36D twin-screw extruders pipe extrusion series

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1 STRONG ON PERFORMANCE, VERSATILE AND HIGHLY COMPETITIVE ON COST 36D twin-screw extruders pipe extrusion series

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White Goods Construction Life Sciences Electrical / Electronics Whatever you aim to achieve in plastics or rubber processing, KraussMaffei is your partner. We are the only company with intensive expertise across the three main engineering fields. And we have a strong track record in integrating this expertise to develop new processes and systems. Ready for any challenge Our Injection Molding Machinery Division supplies machinery and systems from 35 to 4,000 tonnes for standard applications and for all processing variants, together with fully automated solutions. We have a strong customer base in all the relevant industries worldwide. Our Reaction Process Machinery Division supplies machines and complete systems for processing polyurethanes and other reactive materials. Completing our product portfolio, Automotive Component Systems supplies foam molds, cutters and routers. Our customer base is wide, with a focus on the automotive, construction and white appliances industries. Our Extrusion Technology Division supplies machinery and systems for compounding, for pipe, profile and sheet extrusion, physical foaming, and the production of technical rubbers and intermediates for tire production. Machinery from the company s range from single extruders to complete extrusion lines is used in many industries, including chemicals, pharmaceuticals, automotive, construction, furniture and packaging. People for Plastics We are the people for plastics. We are your partners from the first exploratory discussion, through development to commissioning, servicing and operating your system, and final disposal. At all times, you are assured of outstanding competence in planning and engineering, as well as reliable and fast spare parts, service and support. Adding value for customers We put our expertise to work for your success. With machine ranges engineered for modularity, we can deliver application-specific solutions based on our wide range of standard modules and specially engineered solutions. This strategy offers customers technical and cost advantages. Close to customers around the world As an international company, KraussMaffei has a presence in all the major markets for the plastics and rubber processing industries and employs around 3,000 people worldwide. Our sales and service network keeps us close to all our customers around the world.

3 High throughput and top quality with 36D twin-screw extruders Packaging Our parallel 36D series twin-screw extruders have been specifically engineered for PVC processing. Our aim is to ensure you a good return on your investment through a combination of high throughput and top product quality. The platform for our wide product range is a modular machine concept that enables customized production solutions for costcompetitive, high-performance pipe extrusion. Look at the striking advantages. The specially designed screw concept enables very gentle and homogenous plasticizing. Long processing units ensure stable processes and very reliable production in many different applications. You profit from high output, consistently excellent product quality and an outstanding price/performance ratio over the whole performance range.

4 transparent Technology Meet the machine: take a tour of a 36D twin-screw extruder Gravimetric weighing Horizontal metering unit High-torque gear system Choice of AC or DC drive technology Gear lubricating unit for filtering and heating/cooling the gear oil

5 Suction conveyor Material hopper Blowing agent metering Feed throat Mixer 36D processing unit with molybdenumplated screws and deep-nitrided, air-cooled barrel Vacuum degassing with a sturdy waste pipe and quick connection for easy cleaning Vacuum degassing unit with double solids separator Diagram showing a 36D extruder equipped for foamcore pipe extrusion

6 Design basics 36D twin-screw extruders with an optimized screw concept for ultra-flexible processing of PVC pipe compounds The 36D twin-screw extruders with their HPG (High Performance Geometry) screw concept are ideal in every way for producing U-PVC and M-PVC pipe, foamcore PVC pipe and PVC-O pipe. High Performance Geometry (HPG) The HPG screw design incorporates an effective preheating length with an extended output and mixing zone. The whole length of 36 L/D can be used for processing the PVC compound. This results in significant benefits for processors. The long effective preheating zone means a high degree of flexibility to process a range of material formulations and to deliver maximum output. The long metering zone makes it possible to build up a higher pressure; this makes for a very stable process and optimal control of the melt temperature in the whole output zone. The long mixing zone, together with the optimized geometry of the mixer element, ensures a perfectly homogenous melt. They have a positive impact on the dispersal of additives and blowing agent through the melt. The HPG screw concept reduces process fluctuations for all grades of PVC pipe compound to an absolute minimum. Processing zones in a 36D twin-screw extruder screw 15D = Feed zone 2 = Precompression zone 3 = High compression zone 21D 4 = Venting zone 5 = Metering zone 6 = Mixing zone Technical data and dimensions 36D twin-screw extruder pipe extrusion series KMD E/R KMD E/R KMD E/R KMD E/R Output range [kg/h] Power output [kw] Screw torque, max. [Nm] Screw speed, max. [min -1] Screw length [L/D] Screw diameter [mm] Screw temperature system Internal Internal Internal Internal Extrusion height [mm] Dimensions [mm] Length including intake Width incl. operator console Height incl. hopper

7 CUTTING MATERIAL COSTS PVC foamcore pipe produced on 36D twin-screw extruders Raw material costs can account for up to 90% of the manufacturing cost of plastic pipe. Material costs can be slashed by producing PVC foamcore pipe on 36D twin-screw extruders combined with the foamcore pipeheads developed by KraussMaffei Berstorff. The 36D twin-screw extruders deliver premium product quality. They can be used as main extruders or as coextruders. Foaming the middle layer of the 3-layer pipe reduces its density to as low as 0.6 kilograms per cubic decimeter. This reduces the total density of the composite pipe by up to 30% compared with compact PVC pipe. The use of PVC foamcore pipe in non-pressure applications is on the increase, for example, for waste water pipe. Extruder combination for the production of PVC foamcore pipe comprising a KMD E/R for the outer and inner layers and a KMD E/R to produce the foamed middle layer

8 Detailed product information Our modular extruder concept the recipe for success with cost-effective, customerspecific solutions Like all the extruders built by KraussMaffei Berstorff, the twin-screw extruders in the 36D series are engineered to an intelligent modular design. possible. The system is completely maintenance free. There is no risk of scaling, which can occur with copper fins, so that constant high heat transfer is always guaranteed. The extruder concept Starting with a universal machine frame and a standard barrel, KraussMaffei Berstorff can supply customized extruders closely matched to customer requirements. A closed-loop controlled metering unit with a conveying spiral ensures constant specific melt throughput, even with different formulations. The metering unit is part of the standard system. For a fully-automated extrusion process, we also offer the option of gravimetric weighing. This supports a highly consistent process and lets processors make the most of the potential for material savings. All KraussMaffei Berstorff twin-screw extruders are fitted with deep-nitrided barrels, manufactured using a nitrided steel grade which produces an extremely hard surface in the barrel bores. The parallel screws are armored with a patented molybdenum layer as standard. The molybdenum armoring on the screw flights and the nitrided barrel are an ideal friction couple, offering very good surface slip characteristics and keeping wear to a minimum. Aluminum cooling blocks with cast-in heating coils Air-cooled barrels The air cooling unit is part of our standard system. The system uses aluminum half shells with cast-in heating coils and integrated cooling fins. The temperature sensors are fitted to the sides of the barrel between each pair of cooling blocks so as to keep control circuits as short as Cooling fan Page 12 36D twin-screw extruders for pipe extrusion

9 Detailed product information Lower material consumption and constant product quality with twin-screw extruders from our 36D series Big savings in pipe manufacturing costs through the use of fillers or by foaming the core layer cannot be allowed to impact on pipe quality. Horizontal metering unit with corotating twin metering screws Special metering unit for high filler content In the fiercely competitive PVC pipe market, where producers are face constantly increasing pressure on prices, there is a strong trend towards taking filler content as high as possible. This is especially the case for waste water pipe, but also increasingly for pressure pipe. Producers not only need to increase filler content, but also to obtain very high output and meet market demands for perfect product quality. Formulations with high chalk content (up to 60%) demand significantly higher energy input to process and this is optimally satisfied by a longer effective preheating zone. The 36D twin-screw extruder range meets these technical challenges with ease. The extruder is fitted with a horizontal-vertical metering unit to process compounds with a high chalk content (over 30%). An optional metering unit for regrind can also be integrated. The 36D design guarantees absolutely reliable degassing for normal and highly-filled PVC compounds. Color metering Gravimetric metering for regrind KMD E/R equipped to process highly-filled PVC compounds Vertical metering unit

10 DETAILED PRODUCT INFORMATION The C5 control one of the most advanced control and monitoring systems in the industry Centralized control of the extrusion line Meeting tough specifications for product quality and output demands a stable, reliable production process. This is where the C5 control system scores. As one of the most advanced systems in the industry, it offers dependable technology and intelligent functions for centralized control and monitoring of extrusion lines. For the operator, the C5 ensures optimal set-up and start-up, and a clear, consistent overview of the production process. Monitoring and control is facilitated by efficient visualization of the status of different extrusion line components on a series of screen pages. Central synchronization of the whole line, including multiple extruders, is fast and simple. The operator panel allows direct intervention in the operation of all key elements in the extrusion line. The current operating status of the whole line is always displayed, together with a customizable selection of seven actual parameters. Prompts and alarm messages flash up in your chosen language. The C5 offers extensive documentation options and easy connection to a host computer. The standard design features an integrated operator panel; swivel-mounted or mobile panels are offered as options. The swivel-mounted panel, for example, enables the operator to run the whole line from a position near the die. KraussMaffei Berstorff standard operator panel: integrated in the control cabinet Swivel-mounted operator panel (option) Mobile operator panel (option) Page 10 Detailed product information

11 Customer benefits and applications 36D twin-screw extruders pipe extrusion series The parallel twin-screw extruders in our 36D pipe extrusion series are specially engineered for processing PVC dryblend and highly-filled PVC compounds, and for production of 3-layer PVC foamcore pipe. Your benefits at a glance: Low maintenance thanks to internal screw temperature control and air-cooled barrels Optimal control of the melt temperature over the whole output range Reliable degassing also for highly filled compounds Higher pressure build-up thanks to longer metering zone High output and perfect product quality More flexibility with a wide processing window for different formulations Optimal plasticizing and mixing, eg, of masterbatch Outstanding melt homogeneity Optimized mixer geometry for excellent mixing Low compression ratio in the high-compression phase Cost savings from extended service life for the processing unit, higher output and less load on the gear system Outstanding price/performance ratio Customer benefits and applications PVC foamcore pipe Highly filled PVC pipes Socketed PVC pressure pipe PVC pipes for pressure and nonpressure applications Page 15

12 SERVICE WORLDWIDE Service, support and spare parts when you need them, where you need them Rely on us for a fast and competent response to all your service needs anywhere in the world. Whatever you need from troubleshooting and training to spares or repairs we re on the job. We re dedicated to supplying service quality on a par with the outstanding quality of our machines and systems. We offer far more than spare parts and hotlines. We ll work with you to choose the best and most cost-effective solution for your operation. We ll help you test new applications and we ll plan customized service packages. All-round service Our service offering is broad. We ll configure your system, install and commission it, train your staff, plan measures to minimize your downtime risk and maximize productivity, and carry out maintenance, repairs and upgrades. You ll find us fast, reliable and competent. Our hotline is manned by highlytrained and experienced service technicians. If necessary, we ll get a technician to you quickly. Remote diagnosis, interfacing directly with your machine s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We re continuously expanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business. Customer trials and prototyping in our test lab The Extrusion Division operates a test lab fitted with the latest machinery and equipment. We can run trials, produce prototype parts and fine-tune processes on your behalf. We can work with you to test and evaluate processes, machines and equipment in order to identify the best approach for a particular project. Our highly-qualified application engineers are there to help you. Training with high hands-on content Courses are held in our lab and training centre, or, optionally, on your premises. We offer clearly-structured basic and advanced training in operation, process control and maintenance for KraussMaffei extrusion systems. On request, we ll plan and hold special courses on topics of your choice. All participants spend a high proportion of their training working hands-on with original KraussMaffei machines. A well-structured training program produces skilled operators and technicians, which will positively impact your up-time and productivity.

13 Worldwide hotline numbers KraussMaffei Technologies GmbH Munich, Germany Customer Service Phone: (electrical systems) Phone: (mechanical systems) Application Engineering Phone: Fax: Krauss-Maffei (U.K.) Ltd. Warrington, UK Phone: Fax: Krauss Maffei Corporation Florence, USA Phone: Fax: Krauss-Maffei Italiana S.r.l. Abbiategrasso, Italy Phone: Fax: Berstorff Krauss-Maffei OOO Moscow, Russia Phone: Fax: Krauss Maffei de México S. de R.L. de C.V. Mexico City, México Phone: Fax: KraussMaffei Technologies India Pvt. Ltd. Pune, India Phone: Fax: Krauss Maffei do Brasil Ltda São Paulo, Brazil Phone: Fax: Krauss-Maffei Extrusion Technology (Zhejiang) Co., Ltd. Jiaxing City, China Phone: Fax: Contacting us by post If you need to contact any of our international service or spare parts teams by post, use this address: Extrusion Technology Service KraussMaffei Technologies GmbH Krauss-Maffei-Str Munich Germany

14 KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of experience and a strong commitment to research and development. Our 36D twin-screw extruders have been engineered specifically for optimal processing of PVC formulations and for an outstanding cost-benefit ratio. With a wide product portfolio, based on our modular machine concept, we can offer applicationspecific production solutions which are highperformance and extremely cost-effective. Your decisive benefits include the specially engineered screw concept for very gentle, homogenous material processing. Long processing units increase the stability of the process and ensure a highly reliable production system across a wide range of applications. You profit from high output, constant product quality over the whole output range and an outstanding price/performance ratio. 1.0 WE. 2nd edition 05/10. EXT 017 A PRO 09/2007 GB KraussMaffei reserves the right to make technical changes Printed in Federal Republic of Germany. KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Phone Fax