The perforating machines in Detail
The PM5 and PM6 perforating machines are the AFS solution for hot or cold needle perforation of plastomers, non-woven, paper, etc. The production of air-permeable food and plant packaging, for example, can be integrated into any continuous flat film process.
Effective perforation
The PM series essentially consists of two parts: the needle roller section (heating section) and the film guide section with brush and deflection rollers.
To insert the film, the film guide section is moved away from the needle roller. This allows the film to be inserted easily. The interlocking of the needle and brush rollers, i.e., the penetration depth of the needles into the film, can be adjusted continuously. The penetration depth defines the hole diameter.
The horizontal roller shift means that the wrap length of the film is not changed when the system opens.
Energy efficient
Although the perforation process takes place at temperatures of up to 350°C, the energy consumption of the system is pleasingly low. Separate heating and extraction chambers ensure that only the air directly in the melting area is extracted, thus reducing energy loss through waste heat to a minimum.
High safety standard
If the speed falls below an adjustable minimum web speed, the film is automatically guided out of the perforation area to prevent unwanted melting effects. On the other hand, once an adjustable web speed is reached, the film is automatically returned to the perforation area.
After the system is shut down, the hot needle roller rotates until it reaches a minimum temperature. This prevents standstill bending.
Technische Details
| Attribute | Details |
|---|---|
| Perforation width PM5 | 600 – 2000 mm (other on request) |
| Perforation width PM6 | 600 – 1300 mm |
| Perforation speed | 200 m/min mechanically possible, depending on material |
| Dimensions (Perforation) | - Height: 745 mm + 290 mm (for opening) + 50 mm (optional adjustment unit) - Width: Perforation width + 1140 mm - Depth: 560 mm + 200 mm (for opening) |
| Dimensions (control cabinet) | - Height: 1600 mm + 200 mm base - Width: 600 mm - Depth: 500 mm |
| Heating capacity | - Heater - approx. 8500 W/m - Roller - approx. 8500 W/m |
| Needle segmentse | Customer specific - typical widths 50 / 100 mm - offset or linear needle patterd |
| Hole diameter | - optimal results at Ø 0,3 – 1,0 mm - max. Ø 2,8 mm |
The benefits of AFS perforating machines
- Safe and easy access for the operator for adjustment and cleaning
- All available remote control interfaces, Profi-Bus, Can-Bus, Profinet, Ethernet, etc.
- CE conformity
- Usage of non-burnable materials in the perforation zone. Low risk of fires.
- Proven automation via the control known from AFS Corona treaters. No dependency on external suppliers.
- Quick access to the needle roller for fast exchange of the needle pattern.
- Heating of the interior of the needle roller as well as external direct heating of the needles. Quick heat-up process.
- Several independent heating zones, homogeneous perforation over full product width.
System overview
Lid with extractor hood and extraction monitoring
Perforating roller
Spiral brush roller,
movable by pneumatic cylinder Stroke = 100 mm
Outside heating using infrared radiators
Drive: Needle roller with toothed belt drive
Eccentric drive for intermittent operation (PM6 only)
Needle segments
Deflection roller
Needle roller inside radiator
Other features
Functions of the perforating machines PM5 and PM6.
High safety standard
The simple removal and installation of the needle roller and the modular needle segment system enable quick changes to other hole patterns or multiple use through any combination of needle segments. With the electronically controlled penetration depth control, the hole diameter can also be adjusted continuously.
High production speed at perfect perforation quality
With its combination of external and internal heating, temperature measurement inside the roller, and high-precision temperature control, the PM series creates the conditions for perfect perforation results even at high web speeds.
Intermitting (PM6)
Film manufacturers sometimes require unperforated areas, for example for adhesive surfaces.
Our PM6 model offers millimeter-precise and lightning-fast interruption of the perforation process, even at high web speeds. The unperforated zones can be configured quickly and conveniently via the menu on the control cabinet or via a factory bus.
Comfortable operation
The graphical touchscreen and single-button control make operation very easy. The process parameters temperature and penetration depth are clearly displayed and can be changed using the multifunction button or by tapping directly on the display.
Application examples
Hygiene and healthcare
Hygiene and healthcare are major areas of application for perforation: perforated plasters allow air to reach the areas requiring protection while still protecting against contaminants. This speeds up the healing process. In the case of plasters on a roll, the perforation also makes them easier to tear off. A special type of perforation enables a so-called “one-way street effect” for liquids. This means that liquids can be transported away from where they originate and collected in storage media. However, this effect can only be achieved to a limited extent with needles. The perforation of non-woven materials for hygiene applications requires relatively large holes and high web speeds. A process specially developed by AFS for this purpose meets these requirements to a particular degree.
Filling with bulk materials
When packaging powdered materials, the air must be able to escape from the bag quickly. This is what the perforation is for. At the same time, the hole size must be precisely adapted to the filling material. When bulk goods or powdered goods are to be filled into plastic or paper containers, perforation allows the displaced air to escape more quickly. The maximum filling speed increases. Examples: cement, soil, milk powder, etc.
In construction and agriculture
Perforated films have proven to be ideal for keeping moisture out while still allowing air to circulate. This application is primarily used in the renovation of old buildings as a protective layer between thermal insulation and interior finishing. Example: roof underlayment film.
Perforation of coffee filters
The perforation increases the liquid flow rate and controls it precisely. The density and diameter of the holes control the brewing time. This allows you to make coffee or tea with different strengths.
Packaging for groceries
Perforated plastic film is often used for packaging fresh products such as baked goods, vegetables, and flowers. The perforations in the film allow moisture from the product to escape from the packaging, which prevents the film from fogging up without compromising its freshness-preserving effect. Flowers and vegetables stay fresh, and baked goods stay crispy.
