Filter winding machine

Types of filter winding machines

Winding filters are a common practice in cigarette production. The filter winding machine works to ensure that this can be done efficiently on an industrial scale. There are generally two main types of machines based on how they wind the filter tape.

• Horizontal filter winding machines

  As the name suggests, the machine is laid out horizontally. It has a horizontal winding head with an inline set of rollers. This type is usually compact and takes quite a small space to set up. They are very easy to operate since the main filter cylinder simply needs to be inserted, and the machine will take care of the rest. Horizontal filter winding machines have the capacity to produce thousands of filters per hour. These machines are great for always producing large quantities of filters with consistency and little to no variation from the standards.

  Depending on how robust or basic the model is, some feature more advanced components and can produce a higher number of filters per minute. Overall, horizontal filter winding machines are great for businesses on a budget or those looking to have more accessibility and ease of use in their filter production systems.

• Vertical filter winding machines

  These machines have a vertically oriented winding head. It is quite a standard design in the filter-making industry. Vertical filter winding machines are able to produce a greater number of filters in less time compared to their horizontal counterparts. They come with more advanced technology, such as photoelectric sensors, PLC control systems, and even a variable speed drive to help control the degree to which the filters are wound.

  Vertical filter winding machines with a greater capacity usually tend to take a bit more space. Because of their larger capacities, they also tend to be on the higher end of the budget.

Generally speaking, both horizontal and vertical winding machines can be used to make dual filters, triple filters, or any type of filters used in cigarettes today. In addition to these, there are also digital or semi-automatic winding machines that come with a lot of additional technology. They have the potential to produce even more filters in a shorter amount of time than vertical machines. Many of these machines also have the ability to change the size of the filters they produce and even the number of plugs that can be incorporated into a single filter.

Besides these types, there are also swan filter machines that make the swan filter specifically used in swan cigarettes. They usually make a type of filter that is tapered on both ends.

Specifications & Maintenance of Filter Winding Machines

Modern filter winder machines have various specifications based on their types and applications. Here are some key specifications based on the following categories:

• General Specifications

  These filter winder machines' general specifications include model, size, and weight.

  For example, the automatic filter winder machine model is TW-01. Its size is 70x110CM, and the weight is 65kg.

• Power and Voltage

  The power and voltage of a filter winder machine indicates the power requirement and the applicable power supply.

  A manually filter winder machine consumes less power than an automatic filter winding machine. The automatic model may have different types of motor power, such as servo motors and stepping motors.

  For example, the power of the TW-01 winding machine is 1HP, and its operating voltage is 220V. On the other hand, the automatic filter winder machine has a motor power of 80W-1000W, and the voltage specification is from 110V to 380V.

• Production Speed

  An automatic filter winder machine offers a higher production speed than a manual model. Production speed means the number of pieces the machine can produce in a given time.

  For example, the manual winding machine produces up to 180 filters per hour. On the contrary, the automatic model increases production speed to between 21 and 25 pieces per minute. This production speed may vary based on the motor power, fabric used for filters, operator efficiency, and other factors.

• Winding Diameter and Length

  These specifications depend on the model and determine the filter's core or cylinder size.

  For example, the automatic filter winder model TW-01 has a winding diameter of 30-110mm and a winding length of 1000mm. The diameter and length in a manual model may vary.

• Control System

  The control system in an automatic machine model may have different features.

  For example, the controlling system has a digital touch screen for easy setting and operation. The system also has functions like counting, adjusting speed, and parameter storage. In some models, the control may be remote or have an integral locking system for safety purposes.

Maintenance

To operate a filter winder machine for many years, it is essential to carry out regular maintenance. The machine performs the following tasks:

• It filters the raw substances into refined numbers of filters.
• It winds the filter paper with precision into cylindrical shapes using a specified winding ratio.
• It labels the filters clearly for easy identification and reference.
• It facilitates the packing of the filters in suitable boxes or containers for storage or distribution.

Despite its important functions, the maintenance of a winding filter machine is not complicated. The following maintenance tasks are straightforward and can be done routinely:

• Daily Cleaning: It is essential to clean the winding area to remove any bits of paper or dust accumulation. Use a soft brush or a lint-free cloth with a mild cleaning solution to go over the parts without abrasives.
• Lubrication: Lubricate moving parts of the machine with the right oil or lubricant recommended, including bearings and gears. Check and ensure there is no excess oil or residue in the filter-making area.
• Visual Inspection: Carry out a visual inspection on parts of the machine, including conveyor belts, filters, and pulleys, to see if there are any signs of wear or tear and immediate replacement of any parts that need it.
• Calibrate and Adjust: Periodically, parts that need adjusting, such as length and filter width and winding tension, should be calibrated. This ensures consistency in the quality of filters produced by the machine.
• Clean Filter Parts: It is essential to be sure that no paper fibers are stuck in the filter parts and to clear any blockages that could affect production.
• Maintain Electrical Components: Regularly inspect electrical components like sensors and motors to ensure safety and proper machine function as per the manufacturer's instructions.

Finally, a timely review of the winding machine manual helps to understand service requirements, operating instructions, and safety precautions for smooth production.

Usage scenarios of filter winding machines

• Production of industrial oil filters

  These types of filters are made in high volumes using machine winding techniques. The automatic filter winding machine is the true hero in this case. The heavy-duty winder can manage the endless loops of filter material needed for oil filters in big trucks, construction machines, and other industrial gear.

• Production of automotive oil filter cartridges

  Automotive oil filters aren't just small versions of industrial ones. They're engineered to handle the specific demands of car engines. Different machines can be used depending on the number of filters to be made and the size of the filter. An automatic machine may be used if making a large quantity. For smaller production runs, a semi-automatic filter winding machine would be better.

• Production of air filter elements

  This winding machine is perfect for making air filters found in homes, offices, HVAC systems, and the cleanrooms of industrial facilities. Those need to capture as much dust as possible, so they're really big compared to the typical filter behind the vent at home. The filter material is also pleated to get more surface area inside the box.

• Production of water filter cartridges

  Every drop of that filtered water counts! So, water filter cartridges are often small but need to be tightly wound to maximize the filter material's surface area. So, a filter winding machine would be perfect for making those little wonders that could be used in under-sink water filter systems or whole-house filtration setups.

• Production of vacuum cleaner filter containers

  Filters for vacuum cleaners have to be made fast and efficiently. Using a semi-automatic or manual filter winding machine to produce such filters is ideal because customers will purchase filters in many different quantities.

How to Choose Filter Winding Machines

There are a few things that buyers should research before purchasing industrial machines for manufacturing filters. First of all, buyers have to decide what kind of machine they are going to buy for their filter-production business.

Automatic filter winding machines are probably the most efficient option, but they also tend to be the most expensive. Therefore, buyers will have to budget carefully and possibly look for investment options to purchase an automatic machine. If buyers are on a tight budget, they could settle for a semi-automatic or manual machine that is more affordable.

Next, buyers will have to decide on the specifications and details of the machine, including the diameter it offers, the maximum winding length, the speed of the machine, its power, and how the product is fed into the machine.

Product dimensions will differ according to the type of machine ordered, so it is best if buyers familiarize themselves with the types of filters they will be winding. For example, cylindrical filter wands have different dimensions than small, round filters used in air purifiers.

Consider the skills of the employees working at the production line. If the employees are not skilled in using machines, it might be a good idea to invest in an automatic machine that does not require many skills to operate. Training employees is a better and more cost-effective option than wounding money on a semi-automatic or full-automatic machine that needs skilled workers.

Lastly, it is advisable to get samples of the machines from manufacturers before making a bulk order. When buying filter winding machines in bulk, buyers should negotiate bulk pricing. They should look for discount offers when ordering large quantities and consider shipping costs.

Q&A

Q1: Are automatic filter winding machines worth it?

A1: Yes, they are worth it. Automatic machines increase production speed, provide consistent quality filters, and reduce labor costs over time.

Q2: Can a programmable filter-winding machine handle different filter materials?

A2: Yes, most programmable machines can handle various materials as long as they are compatible with the machine's winding speed and tension requirements.

Q3: What is the maintenance requirement for a film-type filter winding machine?

A3: Regular maintenance includes cleaning, calibrating the winding tension, inspecting for wear and tear, and scheduling professional servicing as required.

Q4: Does a manual filter winding machine have any advantages?

A4: Yes, there are benefits. Manual machines are generally more affordable, easier to operate, and suitable for small-scale production or homemade filters.

Q5: How long does it take to wind one filter using automatic machines?

A5: This depends on the machine's speed setting. However, in general, modern machines can wind more than 1,000 filters in one hour.