ITM Sets New Standards in Filter Combining

Source from:  Tobacco Reporter 03/05/2010

ITM introduces the Solaris multi-segment filter combiner, a modular and extendable machine with unique capabilities. The Solaris offers greater flexibility in filter material handling, requires fewer part changes and has the ability to place small plugs into any position within the combined filter.

Because the Solaris does not use suction to transport filter plugs, it can process a wide variety of materials, including highly porous, non-wrapped, high and low density materials. The machine's in-line transport system even enables cigarette manufacturers to use hollow elements. The Solaris can create recesses and cavities just as easily as it can create any other filter composition. In combination with the Advanced Plug Module, the in-line transport of filter plugs allows asymmetrical multi-filter segment patterns. For the first time, according to ITM, tobacco companies will be able to place plugs as short as 6 mm in the center or any other position within the combined filter. Moreover, operators can easily change the segment patterns on the touch screen, often without having to make mechanical changes to the machine. Because each plug feeder module is driven by its own servo motors, the order in which the plugs are inserted in the in-line transport chain is completely configurable. According to ITM, the Solaris is a truly modular machine. Each plug feeder module in the Solaris is fully self-sufficient and contains all necessary controls and supporting equipment. The Solaris can be equipped with two types of plug modules. The Standard Plug Module can handle plugs of 12 mm or longer. The Advanced Plug Module can handle plugs as small as 6 mm and position them in asymmetrical patterns. Any combination of these modules can be created without changing anything to the standard Transfer Module and Rod Maker Module. Replacing a module merely requires linking it up to the in-line transport, connecting the cables and resuming production. Extending a dual filter combiner to a triple filter combiner is just as easy. With the options for off-line configuration of a plug module and the automatic teach-in method in the Solaris control software, a module can be replaced within one hour-this is the true time required from stopping production with one specification to resuming production with the new specification. According to ITM, no other system today offers this level of modularity. Another benefit of the modular design and in-line transport method is the option to interchange the plugs from two modules without physically moving the modules. Simply move the destination of the plugs from the modules to another location in the combined filter rod and run a teach-in procedure. The work is done completely from the touch screen and takes only minutes. The Solaris can handle base rods from 60 to 150 mm and divide these in up to 20 individual plugs. This feature allows cigarette makers to reduce the amount of different base rods used. Thus, the Solaris helps increase the uptime of the base rods-producing machines, because they will need to be converted less frequently. The Solaris modules are driven by separate servo motors via the Siemens Simotion D control system. This enables precise control of all machine parts while at the same time ensuring high flexibility. All production-related parameters are stored in recipes, making it possible to change between different filter configurations in minutes. This minimizes downtime of the machine, even when production changes are performed. The Solaris also reduces the volume of rejected materials. The machine is fitted with various checking mechanisms that allow automatic removal of sub-prime filters without stopping production. With the Solaris' in-line transport technology, a missing plug in one filter does not cause problems for subsequent filters and does not require a restart of production to realign the plugs. The filter segment with the missing plug is automatically ejected, without disrupting production. Enditem