Disposable plastic cup making machine operation and maintenance process

Disposable plastic cup making machine operation and maintenance process and supporting equipment connection plan

一,Operation steps of disposable plastic cup making machine

1. Pre-Startup Inspection

• Power and Air Source: Confirm that the 380V rated voltage is stable and the power cord is not damaged; check the air source interface seal and that the air compressor pre-start pressure reaches 0.6-0.8 MPa.

• Equipment Components: The mold (cup-shaped mold) is securely fixed and not loose or deformed; the feed mechanism (plastic sheet conveyor belt) has appropriate tension and is not stuck; the heater coil and cutter assembly are in good condition, and the wiring terminals are not loose.

• Auxiliary Equipment: The water level in the 5P chiller tank is at the mark (≥2/3), and the coolant (ethylene glycol water solution, 20%-30% concentration) is clear; the drain valve of the 30P air compressor tank is closed, and the pressure gauge is normal.

2. Startup Operation

• Turn on the main power supply, the 5P chiller (set the water temperature to 15-20°C), and the 30P air compressor in sequence. Wait until the chiller water temperature stabilizes and the air compressor pressure reaches the standard (0.6-0.8 MPa). • Start the cup-making machine's feed motor, adjust the conveyor belt speed (5-8 m/min), and place plastic sheet (such as PP or PET) into the feed port, ensuring the sheet is aligned with the positioning pins.

• Set the heating temperature (160-220°C), heating time (8-15 seconds), molding pressure (0.4-0.6 MPa), and cutter pressure (0.5-0.7 MPa) based on the sheet thickness (0.2-0.5 mm). Wait until the heating temperature reaches the set value.

• Switch to "Automatic Mode," and the machine will complete the "sheet feeding → heating and softening → mold forming → cooling and setting → cutting and cupping → finished product output" process in sequence. The operator will check the cup thickness and edge flatness in real time, pressing the emergency stop button to make adjustments if any errors are detected.

3. Shutdown Procedure

• Turn off "Automatic Mode," wait for the machine to complete the current cup-making cycle, stop the feed motor, and clear any remaining sheet from the feed port. • Turn off the heating switch and keep the 5P chiller running. Wait until the heating coil temperature drops below 50°C before turning off the chiller.

• Turn off the 30P air compressor, open the air tank drain valve to drain the condensate, and then turn off the compressor power.

• Clean the equipment: Wipe away any remaining material in the mold cavity and any impurities on the cutter surface. Clean the finished product collection box. Finally, turn off the main power to the cup making machine.

二,Disposable plastic cup making machine maintenance process

1.(1) Daily maintenance (after daily operation)

2. Cleaning: Wipe the surface of the equipment with a dry cloth to remove oil and dust. Clean any remaining sheet debris from the feed mechanism. Use compressed air (0.3 MPa) to blow dust off the surface of the heating coil (turn off the power).

3. Inspection: Check the mold cavity for scratches and the cutter blade for sharpness (remove any nicks). Check the air supply line for leaks and the cooling water line for water seepage.

4. Lubrication: Apply a small amount of food-grade lubricant (5-8g at a time) to the feed roller and cutter drive gear to prevent oil contamination of the sheet.

(二)Weekly maintenance

1. Tightening: Tighten the mold fixing bolts one by one (torque 6-10 N·m) and the heating coil terminals to prevent loosening and temperature fluctuations.

2. Cooling System: Clean the 5P chiller filter (remove the filter and rinse with clean water). Check the coolant level and replenish with a compatible coolant if insufficient.

3. Air Pressure System: Remove the 30P air compressor intake filter and blow out impurities with compressed air. Check the cup making machine's air pressure regulating valve to ensure the pressure is stable at 0.4-0.6 MPa.

(三)Monthly maintenance

1. Mold Maintenance: Disassemble the cup mold, clean the cavity with a dedicated cleaner (such as a neutral degreaser), apply anti-rust oil, and reinstall. Inspect the mold seals and replace if aging (fluororubber seals are recommended, with a temperature resistance of ≥250°C).

2. Power Components: Inspect the cup making machine's spindle bearings and feed motor bearings. If any abnormal noise or sticking occurs, replace the bearings and relubricate with lithium-based grease, model 3#.

3. Auxiliary Equipment: Replace the coolant in the 5P chiller (every 6 months) and clean the condenser fins. Replace the oil in the 30P air compressor (use 46# air compressor oil every 3,000 hours) and clean the oil-gas separator.

三,Disposable plastic cup making machine, 30P air compressor, and 5P chiller connection solution

1. Overall connection logic

•30P Air Compressor → Cup Making Machine: Provides compressed air to drive the forming and cutting cylinders.

•5P Chiller → Cup Making Machine: Provides coolant to the mold and cutter components, controlling the forming temperature and dissipating heat from the cutter.

2. Details of the pipe connections for each device (including type, size, and markings)

3.30P air compressor ↔ cup making machine (air pressure pipeline)

• Pipe type: Pressure-resistant PU hose (pressure rating ≥ 1.2 MPa, aging-resistant, and highly flexible);

• Pipe dimensions: 32mm inner diameter, 35mm outer diameter (30P air compressor with a displacement of 1.8-2.2 m³/min. This dimension ensures pressure loss ≤ 0.05 MPa, meeting the requirements for synchronized operation of the forming and cutting cylinders).

•Key symbols:

◦ The outer wall of the hose should be labeled "Air Pressure Line," "Pressure 1.2 MPa," and "Medium: Compressed Air."

◦ Install a pressure gauge (range 0-1.6 MPa) and a precision filter (DN16, filtration accuracy 5 μm, removes water and oil) near the air compressor. The filter should be labeled "Air Pressure Filter → Clean Monthly."

◦ Install an air pressure regulating valve (DN16, adjustment range 0.2-1.0 MPa) and a shut-off valve (DN16) near the cup-making machine. Label the valve body "Cup-making Machine Air Pressure Valve."

(2) 5P chiller ↔ cup making machine (cooling pipeline)

• Pipe type: PVC reinforced hose (temperature resistant -10-80°C, corrosion-resistant, smooth interior to reduce scale buildup);

• Pipe dimensions: Inlet and outlet pipes are both 25mm ID and 28mm OD (for a 5P chiller with a cooling capacity of 17.5kW, this dimension ensures a coolant flow rate of ≥8L/min, meeting mold and cutter cooling requirements);

•Key symbols:

◦ The water inlet pipe (from chiller outlet to cup-making machine cooling inlet) should be labeled "Cooling Water Inlet," "Flow Direction: Chiller → Cup-making Machine," and "Medium: Ethylene Glycol-Water Solution."

◦ The water outlet pipe (from cup-making machine cooling outlet to chiller return) should be labeled "Cooling Return Water," "Flow Direction: Cup-making Machine → Chiller," and "Temperature Resistance -10-80°C."

◦ Install a shutoff valve (DN20) and a flow meter (range 0-15 L/min) on each of the two hoses near the chiller. The flow meter should be labeled "Cooling Flow Monitoring → ≥8 L/min."

3. Connection considerations

1. Keep air pressure piping under 8 meters in length and avoid excessive bends. Allow 15-20 cm of expansion and contraction for cooling piping to offset equipment vibration.

2. Secure all piping connections with stainless steel hose clamps (size matching the pipe diameter). After tightening, test for leaks with soapy water to ensure there are no air or water leaks.

3. Pipeline markings should be waterproof, wear-resistant labels placed in a conspicuous location 30 cm from the connection for easy identification during maintenance.