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A pope reel for paper machines serves a simple yet crucial purpose: to reel the paper produced by the paper machine into manageable rolls. However, this process is not as straightforward as it may seem. Different types of pope reels have been developed to accommodate various paper types, weights, widths, and machine specifications.
\xa0Single-drum reels
Single-drum reels are the most primitive type of reels found in older paper machines. These machines simply wind the paper around a single drum without any automatic control systems. Operators must frequently stop the paper machine to manually adjust the paper's tension and width, making single-drum reels less efficient than other winding methods. However, they can still be found in outdated facilities that lack modern technology.
Step reeling
Unlike single-drum reels, step-reeling pope reels incorporate a stepping motor to control the reel's winding speed and tension. This winding speed can be changed according to the winding diameter. It provides a better quality of the produced reels and enhances the work's efficiency. Furthermore, stopping the paper machine less frequently can save time, making it a more cost-effective choice for paper manufacturers.
Double-drum/pull-up reels
The pull-up reel system, also known as double-drum reels, is widely utilized in modern paper machines. This efficient winding system consists of two rotating drums that wind paper around them. The pull-up mechanism refers to the way the paper is lifted and wound onto the drums, providing high-speed winding and good tension control. Pull-up reels can handle a wide range of paper grades and offer quick turnaround times for roll changeovers. This efficiency is particularly crucial in high-production environments where maximizing output is essential.
Center-drum/shift reels
Modern paper machines utilize center-drum shifting reels to wind paper centrally onto a shifting drum. This is accomplished by moving the winding drum laterally across the web feed, providing uniform tension control and consistent roll formation. Moreover, center-drum shifting reels have an automatic shift function that enhances operational efficiency by controlling the shifting speed. Additionally, these center-drum shifting reels can handle various grades and weights of paper, making them ideal for high-capacity production lines where optimizing productivity is paramount.
Capacity and diameter:
The final roll of paper produced by the machine is known as the pope reel. Its size and capacity are determined by the parameters set by the machine upstream. Generally, the pope reel diameter fluctuates between 1.5 and 4 meters, while the weight can range from a ton to countless tons.
Reeling mechanism:
The reeling mechanism used in the pope reel machine is the central feature that differentiates one machine from another, whether automatic or semi-automatic, top drive or bottom drive, air-type or hydraulic brakes, or any particular feature that aids in the reeling process.
Cutting mechanism:
The mechanism responsible for cutting the web of paper is also an integral part of how the pope reel operates. Whether it is a flying shear or any other mechanism that enables it to cut with precision is what distinguishes one machine from another.
Core and outer diameter:
Normally, the core of the pope reel is made of robust cardboard, plastic, or metal. The material and size of the core will also depend on what kind of paper is being made, what kind of machine is being used, and what the customer's needs are. The outer diameter of the pope reel can range between 0.1m and 1.5m.
Speed:
The speed at which the pope reel operates is a critical parameter. It is dependent on the kind of paper the machine is manufacturing and the machine's configuration. Normally, speeds fluctuate between 200 to 600 m/min.
Regular maintenance can go a long way toward ensuring that the pope reel's life is long and that it is working as efficiently as ever. Here are some areas that require upkeep.
Lubrication:
Regular greasing of the moving parts, chains, tension systems, bearings, air cylinders, sand shafts, etc., is crucial. Using the right lubricant will ensure that there is no wear and tear from friction.
Air system:
Constant checks on the air hoses and fittings, and cleaning the valves and cylinders, will ensure that the air system is leak-free and pressure-healthy. Any abnormal noise must be immediately taken seriously and addressed.
Electrical parts:
King bolts, clamps, various switches, terminals, circuit breakers, insulation, etc., must be cleaned and inspected regularly, as per the schedule. All electrical connections need to be ensured to be secure and tightly fastened.
Hydraulic system:
The hydraulic hoses, seals, pumps, filters, and valves must all be inspected so that there are no leaks or signs of wear and tear. The system fluid must be changed per the manufacturer's requirements.
Pulp and paper industry:
The pope reel is an essential component in the pulp and paper manufacturing sector, specifically in the final stages of the paper production process. Its primary function during this time is to efficiently wind the newly formed paper onto large cylinders, known as rolls or sheets.
Textile and non-woven fabric industry:
In the textile and non-woven fabric production industries, the pope reel plays a pivotal role in the winding and recoiling of various types of fibrous materials and fabrics. These can include natural fibers like cotton and wool, synthetic fibers like polyester and nylon, as well as composite materials.
Other industries:
Aside from the aforementioned fields, the pope reel also finds application in numerous other industries. For instance, in the metal processing industry, it is utilized to wind metal strips, wires, or cables onto reels. Moreover, in the plastic and packaging industries, pope reels are employed to wind plastic films, sheets, or packaging materials onto reels.
When selecting a pope reel for a paper machine, there are several important factors to consider to ensure that the chosen reel meets the specific requirements of the paper production process.
Make sure it's the right fit for the project
It is important to consider the size and capacity of the paper being produced. This includes the diameter and length of reels needed. If the dimensions do not match, it could cause issues later on, like having to make extra changes during installation or being unable to use it efficiently afterward.
Production line compatibility
It will be very helpful and make things easier if users select a pope reel that works well with the existing paper machine. This means considering things like how it moves, what it does for its job, and its technology features. Choosing a reel that fits nicely with the current equipment will help things run smoothly and efficiently, which is important for maintaining high productivity levels in paper production.
Durability and cost of maintenance
It is a good idea to look for a pope reel that is made to last, as this will cut down on the expenses required for repairs and upkeep over time. By investing in a durable reel, users can help their business avoid spending money on frequent maintenance needs, thereby reducing long-term operating costs and allowing resources to be better used elsewhere.
Choosing energy-efficient machinery
Choosing an energy-efficient pope reel for a paper machine can significantly reduce electricity consumption during operation. This decision not only promotes environmental sustainability but also offers the added benefit of cost savings by lowering energy bills.
Technical support and spare parts availability
A reputable supplier will offer the necessary technical support and readily available spare parts to ensure smooth operation and minimize downtime.
Operational ease and safety measures
Prioritize reels with user-friendly interfaces and robust safety features, such as emergency stop buttons and safeguards against accidents, to protect workers and streamline workflows.
Q1. Which is the most important part of the Pope reel?
A1. The driving unit is the most critical part of the Pope reel. It is the part that drives the reel to perform its functions in the paper-making process. Normally, it consists of a motor, gearbox, and other driving components.
Q2. Are all Pope reels operated the same way?
A2. No. Different Pope reels are operated differently. For example, some are mechanically operated while others are operated using electric motors and hydraulic systems.
Q3. What determines the size of a Pope reel in a paper machine?
A3. The size of the Pope reel is determined by the diameter and length specifications. These specifications depend on the type of paper being produced and the capacity of the paper machine.
Q4. Can Pope reels be modified?
A4. Yes. It is possible to modify Pope reels to suit specific preferences or needs. Nevertheless, modifications have to be done carefully to maintain the functionality and efficiency of the reel.
