alpha single screw extruders
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1 alpha single screw extruders
2 Index Extruder models Applications Basic and optional equipment Technical data Processing unit Screw designs / output list SecuRe functionality Interfaces and synchronization Highlights Customer benefits Summary 2
3 Extruder models alpha alpha 45-25B alpha 45-28G alpha 60-25B alpha 60-28G alpha 75-25B alpha 75-30G ProtonA proton.a 45-25B proton.a 45-28G proton.a 60-25B proton.a 60-28G proton.a 75-25B proton.a 75-30G 3
4 Application I Technical profiles Automotive profiles (car seat), PP, HDPE, LDPE, PC, PS, ABS Support profiles for concrete application, PVC-regrind Co-extruded profiles Price tag boarder, transparent/rigid PVC Roller shutter, rigid/soft PVC 4
5 Application II Technical profiles Light applications, PC, transp. PVC Small tubes and pipes coextruded (Hula Hoop) PE corrugated PA, PP, PE, PVC roughened (perforated) pipe (PVC regrind, micronized) Medical grade pipes 5
6 Basic and Optional equipment Smooth or grooved intake part Direct flanged AC drive 2-stage gear box Rupture disc (safety device) Sliding hopper Hour meter Basic BC- SecuRe control (relay) 3x 400V/230V+PE+N/50 Hz Drive display remote control with 15m cable 3-colour LED warning light Synchronization interface (discrete or CanBus) Mass pressure & temperature sensor UPS (uninterruptible power supply for controls) Optional Gravimetric interface (screw speed) Leveling pads or height adjustable rolls 6
7 Technical data Technical data unit alpha 45 alpha 60 alpha 75 motor power kw screw speed (nom./max) U/min 97/148 81/ /120 screw diameter Unit L/D (smooth/grooved) - 25/28 25/28 25/30 heating/cooling zones - 4/4 4/4 4/4 Adapter zone kw 5,5 5,5 5,5 Tooling zones kw 4 x 5,5 4 x 5,5 8 x 5,5 installed heating capacity kw 8, Installed back pressure 1) bar ) back pressure defined through rupture disc; higher pressures on request 7
8 Processing unit Advantages smooth(b) feed zone: Advantages grooved (G) feed zone: Highest processing flexibility For almost each polymer granulate Simple operation Constant specific output performance High output per screw revolution Back pressure independent PFT-system specific output kg/rpmh Output comparison between smooth and grooved processing unit based on: alpha 45 and 150 bar tool back pressure 0,7 0,6 0,5 0,4 0,3 0,2 25 L/D smooth intake 28 L/D grooved intake 0,1 0, screw speed 150 rpm 8
9 Processing unit Rupture disc - mechanical safety device Rupture disc Bursting pressure 380 bar Rupture disc Tolerance: +/- 5% (360 to 400bar) Melt pressure alarm limit 330 bar Optional: rupture disc for higher pressure available on request 9
10 Screw design 3 zone screw (for multitude technical polymers) 5 zone screw with mixing elements PE, PS, PET, ABS 3 zone screw with shear section soft-pvc, TPE, PP 25 L/D screws 5 zone screw with short mixing elements PVC-pellets Barriere & Maddock screw for grooved version PE, PP 28 or 30 L/D screw 10
11 Output rates Material alpha HDPE kg/h LDPE kg/h PP-R kg/h ABS kg/h PS kg/h PC/ABS kg/h PC kg/h no no no ASA; POM kg/h TPE-S,TPE-V kg/h PA6 1, 11 1, 12 1; PET kg/h no no no PPO kg/h soft-pvc kg/h Rigid-PVC kg/h no no no Notes: (-) on demand: output rates to be defined Minimum output rates are appr. 80% below the warranty values Polymers based on battenfeld-cincinnati material reference list Output rates for 25 L/D depend on: tool back pressure, pellet size, screw design Output rates at 300 bar are appr. 20 % less than at 100 bar PA 1 : recommendation: bimetallic barrel + stainless steel screw special proton.a version alpha B and G is not recommended for PUR= TPU=TPE-U pre-drying is necessary for nearly all technical polymers 11
12 SecuRe functionality battenfeld-cincinnati controller: High precision PID temperature controller Self-tuning capability Integrated on/off function 3- color LED light - is active if: green if extruder is in operation yellow if there are some problems with control voltage or barrel cooling red if barrel or tooling zone are too cold, emergency stop is pressed, melt pressure is too high, control reports internal fault 12
13 Operator panel functionality Remote control Motor display status: stop run ready Motor load in % Set screw speed in rpm Actual screw speed in rpm Display back light Display language English Motor speed control; 0.1 rpm steps 13
14 alpha Interfaces hour meter power receptacles with switch (3x400VAC) (option) E27-CANBus in/out (only in slave mode) Standard analogue (X6) interfaces for: Emergency stop Set value, actual screw speed value (0 10VDC = 0-100%) Start/stop (only in slave mode) 14
15 alpha synchronization Possible synchronization Coex application Via 0-10V if both alpha (master & slave) are based on relays control (SecuRe) Via Euromap if master has a computer control; slave can be a SecuRe Extruder screw speed alpha screw speed (+/-) synchronization via gravimetric signal Haul off speed Haul off synchronization via extruder screw speed only if the downstream can convert the 0-10V DC extruder speed signal Impossible synchronization alpha (SecuRe control) can not operate as CANBUS Master alpha does not support Euromap 27 communication with downstream equipment 15
16 Customer benefits Highlights Costumer benefit 5 clear and precise arguments! 1. Quality 2. Performance 3. Flexibility 4. Reliability 5. Price 16
17 Customer benefits 1. Quality Manufactured with best European materials Mechanical transmission No belts, no slip, exact speed control A.C. Motor Maintenance free Two-stage gear Integrated gear-coupling- motor arrangement Minimum space requirements Thermoregulation unit Ceramic heater bands Even temperature distribution Air cooling distributor Stainless steel execution Control panel A.C. motor Remote control panel for key functions New sliding hopper with 3 positions Stainless steel Control material level Simple and fast to use Temperature control 4 barrel heating/cooling zones 4+1 tool heating zones (8+1 for alpha 75) High precision PID Temperature controller with self-tuning capability 17
18 Customer benefits 2. Performance Best performance with alpha family Maximum productivity; wide range of polymers & applications Each alpha can operate with perfect quality at high output Examples for alpha 60-25B performing above output table upvc profiles: some customers are running up to 100 kg/h soft PVC: up to 140 Kg/h Corrugated pipes: up to 114 Kg/h 47,5 m/min with DN 16 LDPE pipes: up to 80 Kg/h It is possible to process from 10 up to 300 kg/h with different materials for various extrusion applications: profile, pipes, hoses, coextrusion, rods, medical tubes, seals, cables etc Plug and produce: immediate start-up 18
19 Customer benefits 3. Flexibility alphaflexibility = highest modularity on the market!!! 20 different basic configurations + options & different screws to meet customer needs alpha45 25B or 28G proton.a 25B / proton.a28g Bimetallic PA.version - (* special 30G ) alpha60 25B or 28G proton.a 25B / ProtonA 28G Bimetallic PA.version - (* special 30G ) alpha75 25B or 30G proton.a 25B / proton.a 30G Bimetallic PA.version 19
20 Customer benefits 3. Flexibility customer asks for an extruder able to produce with almost any material, for all kinds of products at maximum production capacity, performing also at low speed and with excellent plastification performance the answer is alpha customer asks for an extruder as complete machine with all the necessary components, thermoregulation, safety and alarms, with melt temperature and pressure sensors. A machine which also offers the possibility to be used as a co-extruder, which can be mounted on wheels and which offers the possibility of having a remote control panel in one hand while optimizing the process the answer is alpha 20
21 Customer benefits 4. Reliability Important for you fast on time delivery, constant production quality, without interruptions and without loss in production alpha provides the reliability customers are looking for! Reliability for many years in production!!! Quality Strong construction Simple to use Large range of processed products Minimum maintenance Spares parts easy to find and always available Wide range of materials and applications Many accessories to complete an extrusion line Over 700 alpha produce worldwide The best evidence for customers confidence 21
22 Customer benefits 5. Price Fixed and equal price all over the world Maximum correctness for all customers alpha * * Price Basic extruder prices incl. screw Not included options: Melt temperature- & pressure measuring, UPS (controls voltage drop protection), UL execution * alpha75 with 8+1 tooling zones and frequency converter At first competing products may look interesting, but it is important to compare the offers and the real production agility! 22
23 Summary alpha Extruder: the right choice for technical profiles and small pipes 3 extruder sizes with smooth or grooved intake zone Multiple screw designs for your materials Extruder on stock / shortest delivery time Cash & carry plug & produce Best price/performance ratio 23
24 Successful through successful customers. Long-term profitable growth. leading solutions.
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