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1. Station: Blanking and Deep-drawing The tin plate strip is unwound, its surface coated with a thin film of lubricant and the strip continuously conveyed to the deep-drawing press.
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2. Station: Wall-ironing and end forming The cup is conveyed to the wall-ironing machine from the top. The ram first pushes it through the redraw ring to reduce its diameter to the punch diameter whilst retaining the sheet thickness. The cup is held by a blank holder to prevent puckers.
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3. Station: Trimming In the trimming machine the can is held by a vacuum plate, set in rotation and then moved axially until it reaches the required trimming height. Then the movable cutter unit is guided to the can.
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4. Station: Washing The wall-ironing lubricant used in the can forming process is removed prior to coating the can internally and externally. The cans are transported to the washer on a wide belt and conveyed through several washing chambers upside down.
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5. Station: Outside coating The cans are coated on the outside as protection against corrosion and in order to apply a decorative design. White, gold or transparent coating as well as aluminium-coloured coating can be used according to customer specifications. Generally the coatings are water-based.
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6. Station: Printing The externally coated cans are spaced by the intake wheel, as in the coating machine, and drawn on to the mandrel wheel mandrels by means of a vacuum. The mandrels are set in rotation around their own axis by a rotation belt.
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7. Station: Drying The drying oven is basically divided into 3 zones (2 heating zones and 1 cooling zone). The heating zones serve to heat the cans and to evaporate the fluid constituents as well as to cross link the coating and the printing ink. The air in the heating zones is recirculated to reduce the amount of fresh air which has to be heated.
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8. Station: Initial internal coating Inside the internal coating machine, the can is conveyed to a coating turret and positioned on a vacuum plate. It is set into rotation and passes two spray guns, the first one which coats the lower section of the body and the second the body and the base.
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9. Station: Necking in The diameter of the can which is still cylindrical needs to be reduced in the upper section to accommodate the smaller end. During the necking in process the can is loaded on to a lifter and the axial movement of the lifter presses the open edge into the outer tool.
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10. Station: Flanging The flange is required in order to seal the filled can securely to the end. The flange is produced in the 16th station of the necking in and flanging unit.
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11. Station: End coating The metallic bright can end is coated from the outside in the end coating machine. The cans are conveyed via the intake turret to the working turret. Each of the 6 magnetic chucks picks up one can at the flange and sets it in rotation around its own axis.
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12. Station: Second internal coating Depending on the application for which the can is intended, it is then given a second internal coating. The procedure for the second internal coating is identical to the first.
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13. Station: Testing for holes and flange cracks We test all the cans produced for holes and flange cracks. These two types of defect can occur due to the great degree to which the tin plate is formed. Each can is picked up by a support spindle and immediately moved in an axial direction until the open side has reached the flange seal.
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14. Station: Testing for internal defects This test is a continuous 100% test of the inside of the can. It is performed by a CCD line scan camera system comprising five cameras.Camera no. 5 monitors the end and the lower section of the can. Cameras nos. 1, 2, 3 and 4 concentrate on the respective internal section of the can allocated to them.
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15. Station: Palleting The palleting unit assembles the cans in up to 23 layers to a package unit almost 3 m high. The palleting process starts by picking up an empty pallet. Layers of cans and interim layers are pushed on to the pallet until the required number of layers has been reached.
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