For any tobacco factory, the Molins HLP series (including HLP 2, HLP 4, and HLP 5) is a familiar sight in the hard pack packaging workshop.
However, the equipment frequently experiences problems:
New blades may fray at the cut.
Packs may not fold properly at high speeds.
Gear wear cycles may be abnormal.
The root cause is insufficient "precision" in the spare parts you use.
Today, Hansheng will take you through a breakdown of the core mechanism of the Molins HLP, using our real data and manufacturing processes to show you how to revitalize older machines with high-quality spare parts.
Cutting System
The cutting unit is the most "violent" part of the packaging machine. It needs to cut the inner liner paper, aluminum foil, or cork paper in a very short time. This is like using a pair of scissors; if the two blades don't mesh tightly, the paper isn't being "cut," but rather "ripped."
Pain Point: Why are there always burrs on the cuts?
Many customers find that the Tobacco Cutter Knives or Cigarette Paper Cutting Knife has a short lifespan. This is usually because the clearance between the blade and the base blade (anvil) is not properly adjusted, or the blade itself is not flat enough.
Principle
You can think of it as scissors. The core of cutting lies in the instantaneous contact between the rotating blade and the stationary blade (such as a rotary cutter). If the processed surface of the blade is not flat enough, for example, if there are invisible wavy lines, then the blade will generate tiny vibrations when it hits the base blade. Vibration is the enemy of carbide; it will cause the cut to chip quickly.
Hansheng's Solution: Mirror-Level Machining
To solve this problem, we don't use ordinary grinding machines, but instead employ a Japanese-imported (Western Electric wire EDM) system. It uses electric current to "etch" away excess metal at micron-level speeds.
This allows us to control the insert's tolerances within expected values, achieving ±0.002mm Super Mirror Processing. This means that when you install our Tungsten Carbide Cork Knife, the cutter surface is as smooth as a mirror, with near-perfect fit to the machine. The lifespan is naturally significantly extended.
Transmission System
If cutting is the hands and feet, then the transmission system is the heart of the machine. The core operation of the Molins HLP is "intermittent motion"-turn once, stop once, load a cigarette, turn again.
Pain Point: Why does the machine "shake"?
At the moment the machine stops (Dwell Time), if there is a gap in the positioning parts, the turret will wobble slightly. This wobble can cause difficulty in loading cigarettes, or even jamming. We usually use arcseconds as the unit of gap.
Hansheng's "Zero Backlash" Challenge
Ordinary Cam Indexers may only have an accuracy of ±60 arc sec, which is sufficient for low-speed machines, but disastrous on the HLP 5. To eliminate wobble, we implemented extremely stringent standards in manufacturing the Cam Indexer and Hollow Rotary Table:
- Standard Accuracy: ±30 arc sec (already better than most products on the market).
- Custom Accuracy: ±15 arc sec.
The Secret Behind Gears
Hansheng's Planetary Gearbox and Harmonic Drive focus on solving the "backlash" problem.
- P1 Precision Backlash: ≤ 2 arc min.
- P0 Ultra-Precision Backlash: ≤ 1 arc min.
This is like a car's steering wheel-perfectly precise with no play. To produce gears of this caliber, we use the Kashifuji Gear Skiving Machine KPS30.
This machine can process gears that meet ISO/DIN/GB Level 5 standards. Even with tiny 0.1 module gears, we guarantee perfect tooth profiles, ensuring your machine runs as quietly as new.
Forming System
Friction is the biggest enemy when tobacco is rolled into a cigarette and passes through the Garniture.
Pain Point: Cigarette Misalignment or Wrinkling
If the channel is not smooth, or the drive belt slips, the cigarette will deform. This mainly depends on two parts: the Garniture Tongue Piece for Molding Machine and the Kevlar Garniture Tapes.
Hansheng's Craftsmanship: Silky Smoothness
The tongue, while seemingly simple, is actually a complex curved surface. If the surface is rough, the resistance as the cigarette passes through will increase.
We use a combination of the Brother CNC Lathe Machine TC-S2A and the Taesin CNC Milling Machine for machining, controlling the contour accuracy to ±0.005mm.
This ensures that the cigarette, when passing through the tongue, will neither fall out due to being too loose nor wrinkle due to being too tight. Combined with our high-strength Kevlar Garniture Tapes, this ensures absolute stability in cigarette delivery.
Basic Materials and Casting
Many suppliers focus only on the "moving" parts, neglecting the "stationary" parts-the frame and housing. But if the foundation is unstable, even the tallest building will sway.
After years of operation, Molins machines may experience deformation in their casting housings. Hansheng possesses strong casting capabilities, including Sand Casting and Lost Foam Casting.
We can process castings up to 3800×1500×1200mm.
Even with such large castings, our machining tolerances can be controlled within ±0.03mm.
This means that if you need to overhaul older machines, replacing the entire gearbox housing or frame, Hansheng can provide structural components that meet original equipment manufacturer (OEM) standards, or even be made of superior materials, providing a stable "home" for high-precision gears and cutting tools.
End: Why Choose Hansheng?
After reading this article, you may understand: maintaining Molins HLP machines is not simply about "replacing broken parts with new ones."
- While others use ordinary grinders, we pursue cutting accuracy of ±0.002mm with Seibu WEDM.
- While others are satisfied with ordinary gear standards, we pursue ISO Level 5 transmission smoothness with Kashifuji KPS30.
- While others ignore backlash, we relentlessly pursue Planetary Gearbox accuracy of ≤ 1 arc min.
Whether it's a small Cigarette Paper Cutting Knife or a complex Cam Indexer, every part delivered by Hansheng undergoes inspection by Gear Inspection Machines and high-precision measuring instruments.
Don't let low-quality parts slow down your production.
If you are looking for a partner who truly understands the principles of Molins HLP technology, please contact Hansheng. Let us safeguard your production line with CNC machining capabilities and top-of-the-line manufacturing equipment.
References
ISO 1328-1:2013. Cylindrical gears – ISO system of flank tolerance classification – Part 1: Definitions and allowable values of deviations relevant to flanks. .
Davis, D.L. & Nielsen, M.T. (1999). Tobacco: Production, Chemistry, and Technology. Blackwell Science.
Jameson, E.C. (2001). Electrical Discharge Machining. Society of Manufacturing Engineers.
Litvin, F.L. & Fuentes, A. (2004). Gear Geometry and Applied Theory. Cambridge University Press.