The facility of the Vacuum
Metallizing for Plastic and
Metal Production.
VACUUTEK CORPORATION
台灣三和真空機械有限公司
台灣桃園縣平鎮市民族路雙連二段118巷49弄53號
53, A 49, L 118, Sec. 2, Suang-lan, Pen-zhen, Taoyan Hsien, Taiwan
Phone: 886-3-4203898~9 Fax.: 03-4203900
E Mail : or
The Vacuum Metallizing -pollution free technology found in the year of fifty‘s and becomes more wider range using in Architecture, Automobile, Cosmetic, Packing, Toys, furniture, Decorations and Electronic parts in ninety years.
From following description, you may find out the base and top coat lacquer are using. You may choosing different type lacquer for different material such as ABS, PP, metal, glass and ceramic etc..
Using UV lacquer for hard coating of Architecture, Automobile parts and Cosmetic container for scratch prove coating.
In this proposal provided Equipment, Factory layout, Installation calibration and Technical training. All of the Equipment designed with advance technology and our fifteen years experience to make high quality and low cost production.
The following information present you the complete line of
The proposal of Vacuum Metallizing
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Contents
======
1. Description
2. Flow chart
3. Facility :
(1) Equipment
(2) Manpower
(3) Utility
(4) Space
4. Cost analysis
5. Machine‘s specification
1. Description
This proposal calculation base on mass production Vacuum Metallizing
plant for Christmas ball or Cosmetic container.
1-1 Productivity base 19 pcs lipstick container per jig bar, 144 jigs per coating,
4 coating cycles per hour and total 5,500 pair lipstick container per hour.
Jigs bar 8 mm square x 0.9 m long mild steel.
19 pcs per jig bar of fly-wheels for self rotation. (special jig.)
Lipstick cap 19 pcs per jig. Jigs bar top view.
Cap clip
Turntable & Jigs bar
Top plate Turntable 6 axis self ritation
12 sets
jigs bar
on upper
section.
12sets
jigs bar
on lower
section.
Turntable Side View lower plate Turntable Top View Evaporation Source
Chamber capacity :
12 sets jig bar x 2 sections (upper & lower) x 6 axis = 144 jigs per coating.
1-2 This section shown plastic boxes coating chamber loading.
Productivity calculation by 220mm x 120mm x 100mm boxes.
5 pcs/jig x 3 jigs/axis x 8 axis/chamber x 5 times/hour = 600 pcs/hour
loading jig plastic boxes Evaporation source Turntable upper plate
Turntable lower plate Eight axis Evaporation source
Turntable side view Turntable top view
2. Flow chart :
Products to be Metallizing
(plastic or metal products)
Cleaning
( If necessary)
Base Coating
( Spray or Dipping)
Baking in the Oven
( 120 ~ 150 min.)
Vacuum Metallizing
( Vacuum Coating Machine)
Dipping Base coat Spray Top Coat
( Clear Top coat lacquer
Backing in the Oven mix with pigment for color)
( 30 ~ 50 min.)
Backing in the Oven
Dyeing color in water ( 10 ~15 min.)
10 ~ 15 min in the Oven Final Products
2-1 Base Coating
The surface of the plastic parts are rough, they need cover a layer
of lacquer to becomes a shine surface. This lacquer layer
becomes hard film after two hours baking from the oven.
This hard lacquer base coat also can reduce plastic out gas rate
during the Vacuum Metallizing process.
The stable temperature, timer control, fresh air supply and dust
free stainless ovens are suitable for base coat baking.
2-2 Top caot spray with Color process.
The thickness of the high purity Aluminium Metallizing thin film
app. 500 ~ 1000 A( 1 x 10-9 meter) was easy oxidation and
corruption. It needs spray a clear and fast dry lacquer layer to
provide a protection layer.
The products color can come out from spraying ready mixed with
color pigment top coat lacquer.
The different pigment mix with clear top coat lacquer to make
all kinds color after spray. Such as,
1. Sliver color = no need pigment, just spray clear top coat.
2. Gold color 8k ~ 24k = app. 60~80% yellow + 40~20% orange.
3. Shine Red, Blue, Green, Pink... = mix pigment with top coat.
The uniformity of the color spray is very importane. The more or less spray are to result dark or light color. The AS- 800 turntable type auto spray machine suitable both base and top coat spray. This auto spray machine good for less quantity production in begining and able to add one spray machine for more production in after.
2-3 The factory environment control is very important.
Needs experience person layout the production plant to keep
dust away from products.
2-4 Due to lacquers and thinners are dangerous inflammables
goods. The coating plant must keep production stock away
from the working place.
3. Facility
3-1 Equipment list.
Name / Model / Q‘ty / Unit price / Amount1 / Vacuum Metallizing Machine / OPA-1700 / 1
2 / Auto spray machine for base coat & top coat / AS-1000 / 2
3 / Oven / 4
4 / Spray Both / 2
5 / Spray gun (Japan Iwata) / 10
6 / Dehumidor / 2
7 / Cooling Tower / CV-8 / 1
8 / Trail ( local made) / 40
9 / Jigs (local made)
Total
Remark :
1. Delivery 90 days after receipt of L/C.
2. Price including machine installation and training.
3. Buyer response all expanse during the machines installation..
3-1-1 Raw Material List
Name / Unit Price / Stock / Amount / Usage1 / Vacuum Pump Oil
(Made in USA) / 2 drums / 3 years
2 / Diffusion Pump Oil (Made in Japan) / 12 liters / 3 years
3 / “O” rings full set / 1 set / 2 years
4 / Aluminum foil / 30 kg / 1 year
5 / Tungsten Wire / 20 kg / 1 year
6 / Top coat Lacquer / 10 drums
7 / Base coat Lacquer / 10 drums
8 / Al. wheel base and top coat / 2 drums
9 / Pigment for top / 30 kg
Remark : Raw material quantity depend on buyer‘s request.
5. Machines‘ Specification
5-1 Vacuum Coating Machine OPA-1700
The most advance design, front open double door with two turntables and Tungsten Evaporation sources fixed on each door for Aluminum thin film coating on plastic and metals. All of operations are under the Computer control provided full automatic operation including machine worm-up, operation and cool-down. The Computer with Modem process module combine a most advance machine operation control system.
* This machine‘s control system with modem transducer, just only one
telephone wire connect to machine. The module type decorder
provide very easy maintanance ant for trouble-shooting.
* All of the operations are keep record in computer hard disc in 300 days.
It is very important information for trouble-shooting.
* Special design power division circuits can save energy up to 40%
against other brand machines.
With Swiss Balzers digital vacuum gauge for accurate vacuum measurement, with Japan made mechanical vacuum pump and 36“
diffusion pump for fast pumping speed and reliable operation.
Features:
1. Full Computer automatically process, easy operation.
2. Module and card type control circuits. Easy to service.
3. Stainless cooling channel. Welded diffusion pump for longtime use
Especially built for countries where electrical power supply is unstable.
4. Vertical chamber with two doors for easy loading. Saves jigs
changing time.
5. Equipped with Japan made vacuum pump, provided many years
of operation.
1. Chamber:
1-1 Stainless #304 chamber and pumping pipe with mild steel frame
and sight glass window on each door 1700 mm dia. x 2000 mm hi.
1-2 Chamber usable size 1620 mm dia. x 1800 mm hi.
suitable for 900 mm jig x 2 section.
1-3 Ultimate Vacuum condition 10-6 mbar.
1-4 Operation Vacuum condition 5 x 10-4 mbar.
1-5 Turntable with 8 axis usable size 420 mm dia. x 1800 mm hi.
10 axis usable size 400 mm dia. x 1800 mm hi.
1-6 Turntable rotating rotation speed adjustable from 0-8 rpm.
1-7 Turntable rotating motor : AC, 3 phase x 1 hp x 2 sets.
1-8 Turntable rotating motor speed controller x 2 sets.
2. Vacuum pumping system
2-1 Pumping speed (no insert) to 5 x 10-4 mbar within 6 min.
2-2 Ultimate Vacuum condition. 10-6 mbar.
2-3 Operation Vacuum condition. 5 x 10-4 mbar.
2-4 Rotary pump Japan Osaka KP-15000, speed 15,000 l/m, 1 set.
2-5 Booster pump Japan Ulvac PMB-020 speed 2,200 m3/hour, 1 set.
2-6 Diffusion pump Vacuutek DP-36, 36“, 39,000 liter/sec. 1 set.
Diffusion pump with Stainless cooling channel, provided 10
times more cooling rate then cooper pipe and many years use.
2-7 Water cool Diffusion pump baffle 1 set.
2-8 Pneumatically Vacuum valves, 36“ x 1 set, 10” x 2 sets, 2“ x 1 set.
2-9 Vacuum gauge Swiss made Balzers TPR-250 x 2 sets.
IKR-251 x 1 set.
3. Control System
3-1 The Computer with Modem process module combine a most
advance machine operation control system, and provided fully
automatically process, easy operation including worm-up,
coating and cool-down.
3-2 Air operated vacuum valves with Leeds switches for confirm
valve operation signal.
3-3 Computer equip with one more hard disc with spare operation
data storage.
4. Evaporation system
4-1 Evaporation power 8V x 3000A = 24 kW.
4-2 With automatic soft start SCR control for manual or auto operation.
5. Others
5-1 Compressed air supply 6 kg/cm2 x 1/4“ port.
5-2 Cooling water 30 liters/min. recycle use.
5-3 Total power consumption 45 kW.
Vacuum valves with operation confirm switch.
Evaporation power transformer.
Air supply solenoid valves.
ICP de-modem module box.
Main power box.
Japan Ulvac
PMB-020 booster pump
Japan Ulvac
PKS-070
vacuum pump
Vacuum valves with operation confirm switch,
Stainless cooling channel. Welded diffusion pump for longtime use.
V2 . Diffusion pump back pumping valve.
Standard 586 PC with Win98 and our operation software.
All operation data come from com2 through modem module with 2 wires connect to machine.
with table for spare parts storage.
ICP modem decoder box.
module type very easy service.
7041 for digital input.
7042 for digital out control.
7044 for digital input and
output control.
7017 for analoge signal input.
Relay circuit for output control protaction.
Wires connecting terminal board
5-2 AS-1000 Automatic Spray Machine for base and top coat
Specification :
1. Max. Jig size : Dia. 400 mm x 1000 mm L
2. Reciprocator :
1. Moving speed : from 2 cycles/min. to 100 cycles/min. adjustable.
2. Spray cycle time adjustable from 1 cycle to 20 cycles.
3. Carry arm : enable carry two paint spray gun and one statical
electricity air gun for clean
3. Jigs carry turntable :
1. Round type moving with 8 position jig holder.
2. With jig self rotation device during jig under spray. The self
rotation speed adjustable from 0 to 20 rpm.
4. Vertical spray with vertical holder easy for loading and unloading
5. With suitable stainless water both set required.
5-3 Oven OV-220
Specification :
1. Overall Size : Two doors 2.6mWx2.2mHx1.8mD.
2. Cart : 1.1mW x 1.7mH x 1.6mD.
3. Backing Temperature : 50-160 degree C, Adjustable.
4. Fan motor: 1HP, 1500 ~ 1700 r.p.m.
5. Timer setting : 1 ~ 999 min., Adjustable.
6. Power consumption : 380V, 3 phase, 12kw.
5-4 Stainless Spray Both BT-2S
Specification :
1. Overall size : See table below.
2. Blower : 5HP x 1 set.
3. Water Pump : 2HP x 1set.
4. Water filter : 1set.
Unit : mm
model / Usable width / overall width / Station Highth / Total Highth / DipthBT-1S / 840 / 1140 / 1680 / 3123 / 1680
BT-2S / 1680 / 1980 / 1680 / 3150 / 1680
BT-3S / 2520 / 2820 / 1680 / 3410 / 1680
BT-4S / 3360 / 3660 / 2050 / 3850 / 1680