Processing Technology

System cuts, dries WPC pellets for easy processing

Gala’s i-heat pelletizing and drying system promises WPC processors ease in handling and productivity improvements.

The “i-heat process” permits underwater pellitizing along with drying of wood-plastics composites (WPC). Generally underwater pellitizing has proved unsuccessful for granulating WPC because of its moisture absorption properties. This manufacturer says its results are achieved by utilizing the inherent heat of the produced pellets. In this process, a two-phase flow directly after the pellets are cut allows the pellets’ surface to cool in a fully water-filled cutting chamber to prevent sticking. The second phase is reached by adding gas or air injection within the slurry pipe shortly after the pellets are cut. The air injection creates a mist on the tubing wall and a gas phase in the center of the tube. The gas serves to transport and cool the pellets. The main portion of water is separated from the pellet at an early stage within the process in the slurry tube. The hot pellets reach the centrifugal pellet dryer faster in this method than in standard practices. The remaining pellet surface moisture is removed by centrifugal force. In a standard system, the pellets would be produced at a maximum of 85°C and 0.1% pellet surface moisture in good cases. The WPC pellets leave the i-heat at 110°C and this permits evaporation of most of the remaining moisture. Following this process, moisture readings are less than 0.05%, says Michael Eloo, technical director. Gala Kunststoff- und Kautschukmaschinen GmbH, Xanten, Germany; +49-2801-98013; www.gala-europe.de EXTRUSION Reducing production costs is no pipe dream

KraussMaffei Berstorff’s KM3LRK43 3-layer foam core pipehead offers easy startup and stoppage.

With materials accounting for up to 80% of total manufacturing costs, plastics pipe processors are looking for ways to help economize. This equipment manufacturer says it has a solution with a new multilayer pipehead, KM3LRK43, to produce foam core pipes in diameters from 200-500 mm with wall thicknesses between 3.9-14.6 mm. Maximum output is 1500 kg/hr. Foaming reduces the density of the pipe’s core layer to as low as 0.6 g/cm3. Compared to a compact vinyl pipe, a foam core pipe’s density is reduced by up to 30%. With the KM3LRK43 it is possible to extrude 3-layer pipes with the foamed core enclosed in thin, compact inner and outer layers with a total density of less than 1.0 g/cm3. The pipehead offers tight layer thickness distribution and low densities. Once the three layers are joined in the pipehead, there are no crosspieces to break the flow of the melt. The pressure-optimized design of the flow paths makes it possible to process cost-competitive formulations. The pipehead can be tilted 90 degrees in the carriage to simplify disassembly and cleaning. KraussMaffei Berstorff, Munich, Germany; +49 89-889-92592; www.kraussmaffei.com Specialty technology produces better web

Parkinson’s CRD technology improves films and sheet stretched in the machine direction.

This manufacturer’s patented CRD (compression roll drawing) machine direction orientation (MDO) technology features a simultaneous compression and drawing, or stretching, of the plastics film or sheet. It can be employed on the company’s MDO units to produce low draw-ratio oriented polypropylene (OPP) sheet where the operator can adjust the degree of orientation to match customer needs. The process is said to improve properties such as clarity and haze values, low-temperature impact strength, modulus, and tensile strength. Converters then should have the advantage of improved processing in subsequent operations. The method is said to eliminate PP sagging when thermoforming, and increases sheet rigidity. The company produces MDO units for a variety of polymers (PP, polystyrene, vinyl, polyester, PLA) in versions from small R&D units with 300 mm (12 in) cantilevered rolls to production models with roll face widths more than 4m (157 in). Parkinson Technologies, Marshall & Williams, Woonsocket, RI, U.S.A.; +1 401-762-2100; www.parkinsontechnologies.com Vinyl pipes able to take on tough jobs This manufacturer says its equipment to produce oriented vinyl (O-PVC) pipes produces an end product that provides high impact resistance, stiffness, assurance against fatigue, and good mechanical behavior under loads. Following extrusion, the pipe is oriented to modify the melt’s molecular structure where the molecules align in the direction of the deformation. During this process, there is a transformation of the polymer’s amorphous arrangement into an organized and layered structure. O-PVC equipment can be retrofitted onto existing PVC pipe extrusion lines or the system can be used off-line. Molecor Technología, S.L., Madrid, Spain; +39 902-160-174; www.molecor.com Control systems offer choice of three variants The EXc X20 touch control system for this manufacturer’s extrusion lines offers what it says is decentralized intelligence for centralized operation. This improved unit offers a choice of three desktop keyboard variants as well as the ability to integrate external automation equipment. It has a touch visualization concept with a 17-inch TFT color screen. The combination of intuitive touchscreen operation with simultaneous visualization of process data and keys on a single monitor screen helps make production overview easier. Processors who want to include such automation equipment as ultrasonic wall-thickness gauges or condition-monitoring devices can integrate these items into the central terminal without having to purchase additional operating and display terminals. Cincinnati Extrusion GmbH, Vienna, Austria; +43 1-610-06263; www.cet-austria.com Plus for output highlights line

ZSK MEGAvolume Plus compounder from Coperion Werner & Pfleiderer comes in clean-cut design for operator comfort and safety.

The ZSK MEGAvolume Plus is a co-rotating, intermeshing twin-screw compounding extruder featuring a screw diameter of 76 mm. A new development in this compounder is that it retains a large free volume in the barrel of 1.8 DoDi. Its specific torque has been increased from 8.7 to 11.3 Nm/cm3, which the company says permits this unit’s torque to equal the performance of the ZSK MEGAcompounder. This amount of torque allows compounding of feed-limited products at high throughput rates. Since the mean shear rate during compounding is reduced by the large flight depth and the high filling level, the screw speed can be increased without negative effects on product quality, says the company. Coperion Werner & Pfleiderer, Stuttgart, Germany; +49-711-897-2507; www.coperion.com Product Focus: Temperature Controls Customizable technology gets the heat out

Colortronic’s TCO-U has multiple flow and output options.

Heat placed into plastics processes and parts must be removed, and an increasingly customizable array of technology is currently offered to get the heat out. Compared to central chilling units, which must use high pressure to pump water through an entire facility and can jeopardize plant-wide production if they go down, the Turbogel temperature control unit (TCU) operates beside the press to maximize and localize cooling. Steve Petrakis, president of the North American division of the manufacturer Frigel (Lake Zurich, IL), says the technology, which was recently introduced to North America, also allows processors to isolate specific portions of the mold, with high-pressure water creating turbulent flow (for initial report, see MPW Product Watch, July 2007). The system has a working temperature up to 194°F and is available in single- or double-zone models with high flow rates and a built-in, automatic free-cooling valve. As part of the Ecodry option, this feature automatically provides energy-free cooling when ambient temperatures are lower than process setpoint. Ecodry circulates water at 10ºF above ambient (typically between 75°F and 95°F), with the Turbogel bringing water to the temperature needed at that particular press. Because all Turbogel units operate independently of one another, Frigel says the temperature and pressure will not be affected by what happens on other presses. Turbogel has three models—TD, TB, and TX—with TD providing a direct cooling and heating feature suited for injection molding, blowmolding, and extrusion. The TB model directly cools without heating elements for applications like packaging that require precise control and high cooling capacity. The TX has indirect cooling for processes requiring hydraulic partitions between the cooling circuit and process-circuit isolation. The TCUs use Incoloy low-surface-load heating elements and feature epoxy powder-coated steel frames. Petrakis says the product is nearing energy-efficiency certification in California, with the potential for rebates. The company, which has global headquarters in Florence, Italy, also offers the Microgel, which is a combination chiller and TCU. Customization is the pitch for a new line of Temptek temperature control units that have two levels of microprocessor control with temperature ranges from 30-250°F. Also using Incoloy heaters from 10-16 kW and centrifugal pumps from .75-3 hp, the Temptek TCUs have flows from 35-80 gpm and modulating or solenoid cooling valves. The system’s manufacturer says it has a series of options, which can customize the technology. Flexibility is a selling point for Colortonic’s (Flint, MI) TCO-U, which can be used for a range of processing applications from 100°F (38°C) to 550°F (288°C). The unit features a TEFC (totally enclosed fan cooled) motor, 17-gallon expansion tank with sight glass, and a NEMA-12 control enclosure, ­rating it for protection from dust and liquids by the National Electric Manufacturers Assn. The system is designed with multiple flow and output options, and optional heat exchangers have cooling capacities from 3.9-21 ft2. A “U” style heat exchanger is said to resist thermal stress when exposed to cooling water, and its replaceable tube bundles are cleanable, easing maintenance. From a control standpoint, an off-the-shelf DIN-style auto-tuning PID controller is accurate within ±1%.

Frigel’s Turbogel claims energy efficiency in process cooling.

The controller on Wittmann’s (Torrington, CT) Tempro Plus C Series is designed to grab attention with a color LCD display. Three versions are available: 90°C (200°F) open system; pressurized for temperatures to 140°C (285°F); and pressurized for temperatures to 160°C (320°F). A new design eliminates the heat-exchanger reservoir. Color graphics alert operators to conditions outside parameters, and the system can display up to three values, like set point, flow rate, and pressure, simultaneously. A new control card and software give accuracy of ±0.2ºC (±0.4ºF), with reaction time reduced and the ability to control heating quickly through solid-state relays. Pressure transducers are standard, measuring process line and system pressures electronically to calculate pump pressure, which can also be displayed. The pressurized units reduce the cooling medium by more than 50%, which shortens preheating and cool-down times. By using a solenoid valve to release incoming water into the plant-cooling system, the new Tempro Plus C 140 and 160 units can evacuate molds of any size without overfilling. An optional pump on the 90 model can purge tank water before the mold is cleared. The THW, THO, and THP series from Piovan (Venice, Italy) have also been designed to allow the highest thermal-exchange capacity, with water, oil, and pressurized-water models ranging from temperatures of 20-250°C. Piovan says the systems are suited for injection molding and extrusion, as well as the calibration heads, cylinders, and calenders of thermoforming lines, with the ability to hold set temperatures within ±0.4°C. The heaters here also use solid-state relays to endure thermal wear. Mokon (Buffalo, NY), which offers water and heat-transfer fluid-temperature controls, as well as portable and central chillers and cooling towers, launched a new line of blown-film coolers at Plastec West in January. At the show, Jeff Mallon, sales manager, was only able to bring along a small SLA model of the unit, for which the company had four orders at the time. Utilizing a cabinet design, the system has adjustable legs and can be flipped over, or stacked, which reduces its footprint, so film extruders can use one to cool the inner bubble and one to cool the outer. The system has water throughputs from 600-7500 ft3/min, and a two-way, automatic, chilled-water, flow-control valve, with an optional three-way valve available. Colortronic North America Inc. www.colortronicna.com Frigel Process Cooling www.frigel.com Mokon www.mokon.com Piovan www.piovan.com Temptek Inc. www.temptek.com Wittmann Inc. www.wittmann-ct.com High output highlights extruder entry Making its debut at last autumn’s K show in Düsseldorf, the DS12.28 parallel twin-screw extruder offers processors improved output and greater economy. The unit has a 116-mm screw diameter and a 28:1 L/D. It is said to offer a maximum output of about 600 kg/hr for vinyl window profile extrusion and about 1000 kg/hr for rigid PVC pipe. It was developed, says the manufacturer, especially for increased performance requirements for window profile extrusion. For dual-strand lines, two of these extruders can be arranged to form a pair in the company’s DUO concept, and additional coextruders can be located above these units. The company also has a special feedblock die head, the FRK315, which complements the company’s existing FBL feedblock. This new unit is optimized for production of vinyl foam core pipes in diameters up to 315 mm. Hans Weber Maschinenfabrik, Kronach, Germany; +49 9261-4090; www.hansweber.de Compounding benefits from unit’s new design The recently launched ESE single-screw discharge extruder can be mated in a cascade arrangement with the co-rotating twin-screw RHC compounding extruder to facilitate compounding highly filled polymers. Despite having a process length of only 8D, it is able to build up consistent pressure without increasing melt temperature. The ESE provides a gentle melt treatment and it is said to have large power reserves. Like the RHC twin-screw extruder, it features newly designed heating cartridges and a multistage cooling system. Reimelt Henschel MischSysteme GmbH, Kassel, Germany; +49 561-801-5889; www.reimelt-henschel.com Easy retrofits bring extruders up to speed

West Control Solutions, working with PMA, has come up with retrofit upgrades that improve existing extrusion line performance.

Special retrofit controls to upgrade extruders are said to be easy to install. The system is complete with HMI industry touchscreen and integrated PLC that includes user-friendly features such as graphic color images for temperature zones, pressure, drives, heating current, and melt temperature. Other features include trending, pre-set timer for heating of temperature zones, cold start prevention recipes, and Ethernet connection for off-site monitoring. West Control Solutions, Gurnee, IL, U.S.A.; +1 860-235-4248; www.westinstruments.com High-grade wire compounds benefit

Melt temperature in the MX Kneader rises slower with screw increased speed than in previous MKS models. This is said to provide better compounding quality at 2.5 times higher throughput.

MX Kneader family features 2.5 times more throughput without an increase in line size. Thanks to the redesign of the kneading chamber, a larger volume is possible. Individual processing zones have also been optimized. This means the usual melt-temperature increase as a function of screw speed of high grade polyolefin-based wire and cable compounds is said to be significantly less than with competitive equipment. Screw speed is now up to 750 rpm. The screw oscillates axially each time it rotates, generating a combined motion that is said to intensively but gently mix the melt. Power consumption for compounding is about 15% lower than in competitive lines. Buss AG, Pratteln, Switzerland; +41 61-825-6551; www.busscorp.com Ancillary equipment Device offers alternative for constant flow filtration

Kreyenborg melt reservoir 121/125 helps maintain even melt flow during extrusion.

The melt reservoir presents an alternative concept for processors needing exact pressure and constant-volume flow filtration of the melt. The concept is implemented into a control-oriented combination with a backflush screenchanger and a melt pump. One of the first applications, in a line for extrusion of PET packing straps, showed it can stabilize the melt during highly sensitive processing. The melt reservoir becomes active as soon as the screenchanger requires backflushing. This is reached by a defined limit value. At that time a piston in the reservoir is retracted for a specific time and the reservoir is filled with melt. As soon as this process is finished, the backflushing of the screenchanger starts. Any mass flow loss at the screenchanger is offset by a higher throughput capacity of the melt pump. Following backflushing, the melt reservoir piston is reset in the forward position. Flow channels have been optimized so no degraded material enters the reservoir. Kreyenborg, Münster, Germany; +49 251-214-05856; www.kreyenborg.de Mold temperature control Cold runner system for LSR

D-M-E’s Cold Runner System comes Stateside due to the growing market for elastomer processing in the U.S.

D-M-E Co. expanded its North American product line with the addition of its Cold Runner System, which is designed for molding materials such as liquid silicone rubber (LSR), high-temperature vulcanizing (HTV) silicone rubber, and other elastomers. D-M-E has offered the Cold Runner System in Europe since the early 1990s and is bringing it to the U.S. because of the growing market for elastomer processing. Michael Kreitner, business manager for quick change mold systems and emergent technologies with D-M-E, says the medical, food container, electronic, and automotive markets are ideal candidates for this system. “We believe this is a great product for these industries because of the soft-touch and flexible product applications,” he says. Unlike plastics, which are injected at high temperatures and cooled inside the mold, elastomers are injected at lower temperatures and cured by heating the mold, creating the need for a cold runner system. The technology enables the leftover sprue to be minimized and cycle times and setting times to be reduced. System nozzles are adjustable by volume for optimal filling and each nozzle has a separate piston drive, allowing for further sequential adjustment. Water-cooled nozzles are also available for processing rubbers of varying viscosities. The Cold Runner System can also be accompanied by a valve gate for absolute shut-off; a vacuum unit ensuring very tight tolerances; and a valve gate controller, creating a complete package aimed at the needs of this growing market. Systems can be designed and customized as needed for multicomponent tools. D-M-E Co., Madison Heights, MI, U.S.A.; +1 248-398-6000; www.dme.net Auxiliaries Weekly bolt tightening is a thing of the past A pre-energized technology is said to eliminate the need to tighten bolts on assembly line presses and hydraulic equipment used in the processing sector. Vee-Packings are multiple-lip (chevron) seals comprised of a group of endless rings and can create a seal simply by being fitted into the gland. Tightening of the gland follower to maintain the seal is not required. These seals can be used on hydraulic injection presses, extruders, valves, pipeline expansion joints, and swivels. These units can accommodate temperatures from –40°F to 400°F (-40°C-205°C). They can also be specially designed for split configuration. The company says that properly installed Vee-Packings, always mounted in sets, will generally outperform other lip-type seals. American High Performance Seals, Pittsburgh, PA, U.S.A.; +1 714-593-9780; www.veepacking.com Unit offers perfect cut for high quality From cutting small tubular products at high speed to large, rigid profiles, the Rotary Fly-knife Cutter, CSRK8, is suited for processors who make multiple product changes within a short time frame. Features include a heavy-duty positional 10-hp servomotor that guarantees greater speed-holding consistency, and a higher degree of cut-length repeatability than clutch/break cutters, says the manufacturer. It also has a user-friendly touchscreen PLC panel. The 22-inch aluminum fly-knife wheel permits 400 cuts/min with a ­single blade. CDS Inc., Lachine, QC, Canada; +1 514-633-5933; www.cdsmachines.com Winders PAC50 surface winder gets ­special upgrades

The upgraded PAC50 surface winder family features a touchscreen control mounted on a pendant.

The existing PAC50 series surface winders now feature a compact hydraulic system that uses high-speed digital electronics for lay-on pressure control. This feature is designed to reduce blocking at the core, a problem typical on many large-roll surface winders where the lay-on force is not controlled or is controlled through mechanical means. The new design also features a device to bring the new core up to speed prior to transfer to allow for smoother starts on thin, high-speed webs. A further addition is an integrated shaft-hoist system that allows the operator to easily return the shaft to the transfer position without having to lift it. Davis-Standard, Pawcatuck, CT, U.S.A.; +1 860-599-1010; www.davis-standard.com Plastic pipe repair

The Weldy Plus can repair PVC, PE, and PP, with output temperatures up to 1200°F.

A new hot-air tool can be used for repairing SCH 40 and 80 polyvinyl chloride (PVC) piping systems without glue. The Weldy Plus is a programmable tool that features adjustable heat and airflow, a pipe-welding nozzle, and a 2-lb supply of PVC, polyethylene, or polypropylene welding rod. In addition to piping systems, this kit is also available with nozzles for repairing liners, tanks, and other products. The system features a 120V digital display showing temperatures, which can range from 180-1200°F, with air flows from 7-17.5 ft3/min. The system costs $399. Malcom Co. Inc., Tiverton, RI, U.S.A.; +1 800-289-7505; www.malcomcompany.com SIZE REDUCTION Reclaim problems call for flexible solutions

Cumberland’s 40 series granulators are said to allow access to both bed knives at a ­comfortable working level.

The 40 series general purpose granulators can be used in injection and blowmolding operations, extrusion, and thermoforming applications. The unit offers a pivoting, sound-deadened infeed hopper and the cutting chamber has a drop-down screen cradle. Model 4050 comes complete with a mounted blower and cyclone. It has a 419-mm diameter cutting circle, scooped rotor, and forward offset design. It can handle a wide range of materials. The three-knife, open slant-cut rotor has scooped wings and rotating end discs to provide positive feeding of bulky parts. It also has improved airflow for cooler operation. Cumberland, S. Attleboro, MA, U.S.A.; +1 508-399-6400; www.cumberland-plastics.com Dosing/blending Device gives accurate composition The BDS8 Oberpleis dosing unit is a gravimetric batch blender that can handle up to eight different components. The four main components are added with the aid of a slide valve and up to four auxiliary components can be fed with a special dosing screw. Total output of free-flowing pellets, regrind, additives, and masterbatches is up to 100 kg/hr. Accuracy is ±0.2% batch/hr. Slide valves, blender, and weight-hopper are all stainless steel while the blender top and casing is made of aluminum. Noise level is less than 65 dB (A). Options for the unit include silos, bag emptying stations, big-bag discharge stations, suction conveyors, filters, and piping material. FDM GmbH, Königswinter, Germany; +49 2244-902-532; www.fdm-technik.de Testing & measurement Unit promises leap frog jump in testing The 500 Aloxide heat deflection temperature/Vicat unit permits mechanical testing at temperatures as high as 500°C without endangering operations or lab personnel. This is important for processors of value-added engineering polymers that have a high heat profile. The unit is said to avoid environmental problems related to silicon oil use due to its aluminum oxide heating system. The manufacturer says there is no known oil that can withstand temperatures above 300°C without burning. Therefore the 500 Aloxide uses a micronized aluminum oxide fluidized bed as the heat transfer medium. This permits automatic airflow regulation and the Auto Air System allows best temperature uniformity. CEAST SpA, Pianezza, Italy; +39 011-966-4038; www.ceast.com Noncontact web measurement A noncontact thickness gauge measuring system has been upgraded to include real-time 3D web views, including topographical maps that generate false-color images so thickness data can visually interpreted more easily. The Model 5600 Multichannel Array Gauge features a C-frame measurement head that houses up to 24 lanes of continuous measurement and can measure webs up to 24 inches wide. Information for process setup, process monitoring, troubleshooting, and quality control is displayed by the control software. The unit is said to be ideal for pilot lines and narrow web production. SolveTech, Wilmington, DE, U.S.A.; +1 302-798-5400; www.gauging.com Pipe processing profits from online OD/ID control The demand for improved product quality and reporting by today’s plastics pipe processors has generated the need for more immediate controls to correct any deviation from a norm. The ODAC/UMAC/Wallmaster systems are said to deliver the performance needed online during production. The systems help reduce startup time and scrap because the operator gets an immediate picture of the product’s centering. It also reduces material usage by helping to eliminate running oversized product. Without such systems, the operator often pads the product size of the extruded pipe to ensure the minimum wall thickness is not violated during normal process fluctuations. But by measuring at the exit of the sizing sleeve, this controller system can improve or eliminate this function by staying within an exact, predetermined thickness, thereby cutting expensive resin use. Zumbach Electronic AG, Orpund, Switzerland; +41 32-356-0400; www.zumbach.com Inline hot-fill bottle testing

Inline hot-fill testing with this Connell unit ensures Graham’s bottle output.

Bottle blowmolder Graham Packaging has turned to Connell Industries for a hot-fill bottle-testing system at its Rockwell, TX plant. The system inspects a random 28-lot of product, and for high-speed lanes, plastic molds are checked at least once every hour, with inspections sometimes scheduled every 30 minutes. The hot-fill testing system joins vision and leak-detection systems, and according to Connell, investments in such equipment have a speedy return, saying “avoiding one day of bad bottles would easily pay for this system.” Connell Industries, Rahway, NJ, U.S.A.; +1 877-926-6635; www.connell-ind.com Printing & decoration Pad printer offers new post-treatment option The Pad Print Conveyor Dryer is billed as a flexible, durable parts dryer that can be integrated into inline pad-printing manufacturing environments. Pad-printed parts are conveyed through a drying chamber for post-treatment with the infrared dryer. The dryer&rsq