PROTOS-M5 at full throttle

To meet the demands of the market, Hauni is now also offering its trusted PROTOS-M5 twin-rod cigarette maker with a 14,000 CPM capacity

The highest level of cigarette production reliability with consistent quality and low production costs – the PROTOS-M5 should offer all these advantages at a speed of 14,000 cpm.

The solution: take tried and tested high-speed components and use them to replace the speed-relevant components of the PROTOS-M5. Increasing the speed to 14,000 cpm involved a number of alterations, such as optimization of the drums and transfer in the MAX, adjusting the performance of the MAX main fan to take account of the higher process speed. The maker has a selective sampling unit (SAM) for finished cigarettes, which has been created for use at the higher speed.

It also has a large filter reservoir for approx. 9,000 filter rods. The perforation performance of the LASER 550S can be adjusted individually for each laser drum. In the SE, the oscillating ledger drive has been replaced by the rotating ledger drive on the knife carrier. This is used successfully in the PROTOS-M8 and thus meets the high standards required for cutting quality while providing flexibility and repeatability during format changes. The PROTOS-M5 for 14,000 cpm sets a new benchmark for cigarette production with its unique tobacco processing system, optimized rod formation, pioneering automation and minimal cleaning times made possible by a continuous cleaning function in the tip-jet-gluing unit during production.

Black and white

With the first KDF-M units now in place in a manufacturing environment, Hauni’s latest double-track maker for acetate and charcoal filter rods has a chance to demonstrate THE STAR QUALITIES expected of M-generation machines.

KDF-M got off to a spectacular start last year when the test machine passed its pre-production trials in record time, chalking up a top output of perfect filters. "We expected good test results," comments project manager Ralf Meyer. "We have extensive experience designing filter makers and we have a reputation to live up to."

Understandably, developers at Hauni, where standards are traditionally high, are ambitious and like to go one better. They feel they owe it to their customers who, over the years, have purchased more than 2,300 filter makers. KDF-M is a line that ideally complements the Hauni product family which includes the leading single-rod filter maker AF-KDF 4, multi-filter maker MERLIN as well as the most recent development TURMALIN for filters with high charcoal loads.

Boasting speeds up to 2 x 500 metres, or in unit terms 10,000 filters per minute, this double-track model gives top performance in all disciplines including slim and super-slim rods. That adds up to shift outputs in excess of 4 million. But KDF-M is not simply a fast line making superb filters. Flexibility is another of its qualities. Little time is needed to change brands, making for a high machine availability figure.

The recipe for success has been to introduce new innovative features while retaining technologies that are known to be good and effective. "We had ambitious goals in mind for the KDF-M, and the technical innovations we’ve integrated on it underline that," says Manfred Dallmann from Product Consulting. "It’s all a matter of ensuring that our customers get the maximum benefit." Features include the spider, the well-established system used in cigarette making and cleverly adapted for use in a filter-making context. It provides an efficient and extremely gentle way to transfer filter rods on KDF-M. Another feature appearing for the first time on a filter maker is the vacuum system now fitted on the drums of the downstream transfer unit, an addition that contributes to the line’s gentle action. "In addition to the standard materials, KDF-M naturally processes highly porous papers and heavy filters with a high acetate density or charcoal load," says Dallmann, picking up a point important to many manufacturers in view of the widening variety of filters and wrapping papers now in use. KDF-M is also the first filter making line to feature a top-mounted gluing unit for more consistent seam quality.

The engineers designing the new AC-M charcoal unit have integrated proven AC features which ensure extremely even distribution of the granules, enabling KDF-M to make top quality charcoal filter rods at faster rates than ever before. Innovative elements include the transport jet in the charcoal section with a new design to optimize tow conveying action and allow easy access. Surplus charcoal is aspirated and returned to the AC-M’s charcoal feed system.

KDF-M exhibits a high automation level, a factor that contributes both to easier operation and the line’s high availability figure. The line restarts automatically after normal machine stops and downstream unit stops, and is also able to perform a semi-automatic on-the-run tow bale change. A standalone BOB-ME bobbin loader keeps the line supplied with filter paper. Waste is shredded and automatically removed.

The KDF-M’s design marks it as a true member of Hauni’s M-generation and customers will be quick to see the benefits. With many components in the new filter maker’s drive and control system identical to those on PROTOS-M5 and PROTOS-M8, less spares need to be stocked at a customer’s facility. Courses of instruction and on-the-job training for operators are shorter, and the similarities between cigarette and filter making lines make it easier for staff to switch between them. "The line has been designed with a modern drive and visualization concept, so that operators and maintenance staff immediately feel at home with it," explains Dallmann. An Operator Guidance System helps to maximize uptime by allowing operators to keep a record of faults and their causes for future reference.

Factors like the line’s unique combination of M-generation twin-rod cigarette maker technology with features from AF-KDF 4, with its advanced tow processing system, are what prompt Meyer to say he’s confident, "KDF-M is going to be yet another of Hauni’s success stories."

Discreetly efficient

Looking for a machine that will effortlessly move any product from A to B? Prefer a fully automatic solution – or a semi-automatic one? A unit that accepts different tray types? One that will let you switch products fast? Hauni’s New-Generation Tray Handling System promises unprecedented secondary efficiency.

Some machines are not headline hitters. Despite doing a great job, they simply don’t produce anything. No record-breaking outputs – no claim to fame. But logistics systems are amongst those indispensable backstage helpers that untiringly go about their work, conveying and storing filters and cigarettes and ensuring that the makers can achieve the high outputs they are capable of. Everyone simply takes star performance for granted, expecting unobtrusive efficiency, dependable function (automatic for preference), adaptability and of course the much-needed "gentle touch".

In designing its new tray handling series, Hauni has concentrated efforts on evolving a system that confidently satisfies those needs, assisting the manufacturing process and making a major contribution to its efficiency. The units can be configured to match the speed and equipment status of the production machinery and suit local manufacturing requirements. Needless to say, each member of the new tray handling family bears the hallmark of genuine Hauni quality with a design that promises gentle product treatment. Manufacturers running standard applications will find themselves dependably served by the C-line, a system consisting of HCF-C tray filler, MAGOMAT-C tray discharger and COMFLEX-CV linkage system. Although C-lines are primarily designed to operate with PROTOS-C making machinery, they can be used equally well in conjunction with rebuilds, earlier maker models and Decouflé machines. As with all other configurations, the element used to connect them is the RTS-V, a newly developed massflow conveying system designed for extremely versatile layouting and featuring optimized conveyor chain geometry for maximum gentleness.

MAGOMAT-F, a tray discharger specifically configured for filter rods including longer, heavier formats, combines versatility with advanced technology. The unit will convey rods of lengths up to 180 millimetres and converts quickly from one product to another. MAGOMATF can be loaded either manually or automatically with standard trays, compartment trays or cardboard boxes and will fit into a making line upstream of any maker type.

Designed for even more convenience, the M-line (consisting of HCF-M, MAGOMAT-M and COMFLEXMV) is the partner of choice for current Hauni maker models, particularly PROTOS-M5 and M8, the MERLIN multifilter maker, the new KDF-M double-track filter maker and AF-KDF 4. Their modularity allows the speed and equipment status of all logistics units to be individually adapted to suit specific manufacturing requirements.

Flexibility is frequently an important consideration, and it is essential for a logistics system to be capable of giving full rein to a modern maker’s potential. With the appropriate Quick Size Change (QSC) kit, brand and length changes (up to 180 mm) are simple, some configurations taking only minutes to complete. This can make an enormous difference efficiency-wise, especially in factories making a wide range of products in small volumes.

Manufacturers keen to push efficiency figures even higher can achieve that by going for a higher automation level. Using compartment trays will minimize rod misalignment and the resulting downtime whilst requiring less human supervision of the process. RFID (radio frequency identification) chips can be attached to trays, providing a technical means of identifying products and ensuring that the correct one is always in the right place at the right time. Tray handling, in fact, is a process that lends itself to gradual automation by increasing the level in a series of planned steps.

The M-line is the ideal choice for manufacturers striving to satisfy the ever-changing demands of the market, as its stage-by-stage upgradability allows them to adapt gradually as needs change, equipping them to cope with tomorrow’s manufacturing scenario yet without putting themselves at risk.

Getting products from A to B is a fast, no-hassle procedure with Hauni’s latest tray handling machines, helping customers to hold their own in the rapidly changing world of cigarette manufacturing.

KDF-M passes muster

With various record results, the new double-track filter maker KDF-M for an output of 10,000 fpm passed the JT Group’s acceptance test with flying colours at its Trier cigarette factory in Germany.

• An average efficiency of 98.5% was achieved in the last 25 shifts to the end of the test.

• During one shift, due to the statutory working-hour limit the KDF-M had to be stopped manually after operating non-stop for 10 hours at maximum output. This record shift ran at maximum efficiency - with a total waste of only 0.03 %. Throughout the entire test, the KDF-M produced a total waste of only 0.13 %.

• Production ran at 100% efficiency in a total of 7 shifts. The last 3 shifts of the test were all completed one after the other at 100% efficiency and without a single stop.

• The KDF-M also delivered outstanding results with a Quick Size Change (QSC) in less than 22 minutes. A Quick Brand Change (QBC) was performed in 2 minutes.

• The quality of the filters produced in the test exceeded all the physical parameters stipulated by the JT Group.

More than 2300 filter makers in the market prove Hauni’s long-standing experience in the development of filter makers. Ambitious developers designed the new member of the M generation family based on the twin-rod principle employed in the successfully established PROTOS-M maker. Whether it’s high porosity paper, acetate or charcoal filter rods, king size or slim and super slims, the KDF-M delivers top performance in every area with maximum flexibility, product quality and efficiency.

Swapping roles

Two BOB-ME bobbin loaders get their bobbins automatically from a gripper that lifts them straight off the pallet. Particularly useful on high-speed lines that require new bobbins in frequent succession, it not only provides a rapid, dependable supply of cigarette paper, tipping and plugwrap bobbins from a central source but also takes a very laborious job off the hands of the operator.

The BD can optionally be connected to a fleet of AGVs (automatic guided vehicles) to automate the supply of full pallets and the removal of empty or near-empty ones. Linked into a customer’s central materials management system, the BD can even generate its own material demand signals.

Hauni and Key Technology OEM

Hauni Maschinenbau AG and Key Technology, Inc. have announced the signing of an OEM distribution agreement that gives Hauni exclusive rights to market Key Technology products to the tobacco industry worldwide. Key Technology will now be the sole supplier of optical sorting equipment to Hauni. Key’s Tobacco Sorter 3 (TS3) and Optyx sorter remove NTRM (non-tobacco related materials) from primary processing lines and threshing lines to help tobacco processors maximize product quality.

The new OEM agreement allows Hauni to market, sell, and service Key Technology’s optical sorters and vibratory conveyors to tobacco processors worldwide. Key will focus on R&D and manufacturing and will support Hauni’s activities, as well as providing upgrade opportunities to eliminate the risk of obsolescence.

"This development combines the expertise of two industry leaders into one comprehensive solution to offer tobacco processors a single source for best-in-class products and services," noted Wolfgang Benz, executive vice president Tobacco Division responsible for Hauni Primary. "Key brings a powerful technology platform and shares Hauni’s dedication to continuous innovation. Hauni complements Key’s product line with a portfolio that includes machines and systems for every processing step. This relationship strengthens our position as the leading solution provider to the tobacco industry because it gives us a superior technology base and supports the development of joint products."

"We are excited to join forces with Hauni because it creates a winning situation for tobacco processors worldwide an both Key and Hauni," noted John Boutsikaris, senior vice president of Global Sales and Aftermarket at Key Technology. "With Hauni’s extensive international sales force bringing Key’s products to market, Key can continue to grow its tobacco business, while maintaining our focus on developing new technologies that will benefit processors in the tobacco industry and beyond."

To achieve superior product quality, tobacco processors rely on Key’s Tobacco Sorter 3 (TS3) and Optyx to detect and remove NTRM including inorganic matter such as cardboard, plastic, metal, string and glass as well as natural materials such as insects, bird feathers and non tobacco plant matter. The high capacity TS3 is ideal for high volume primary processing lines and lamina line applications, while Optyx is ideal for lower volume applications such as inspection of stem, cut tobacco and cigar filler, as well as recovery operations on rejected product for the primary processing lines.