MK8 Machine Upgrade & Conversion

1. Objectives:

MK8 Machine Upgrade – Transition from Analog Controls to Human Machine Interface (HMI)

2. Project Background:

The MK8 cigarette making machine, traditionally operated via analog controls and mechanical switches, has proven to be reliable over the decades. However, as technology advances and production demands increase, the need to modernize machine control systems becomes essential. Transitioning to a Human Machine Interface (HMI) allows for enhanced control, improved diagnostics, easier maintenance, and better data visibility.

This upgrade initiative aims to modernize the MK8 by replacing outdated analog systems with a digital control platform built around a Delta DOP series HMI and a Programmable Logic Controller (PLC). This will streamline machine operations, enhance user experience, and enable remote diagnostics and real-time production data monitoring.

3. Benefits:

• Replace existing analogue interface with modern HMI touchscreen.
• Integrate PLC (Programmable Logic Controller) for centralized logic control.
• Improve operator interface and error handling.
• Reduce downtime through enhanced diagnostics and alarms.

OLD ANALOG INTERFACE

UPGRADED Delta DOP Series Human Machine Interface HMI

1. Objectives:

MK8 Conversion from King Size (Ø7.8mm × 84mm) to Slim Size (Ø5.35mm × 97mm)

2. Project Background:

The MK8 was originally configured to produce standard King Size cigarettes (84mm total length, Ø7.8mm diameter). Due to market demand for Slim Format cigarettes, there is a need to convert the machine to produce:

• 5.35mm diameter
• 97mm total length (30mm filter + 67mm tobacco rod)
• 120mm filter rods (4-cut for 30mm)
• 77mm tipping paper

This conversion involves significant changes to key modules, especially in rod forming, cutting, tipping, and filter processing systems.

3. Benefits:

• Product Line Expansion: Serve niche markets and high-end customers.
• Flexible Format Capability: Keeps the machine adaptable to market changes and prevents obsolescence.
• Efficient Use of Equipment: Maximize ROI by adapting existing MK8 machine.
• Improved Accuracy: Reduce waste through precise size fitting and calibration.

MK8 drum configuration for size conversion to 5.35 × 97mm format.

Following major tasks need to carry out for the above conversion on this maker combination:

1. 1. The hopper drive gear box.
   2. Trimmer unit complete.
   3. Trimmer drive gear box.
   4. Variable pulley
   5. Dense end timing setting
   6. Printer unit / setting.
   7. Printer drive gear box
   8. Main drive gear box
   9. Garniture unit
   10. Cut off unit complete
   11. Ledger crank / stroke setting
   12. Garniture unit / short / long / heater/ weight control setting.
   13. Tape drum setting
   14. V way / accelerator setting.
   15. Link up gear box.
   16. Fluted drum.
   17. Cig grading drum
   18. Filter hopper
   19. Filter cutting drum / guides.
   20. Filter round knife unit
   21. Filter grading drum
   22. Aligning drum/ guides/cover.
   23. Accelerating drum / guides.
   24. Swash plate drum
   25. Rolling drum
   26. Rolling block complete
   27. Turning drum
   28. Tipping bobbin
   29. Tipping paper guide
   30. Tipping spicing
   31. Glue roller
   32. Cork drum / knife
   33. Inspection drum
   34. Transfer drum
   35. End scanner
   36. Sampling device
   37. In feed unit
   38. In feed conveyor
   39. HCF filler device
   40. HCF upper transport
   41. HCF lifter unit.