edit or remove this text inline or in the module Content settings. You can also style every aspect of this content in the module Design settings and even apply custom CSS to this text in the module Advanced settings.
Disconnect the black connector
- Unscrew the lead from the back of the applicator by turning it anticlockwise until it unlocks.
- Pull out the connection.
Remove the Applicator Assembly
- Use an Allen key to unscrew the four large bolts on the top of the applicator.
- Lift the applicator off the press and place it on the glue bench for further disassembly.
Disassemble the Applicator Head
- Unscrew the eight smaller screws on top of the applicator head using an Allen key.
- If the applicator head is difficult to remove, use a rubber mallet to gently tap and loosen it.
Attach the new Applicator Head
- Position the new applicator head on top of the applicator, ensuring that the holes align with the correct end.
- Secure the applicator head by first screwing in the bottom right screw from underneath, then rotate the applicator and secure the top left screw.
- Flip the applicator over and insert the remaining screws to secure the head in place.
Clean and Store the Previous Head
- Place the previous applicator head in the acid bath and set it to “timer” for cleaning
Reattach the Applicator Head
- Place the applicator back on the press and secure it with the four large bolts previously removed.
Reconnect the Black Connector
- Ensure that the slot at the bottom of the connector aligns with the groove in the fitting and screw it back in tightly.
Reconnect the Glue Hose Fitting
- Align the groove on the fitting with the small round metal dot.
- Pull back the sleeve and push the hose firmly onto the fitting until the sleeve clicks into place and can be rotated.
Glue Applicator HMI Settings
Once the new applicator head is in place, update the settings on the HMI (Human-Machine Interface) control panel:
Turn on the glue applicator and initiate the purge function to ensure that the glue is flowing properly and that all holes in the new applicator head are clear.
- Navigate to the workpiece settings.
- Change the setting to the appropriate width for the laminate being processed (either 70mm or 90mm).
This ensures that the glue system is calibrated to dispense the correct amount of adhesive for the new laminate size.
Adjust Infeed Belt Rollers
Next, you will need to adjust the rollers on the infeed belt to match the width of the new laminate size:
- Loosen the three screws on both the front and back rollers using an Allen key.
- Slide the roller forward or backward until it aligns with the pre-marked line corresponding to the new laminate size.
- Tighten the screws to secure the roller in the correct position.
This step ensures that the laminate feeds smoothly into the press.
Adjust Laminate Array Height
The final size adjustment involves changing the height of the laminate array:
- Plug in the drill using the extension lead at the power point located outside the isolation fencing.
- Position the drill head over the lug at the end of the press array.
- Use the drill to adjust the height until it aligns with the pre-marked line on the metal for the new laminate size.
- Unplug the drill and return it to its storage location.
Perform a Glue Test
Well Done!
- By following these detailed steps, you will successfully complete the size change on the rotary press, ensuring that it is properly configured for the next production run. Always double-check all adjustments before resuming operation to maintain safety and production quality.