Name Raja Mansoor Irshad

Card Number 550591

Department Metalizer Production

Dated 22nd July, 2019

Difference Between Metalizer K5000
& K5Expert
Table Of Content
01 Number Of Boats 06 Water Circulation Of Copper
Blocks
02 Hawkeye Vs O.D Meter
07 Boats Temperature Control
03 AlOx Reaction Buttons

04 Vacuum Pumping System 08 Shield & Shutter

05 Winding Zone

Drum & DTR1 (Chilled Rollers)

Shafts & Chucks Design

Web Width

Unwind & Rewind Diameter

Number Of Boats

K5000

In K5000 number of boats are 30, each boat cover 95mm pitch.

K5Expert

In K5Expert number of boats are 40, each boat cover 75mm pitch.

Results.

K5Expert produce better quality product.

K5Expert Require more water flow

Hawkeye Vs O.D Meter

K5000 K5Expert

In K5000 O.D meter is installed which In K5Expert Hawkeye is installed which

measure O.D between the range of detect O.D, pinholes,and other defects.
0.00 to 3.0
An O.D beam measuring O,.D upto 4.5 at
Pitch of each O.D beam is 95 mm 25mm pitch

Minimum size of detectable hole is

0.1mm to 0.2mm

100% functionality between (10-45)oC

AlOx Reaction

K5000

In K5000 this reaction can’t take place

K5Expert

Oxygen gas released close to the drum over the evaporated aluminium cloud to
produce aluminium oxide

Results:

Increase barrier properties

Decrease the aluminium consumption

Decrease the cost

Better visual appearance

Precautions
Make sure that during cycle change there should be no condensation on chilled parts of
the evaporation zone

Process must be start at better vacuum levels

Powder Fire Extinguishers must be available near to the machine

Waste bucket of Aluminium Oxide must placed beside the emergency exit

Wear Personel Protective Equipment During Cleaning

Vacuum Pumping System
K5000
02 rotary pumps & 03 booster pumps are
installed to create vacuum inside the
winding zone
01 rotary pump, 01 booster pump & 02
diffusion pumps are installed to create
vacuum inside the evaporation zone
Fore Line of both zones are separated
Diffusion Pumps size is smaller
K5Expert
01 rotary pumps & 02 booster pumps are
installed to create vacuum inside both zones
(winding zone,evaporation zone) because, their
foreline connected with both zones
02 rotary pumps & 04 booster pumps are
installed to create vacuum inside the winding
zone
01 rotary pump, 01 booster pump & 02 diffusion
pumps are installed to create vacuum inside the
evaporation zone
Diffusion pumps size is larger
Winding Zone

Drum & DTR1 (Chilled Rollers)

K5000
In K5000 the drum diameter is lesser
The angle of the Drum & DTR1 with respect to each other is also changed due to this the
contact area between web(film) and these two rollers are lesser

K5expert
Drum diameter is larger 700mm
The angle of the Drum & DTR1 is also updated to increase the contact area between
web(film) and these two rollers.
Results
Increase web cooling efficiency
Due to increased diameter of the drum, the surface area above the oven is also increase,
which reduce aluminium consumption.

Shafts & Chucks Design

K5000
V-shape shafts & chucks

K5Expert
Gear shape shafts & chucks
Extra support is given to chucks
Results
Maximum load is on chucks support safe the chucks & shafts.

Web Width

K5000
1450mm to 2850mm

K5Expert
1450mm - 2900mm
Unwind & Rewind Diameter

K5000
Maximum diameter is 1200mm

K5Expert
Maximum diameter is 1250mm
Water Circulation Of Copper Blocks

K5000
Circulation of water for Neutral side copper blocks through the oven

K5Expert
All copper blocks given separate water flow connection.
Boats Temperature Control Buttons.

K5000
Not available

K5Experts
Boats temperature control buttons are available in front of the source area

Shield & Shutter

K5000
Shield operated by hydraulic

Shutter operated by motor drive

Shild Evaporation window size in machine direction is approx 405mm

K5Expert
Shield operated by a rope connected to the motor drive

Shutter operation is pneumatic

Shild Evaporation window size in machine direction is approx 460mm