Alfa Training Report-Sujit Rana

ALFA PEB LIMITED
Following sections are the backbone of inprocess production and Quality of the plant
➢ De-coiling section
➢ Roll forming section(Wall & Roofing)
➢ Polyurethane foaming section
➢ Double belt conveyor with side guide & mould section
➢ Auto panel cutting m/c (Band saw type) section
➢ Stacking section (Vacuum type)
➢ Wrapping section
➢ Slitting, Bending and Hemming section
➢ Single skin roofing sheet making section
1. De-coiler section :
PCGI COIL LOADING AND SETTING:-This is the initial setting process before starting the final setting
process of machine and production of sandwich wall/Roof panel (PUF,PIR,Rockwool). This setting
process are mentioned in below.
Fitting and working procedure of PCGI coil on decoiler mandrel:

1) Discharge the inner axis out of the decoiler, then insert it into the PCGI coil.
2) Carry the PCGI coil together with the inner axis to the decoiler, install the axis on the frame of
decoiler.
3) Use the control panel swtich to tighten the inner diameter of the PCGI coil.
4) Release the brake of decoiler, make the coil sheet run out.
5) working on both Auto and manual mode setting whichever required.
5) There are three de-coiler in our factory one is for bottom skin and other two are for top skin.
Technical Parameters of 5T PCGI coil de-coiler mandrel:

1) Length of axle: 1500 mm
2) Feeding Width: 1000 to 1220mm
3) Capacity: 5 tons
4) Inner diameter: 500mm or 530mm
5) Working mode: inner axle can be expanded & shrank, controlled by control panel swtich.
2. Roll forming section: (Wall & Roofing)

• This is the 2nd setting process before starting the final setting process of machine and
production of sandwich wall/Roof panel (PUF,PIR,Rockwool ) .
• According to the job card and BOQ of the company setting will take place for roofing or wall
partition panel with variable width, plain panel setting or profiled/RIB panel setting.
3. Foaming section:
• This is the 3rd setting process of machine and production of sandwich wall/Roof panel
(PUF,PIR,Rockwool )
• Chemical loading procedure (Iso(MDI), Polyol, Pentane (C5), Catalyst (C1), and Nitrogen
(N2))
• Setting of flow of chemical with proper pressure parameter and reading.
• Foaming machine setting for wall panel with variable width & thickness, roofing panel with
standard width & variable thickness.
• Setting of mixer head position for wall and roofing panel of variable thickness.
• Servo robot setting for delivering the chemical mixer during production.
4. Double belt slate conveyor (Caterpillar) section:
• This is the 4th setting process of machine and production of sandwich wall/Roof panel
(PUF,PIR,Rockwool )
• Setting of center mould for roofing panel (208 x 3 nos mould each).
• Setting of width of bed, setting of caterpillar and chain and side support setting for variable
thickness of roofing/Wall panel.
• Setting the height of the double belt slate conveyor according to the thickness of panel.
5. Side Guide and Block system (Mould):

• This is the 5th setting process of machine and production of sandwich wall/Roof panel
(PUF,PIR,Rockwool )
• Setting of side guide mould (161 nos) each side according to thickness of panel.
• Setting of sticker tape (Plain/Alfa/Any client requested)
6. Auto/Manual Panel Cutting M/C (Band saw type):

• Setting of panel length and no of panel with tolerance limit.
• Both Auto and manual mode of setting available and I have gone through all the setting
details of cutting machine.
• Cutting area premises should be cleaned.
9. Discharge conveyor:
• Discharge conveyor here are operated by sensor and also manually by electric control panel.
• We have to check and look after the roller system, bearings, Chain, chain sprocket and
motor associated with it.
7. Turning and stacking section (Vacuum Type):

• Turning and stacking here are operated by sensor and also Auto/manually by electric control
panel setting.
• It’s operated by hydraulic pressure system and sensor.
8. Orbital/Horizontal Stretch wrapping section:

• It utilizing a moving conveyor to move the load through the stretch wrapping machine and a
rotating ring circle.

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ALFA PEB LIMITED

Fitting and working procedure of PCGI coil on decoiler mandrel:

Technical Parameters of 5T PCGI coil de-coiler mandrel:

2. Roll forming section: (Wall & Roofing)

5. Side Guide and Block system (Mould):

6. Auto/Manual Panel Cutting M/C (Band saw type):

7. Turning and stacking section (Vacuum Type):

8. Orbital/Horizontal Stretch wrapping section:

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