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Davis-Standard says recently completed testing of its direct-drive extruders reveal a system that is quieter and more energy-efficient than AC- or DC-drive counterparts. That direct-drive technology will be on display at the upcoming K exhibition in Düsseldorf, showcased in a 2.5-inch (65-mm) extruder.

August 31, 2010

3 Min Read
Davis-Standard to highlight direct drives, dies, controls, and pelletizers at K

Davis-Standard says recently completed testing of its direct-drive extruders reveal a system that is quieter and more energy-efficient than AC- or DC-drive counterparts. That direct-drive technology will be on display at the upcoming K exhibition in Düsseldorf, showcased in a 2.5-inch (65-mm) extruder. The stand will also feature a ProCone die mandrel, a new pelletizer technology, and control systems for both blown-film and extrusion processes. Interested attendees can also hop a shuttle from the Messe Düsseldorf fairgrounds to Davis-Standard’s Erkrath facility, which is less than 20 km away, for winder demonstrations.

Davis-Standard reports that its testing showed that direct-drive extruders are as much as 70% quieter at 100 rpm, while being as much as 25% more energy-efficient then AC- or DC-drive extruders. Instead of requiring a mechanical gear reducer to multiply the torque and rotate the screw, direct-drive technology utilizes a permanent magnet synchronous motor. Davis-Standard says these extruders are capable of processing a variety of resins for a wide range of extrusion applications, with these systems available in sizes up to 4.5 inches (114 mm).

Die allows layer-ratio changes
Davis-Standard will also display the internal mandrel of its new ProCone die technology, which is engineered for 5- to 7-layer barrier-style blown-film structures. The die’s stackable mandrel allows vertical movement of mandrels within the stack. By allowing mandrel movement relative to each other, the die has greater flexibility to change layer ratios without changing extruder position. The modules, which consist of one cone and one ring, can be rotated to share an extruder or uncoupled and shifted within the stack for use with another extruder. Modules also have a rate-range design for higher or lower output rates or for special resin changes as needs require. The die is available in sizes from 2 to 12 inches (50 to 300mm).

Controls integrate monitoring and parameter changes
In terms of controls, Davis-Standard will display both an Integrator and EPIC control console, with the Integrator being shown engineered for blown film processes. That system controls thickness measurement, internal bubble cooling (IBC), and speed, as well as winder, alarm, and recipe functions.
Davis-Standard calls EPIC its most complete and efficient control system for extrusion operations. In addition to user-friendly control for multiple lines, the EPIC has Remote ACcess Technology (REACT) so that the company’s process engineers and technicians can support customers in real-time from anywhere in the world. REACT allows service technicians to remotely view process conditions at a customer’s plant during a production run and offer a diagnosis without stopping the line.

New pelletizers boost production, die-face life

A new series of underwater, water-ring, and air-ring pelletizers for micro pellets, normal pellets, and macro pellets will be shown by Davis-Standard’s Converting Systems group. The Black Clawson Converting Machinery pelletizers range from laboratory sizes to high-capacity virgin resin plant sizes. These pelletizers allow for 5-25% more production than previous models, according the company, with the in-house manufactured die plates redesigned to enable greater throughputs while nearly doubling the die plate’s face life. Davis-Standard says this enables greater process flexibility for a broad melt viscosity processing range without a die change. The technology was developed to support new markets such as bio resins as well as de-bottlenecking projects and improved scrap recovery at all levels.

Finally, Davis-Standard will shuttle show attendees to its Erkrath Facility, which is about 20 minutes east of Düsseldorf, for a demonstration of new horizontal winding technology. The company says several winders will be shown, in addition to extrusion equipment for a variety of applications. The transportation schedule for this service will be available at the show.
 

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