Automatic Mask Making Machine APL110
APL110 Automatic Mask Production Line is the latest medical mask production solution offered by TESTEX, featuring in:
- High capacity of 110 pcs / min;
- The movement control system adopts servo motors, offering the most stable welding actions, result in accurate earloop welding performance;
- Smaller 1+1 design, saving your shipping cost.
Full Automatic Face Mask Making Machine (APL110) is constructed with 3 major parts, they are automatic mask bodies forming machine, automatic earloop welding machine, and the conveyor.
The mask raw materials (Meltblown, Exterior & inner layer Spunbonds, and Nose wire) are formed together by the automatic mask body making machine, then be delivered to the automatic earloop welding machine and be weld with the earloop automatically, finally stacked on the conveyor.
|Automatic Mask Body Making Machine||1 Set||120+ pcs/min||110+ pcs/min①|
|Automatic Ultrasonic Earloop Welding Machine||1 Set||110+ pcs/min||110+ pcs/min|
① Need to be adjusted to match the capacity of the automatic earloop welding machine
② The movement frequency of the conveyor can be set on the automatic earloop welding machine controller, like 10 pcs, 15 pcs, 20 pcs …
Advantage #1: Avanced conveyor belt + servo motor
The Ultrasonic Earloop Welding Machine’s transmission mechanism is: servo motor + rubber conveyor belt, to ensure the welding speed, accuracy and stability of the mask ear belt.
However, the low-quality mask machines on the market still use the lowest-cost ordinary motor to drive the chain drive (similar to the chain of a bicycle). This structure is not only easy to break, increasing the number of maintenance and cost, but also the lubricating oil on the chain is easy to cause Contamination of masks.
Advantage #2：Well-organized wires & details
When designing APL110 Mask Machine, our engineers take the elgant and uniform into consideration, which resulted in well-organized wires, tubes, data lines and details.
Benefits of keeping every detail uniform:
- No accident interuptions caused by wires loose, tubes diconected, and etc.
- Easy maintenance
- Elegant appearance
Advantage #3：Quality proved by repeat sales data
After we counted the sales data of mask machines from March to the end of September, we found that repurchase rate of TESTEX mask machines is up to 60%.
Advantage #4：Long-term production verification on stability
At the 2020 China (Dongguan) International Medical Epidemic Prevention and General Health Development Forum and Exhibition, TESTEX APL110 mask machine is the ONLY mask machine that dared to maintain the production of 110 pieces per minute throughout the exhibition. The stable quality is obvious to all .
In order to let oversea customers to check the stability of the mask machine, we continue to broadcast live on the Youtube platform for up to 2 to 3 hours.
|APL110 We offer||Automatic line in the market|
110 is our stable value we promise, which is not the testing or unstable capacity
|80 ~ 100 pcs/min |
1+2 model, This is just the claimed capacity by the supplier, in fact, the actual production is less than 80 (due to the frequent interruption during the production, since the machine line has more components to sync).
For 1+1 model, the best we can found in the market is 100 ~ 120 pcs/min (while 120 is disclaimed as testing performance, not meant for stable)
|How many earloop welding machines in one line?* ||1 Set||2 Sets / Set |
|Set-up||4 hours set-up time||Many days of trial and error |
|Machine quality||Brand accessories: SMC cylinders, scissors, sevo motors, belts, and etc.||Most are no warranty for key components for low-cost purpose, which result in endless after-sales problems|
|Machine structure design||1+1 model design, specialized for exporting purpose, reduce the total shipping cost||1+2 design, compared to 1+1 design, add shipping volume up to 50%, which means about 50% extra cost |
Even the 1+1 models are most large and dull (Simply remove one set of earloop welding machine from the 1+2 model, not redesigned)
|Main controller interface||Customized UI for mask production, easy & intuitive to use Language available: English, Korean, Chinese, and your language||Interfaces provided by suppliers, no optimization for mask production, poor translation|
|Services||Detailed video guides on machine installation, material loading, and troubleshooting; |
Live-stream personal support by engineers with clear English communications
Timely & Professional
|Most after-sales services are provided by sales only |
1. Ultrasonic System Tests: Validating Key Components Stability
Before assembling, ultrasonic generator, transducer and steel mold are all tested by professional equipment, detailed tests are as follows:
Each generator will perform repeated wave overload tests under the condition of 3 times the load of the simulated normal production parameters, so that the equipment can be started normally under any high-load work and the components will not be damaged.
Each transducer will strictly detect core parameters such as resonance frequency, impedance and capacitance through professional instruments.
The steel mold adopts American D2 imported steel, processed by state-owned enterprises with advanced heat treatment technology, and the quality is excellent. The frequency, current and other data of the steel mold are strictly tested.
Aging test with ultrasonic combination:
Aging test standards
- Long wave mode: test time> 12 hours, temperature < 50 ℃;
- indirect wave mode: test time> 12 hours, temperature < 40 ℃
2. Prodcution Stimulating Tests: To Validate System Stability
Before packaging, each set of APL110 mask making machine will tested with true mask materials, meltblown fabric, and two layers of PP non-woven, to stimulate the real production condition of medical face masks, to test the stability at the higher producing speed.
Only tested with 3 complete layers of materials, exterior 25 gsm PP non-woven, filter middle layer 25 gsm meltblown, and interior 25 gsm PP non-woven, can we tell our mask making machines ready to perform well at our clients’ facility.
Mask making machine line is a system, so it need to be tested as a whole system, and serveral minutes of high speed production can tell very little of the system’s stability, the standard we use for APL110 is 4 days of production testing.
3. Redesign & Improvement Based On APL80: Matching The Higher Speed and Stability Requirements
APL80 have a solid foundation of stability at the speed of 80 pcs per minute, we have to redesign and make some structure improments to match the higher (from 80 to 110 pcs/min) speed requirments for APL110.
APL110 redesigned the position of the earloop fetching belt transmission structure, and changed the side transmission to the middle transmission. The uniform force makes a single belt have a longer service life and reduces the frequency and time of replacement of wearing parts.
The earloop feeding structure is redesigned, and the APL110’s design is closer to the ear belt raw material compared to APL80, shortening the earloop transmission distance and reducing the production interruption caused by the tension of the ear belt
Add the nose wire shortage detection function to the alert system (previous model only have the detection on the shortage of mask fabrics), when the nose bridge is used up to avoid the production of masks with missing nose bridge.
For customers who need to fold masks inwardly, without affecting the overall speed, a new device for inward folding masks has been added (Optional function).
|1 kg material can produce masks|
|1 ton material can produce masks|
|How many days 1 ton material can be used|
|One day material consumption |
|Blue/White/Pink||25 g/㎡||Width: 175 mm|
Dia. 55 cm
|Meltblown||White||25 g/㎡||Width: 175 mm|
Dia. 55 cm
|White||25 g/㎡||Width: 195 mm|
Dia. 55 cm
|175 mm||0.853||1172||1,172,333||12||85.3 |
|White||350 m/kg||Width 3.2 mm||90 mm||0.26||3889||3,888,889||39||26|
|White||770 m/kg||Dia. 3 mm||195 x 2 mm||0.47||1974||1,974,359||20||47.10|
Note: The data used in the table are theoretically calculated results and used to estimate the consumption of raw materials only.