THERMOPLASTIC EXTRUSION. Automated pump and screen changer systems

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1 THERMOPLASTIC EXTRUSION Automated pump and screen changer systems

2 Maag is the worldwide leading manufacturer of gear pumps, pelletizing systems, and filtration systems for demanding applications in the plastics, chemical, petrochemical, and food industries. Maag develops, manufactures, and distributes innovative, customized solutions for complete pump and pelletizing systems combining the latest technology with longtime experience. Automatik has been manufacturing innovative pelletizing systems of the highest quality for several decades. It is the world leader in underwater strand pelletizing systems. That leadership position is founded on state-of-the-art technology and on comprehensive know-how in all pelletizing techniques and pellet forms. The company's longstanding tradition in development, production and global sales and distribution is complemented by comprehensive advice and service backup. The whole company employs more than 500 staff at its headquarters in Switzerland and its production sites and sales offices in Germany, France, Italy, Singapore, Taiwan, Malaysia, China, Brazil, and the USA and is represented in the markets with its brands Maag Pump Systems and Automatik Pelletizing Systems. Maag is a Dover Corporation company (NYSE:DOV). 2

3 EXTRUSION PROCESSES For high-quality finished products Gear pumps optimize the extrusion process of thermoplasts as they supply the required melt very precisely and efficiently build up the tool pressure thus relieving the extruder itself from building up the pressure. This enhances the performance of the production line, improves the quality of the finished product due to reduced melt temperatures, and increases the lifetime of the extruder. In addition, pressure pulsations and pressure peaks of the extruder are eliminated or at least smoothened as the gear pump dampens such pulsations and peaks. Further benefits of the gear pump are that the chips produced during the cutting process can be recycled and that the pump supplies the melt very uniformly through the die, which in return ensures a constantly high quality level on the final product s side. In terms of processing quality and optical characteristics, products are subject to high standards. Another important aspect in manufacturing and processing of plastic material therefore is filtration, with the filter discharging impurities from the liquid plastic melt. maag pump systems supplies the devices necessary for filtration in numerous fields of plastic production and processing. Permanent development processes improve these filtration devices and thus contribute to our customers and end users satisfaction concerning quality. Without gear pump With gear pump ΔT ΔT Pressure generation Homogenizing Plasticizing Pumping and compressing Pressure generation Homogenizing Plasticizing Pumping and compressing Pressure Temperature Pressure Temperature Modular downstream equipment for customized extrusion processes 3

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5 INTEGRATED THINKING Optimal performance can only be expected from systems which are truly designed to work together Thermoplast producers and processors need to compete in the global marketplace. With our worldwide network of service and parts centers located close to where you are, maag helps you to do this better. Together with our local representatives and OEM partners, we are always ready to provide rapid and competent support to our customers, wherever they are. In planning and optimizing your production system, the experienced sales engineers from maag provide comprehensive advice which is balanced and takes an integrated view across your entire production chain. Our entire staff understands that your success in the marketplace depends upon your product quality and operating productivity. Our approach is therefore to analyze your requirements in precise detail so that we can offer you complete, optimized solutions. Our systems and components are designed for optimal rheological performance and tailored to your material and operating requirements to ensure unsurpassed process reliability and production economics. maag helps you to get the most out of your investment by recommending the processes and solutions which are best suited to your specific application. The maag technical development and testing center provides you with expertise and equipment to perform trials on your material and to put your most innovative ideas to the test under real operating conditions. Our development and testing facility is also ready to perform test runs on your behalf or to devise solutions tailored to your exact filtration and pelletizing needs. With more than m² of floor space, this state-of-the-art laboratory facility is fully equipped with multiple complete extrusion lines, including gear pumps, screen changers, and both underwater and strand pelletizers. We also offer a special test line for elastomer intermediates. The valuable data obtained through this precisely controlled testing, such as flow consistency, surface finish and processing temperature, helps you to maximize your product quality. The maag development and testing center also offers a drop pelletizing tower for low-viscosity melts and liquids. If interdependent components are to seamlessly work together as an integrated system, they must be more than just compatible. The entire product range of maag gear pump, filtration and pelletizing components is designed from the very start to fit together and work together perfectly. The end result to you is a highly efficient, troublefree production line which delivers best possible product quality and output. Our commitment to technical excellence means that long operating life and the highest possible energy efficiency are more than just vague promises. And our commitment to you, the customer, is ontime delivery of the ideal solution at a highly competitive price integrated and complete, from initial requirements analysis through to installation and start-up, and with training, maintenance and support you can count on from day one. 5

6 GEAR PUMPS We have the appropriate solution for every application The compact, durable gear pumps made by maag pump systems meet highest requirements for thermoplastic applications. Thanks to optimized flow channel geometry, short and quality-supportive dwell-times are feasible even for temperature-sensitive products. The gear pumps are easy to handle and guaranteee reliable and quick start-up and shutdown processes for processing extruders and compounding extruders. High conveying stability and task-oriented configuration in combination with a high level of reliability support production stability for repeatable processes. The maag gear pumps convey the medium in a low-pulsation way even when exposed to high differential pressures. Special materials and material processing steps as well as innovative bearings, mainly made from highly wearresistant tool steel, allow high revolutions with corresponding high throughput rates. The excellent degree of efficiency is also due to the flow-optimized design of the flow channels. The modular design and three different series meet varying requirements: extrex GP is the allrounder, extrex HV features a 25% higher pumping volume, and extrex HP is capable of dealing with a differential pressure of up to 400 bar. The trudex gear pumps have been especially designed for high-pressure applications. These high-pressure gear pumps ensure reliable supply quantities at up to 700 bar. This guarantees highest possible product quality. Special, spur-toothed shafts and special sliding bearings ensure excellent efficiency factors while the conveyed medium is stressed only to a very little extent. Optional accessories such as cooling for shaft seals, melt pressure sensors, or temperature sensors complement this efficient gear pump line. 6

7 extrex GP General Purpose extrex HV High Volume Sizes: Throughput rate: 4 to 15,000 kg/h Specific volume: 10.2 to 3,224 cm 3 /U Temperature: Up to 350 C Heating: Electric or liquid Inflow pressure: Up to 120 bar Outflow pressure: Up to 350 bar Sizes: Throughput rate: 80 to 4,000 kg/h Specific volume: 57.6 to 453 cm 3 /U Temperature: Up to 350 C Heating: Electric or liquid Inflow pressure: Up to 120 bar Outflow pressure: Up to 300 bar extrex HP High Pressure trudex High Pressure Sizes: Throughput rate: 10 to 6,000 kg/h Specific volume: 15.6 to 959 cm 3 /U Temperature: Up to 350 C Heating: Electric or liquid Inflow pressure: Up to 120 bar Outflow pressure: Up to 500 bar Sizes: Throughput rate: 60 to 4,205 kg/h Specific volume: 11 to 690 cm 3 /U Temperature: Up to 350 C Heating: Electric or liquid Inflow pressure: Up to 120 bar Outflow pressure: Up to 700 bar 7

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9 SCREEN CHANGERS Best product purity for any filtration application Depending on the particular application, there are various screen changers available for extrusion processes. The sturdy CSC screen changers are based on the proven double-piston design, which operates in a leak-free mode without any additional seals. Rheologically optimized flow channels result in minimized pressure losses. CSC-PE screen changers are particularly suited for applications under restricted space-related conditions. CSC-DV screen changers are perfect at extruding, for example, start-up melt from twin-screw extruders or also change material. The continuously operational CSC-BF/4F backflush screen changer is used for the purification of highly contaminated polymers mainly in recycling processes. CSC Continuous double-piston screen changer CSC-PE Screen changer with optimized filtration area Screen diameter: 30 to 400 mm Screen diameter: 159 to 560 mm Filtration area: 14 to 2,513 cm 2 Operating temperature: 350 C Operating pressure: 500 bar Differential pressure: 100 bar Filtration area: 266 to 3,312 cm 2 Operating temperature: 350 C Operating pressure: 350 bar Differential pressure: 100 bar CSC-DV Screen changer with start-up valve CSC/BF-4F Backflush screen changer Screen diameter: 30 to 508 mm Screen diameter: 30 to 300 mm Filtration area: 14 to 4,052 cm 2 Operating temperature: 350 C Operating pressure: 500 bar Differential pressure: 100 bar Filtration area: 28 to 2,826 cm 2 Operating temperature: 350 C Operating pressure: 350 bar Differential pressure: 100 bar 9

10 SCREEN CHANGERS Minimum pressure loss and leak-free operation The C-SSC single-piston screen changers are based on the proven design which operates with two screen cavities. These two screen cavities are also well suited for continous operation thanks to simple screen aeration. DSC and SSC are an alternative for extrusion applications which accept a disruption in melt flow during the screen changing process. for the handling of thermally sensitive materials. The continuously operational C-FSC screen changer allows a screen change without any melt flow disruption thanks to several screen cavities. The manual screen changer HSC is available in size 45 with a transmission which allows easy screen changing even when space is limited and the device is exposed to high sealing forces. The FSC plate screen changers are all equipped with a pressure-related sealing system and are particularly suited C-SSC Continuous screen changer DSC Single-piston screen changer Screen diameter: 58 to 270 mm Screen diameter: 30 to 508 mm Filtration area: 27 to 572 cm 2 Operating temperature: 350 C Operating pressure: 350 bar Differential pressure: 100 bar Filtration area: 7 to 1,256 cm 2 Operating temperature: 350 C Operating pressure: 700 bar Differential pressure: 300 bar FSC Plate screen changer C-FSC Continuous plate screen changer Screen diameter: 45 to 300 mm Screen diameter: 45 to 180 mm Filtration area: 16 to 707 cm 2 Operating temperature: 340 C Operating pressure: 700 bar Differential pressure: 200 bar Filtration area: 32 to 1,414 cm 2 Operating temperature: 340 C Operating pressure: 550 bar Differential pressure: 220 bar 10

11 HSC Manual screen changer SSC Compact screen changer Screen diameter: 20 to 160 mm Screen diameter: 30 to 200 mm Filtration area: 3 to 201 cm 2 Operating temperature: 340 C Operating pressure: 700 bar Differential pressure: 200 bar Filtration area: 7 to 314 cm 2 Operating temperature: 350 C Operating pressure: 350 bar Differential pressure: 100 bar START-UP VALVE Process-reliable start-up and shutdown of extrusion lines The DV melt valves are based on the proven bolt design operating without any mechanical seals. Such melt valves are applied as diverter valves, safety valves, or start-up valves in plastics production and extrusion and compounding applications. The sturdy design and a reliable electric, liquid, or steam-driven heating system ensure leak-free and trouble-free operation for years, e.g. as start-up aid for underwater pelletizing processes or when start-up material has to be discharged in extrusion applications. When set to production, the melt stream flows down the melt channel and reaches the next downstream station. In order to divert the melt to start-up, the bolt is activated hydraulically. This switching can be slow or quick, depending on the individual process control-related needs and is ensured through various hydraulic systems. DV Start-up valve Channel diameter: 25 to 100 mm Operating temperature: Up to 350 C Operating pressure: 500 bar Advantages: Compact dimensions Any installation position feasible 11

12 SYSTEM CONTROLS For integrated systems The automation systems of the maax series are especially suited for retrofitting and for comprehensive modifications on extrusion and compounding systems in combination with the installation of a melt pump or a screen changer. Central operation, optimal control circuits, and permanent monitoring through maax control systems ensure a significant rise in quality of the final product due to the interaction with the new components. The maax 100S with its well-adjusted standard version covers another system range and gives access to a production routine under optimal and repeatable conditions. The maax 600S is particularly suited to equip entire and complex coextrusion and compounding systems requiring tailored solutions. maax 100S for common extrusion processes Display: 5.7 colour touchscreen Temperature zones: Up to 16 Features: Integrated fi lter monitoring Confi gurable control function for pump infl ow pressure Monitoring of all desired process values Quick fault detection due to plain text messages Online language changeovers maax 600S for complex extrusion processes Display: 15 colour touchscreen Temperature zones: Up to 48 Features: Integrated melt pump control and fi lter monitoring Semi-automatic lifting and retracting of the extruder and of the gear pump Freely confi gurable control functions for all components Drives for downstream devices can be synchronized Monitoring of all desired process values Quick fault detection due to plain text messages Online language changeovers 12

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14 CONTROLS Automated processes do a better job maax 3 is a control concept for small extrusion units with low throughput rates and thus reduced investment volume. The pre-pressure control for gear pumps integrated in the frequency converter in combination with the simple operation and information display offers considerable savings if a gear pump is retrofitted and integrated into the existing system. The maax BF automation system, especially designed for our continuously operational CSC BF/4F backflush screen changers, is the proven control system for recycling applications. As a tailored solution, it offers simple filter operation as well as fully automatic screen cleaning and multiple screen utilization to the fabricator of highly contaminated polymer melts. maax 3 cost-effective solution Display: Temperature zones: Features: Operating panel Optional Simple and unambiguous operation Integrated pressure control Price-optimized for reduced investment volume Fault detection through diagnostic trouble code maax BF optimized for backflush screen changer Display: 5,7 colour touchscreen Temperature zones: Optional up to 6 Features: Anti-blocking mode with movement monitoring Integrated melt pressure measurement Online language changeovers Composition memory Integrated heating zones Screen changer mode Manual or fully-automatic backfl ush mode 14

15 RETROFITTING FOR EXTRUSION SYSTEMS Improving quality and results The expac system made by maag reduces negative impacts such as the pulsation of an extruder. Pulsations may lead to dimensional deviations of up to 5% on the final product due to wear or added recycling material. The expac system significantly reduces such deviations and thus improves product quality. The quality of the material, and of the product later on, also depend on short dwell-times of the melt inside the pumps, screens, and mixing elements. The speed of the entire process and resource-conscious usage of energy define process productivity. expac systems are mainly intended to retrofit already existing systems but can also be integrated into new systems. expac consists of: Drive unit with gear motor and drive shaft Pump Control system, installed in switch cabinet Corresponding instruments Interfaces to already existing systems Screen changers, if applicable 15

16 PARTS, ACCESSORIES, SERVICE AND SUPPORT For maximum productivity and production reliability Products from maag are known not only for their superb operating performance but also for their durability and long operating life. Tailored to material-specific and customer-specific requirements, they help to maximize process efficiency and thus ultimately profitability. Our customers can count on us for comprehensive technical and operating advice, for a complete range of accessories, and for fast, reliable service and parts delivery where you need it, and when you need it. Process reliability and precisely controlled product quality are critical to your competitiveness in the marketplace and a promise that maag makes to its customers from planning and start-up through to maintenance and ongoing system operation. Our gear pumps, screen changers and pelletizing systems are installed and put into service by our experienced technicians, working closely with the customer to optimize operating parameters and system configuration according to technical requirements. Following successful installation, we then provide comprehensive, hands-on training to your operators and production staff. And needless to say, the technical support team at maag is always just a phone call away, whether for routine maintenance or any other needs. This ensures maximum availability and minimum downtime. maag offers its customers the benefits of a truly global service network, including the world s largest network of rotor and knife regrinding services in the pelletizing industry. This enables us to provide fast, reliable, expert service and support which is close to where you are. Rounded out with our pump repair service, our comprehensive range of service offerings means that you can rely on us to meet all your needs. maag repairs and overhauls gear pumps for an extremely wide range of chemical, extrusion, polymer, compounding and other industrial applications. The engineering team at maag is constantly working to offer upgrades for existing systems, so that your production line is always at the leading edge. This serves not only to improve production reliability but also to improve process efficiency, such as by reducing energy costs. Maximizing the operating life of your capital equipment, minimizing production waste, improving operator convenience and safety, and ultimately helping you to achieve the best possible final product quality at the lowest cost these are our objectives in serving you. Because of our installed worldwide base of thousands of systems, along with our own commitment to ongoing R&D, our customers are in a unique position to benefit from our expertise in providing state-ofthe-art solutions tailored to individual process requirements. Superior product quality together with high operating productivity that s our commitment to you. 16

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18 YOUR BENEFITS WORLDWIDE Reliable, expert service and support Our global team of experts and qualified engineers ensure that your production equipment is correctly maintained for maximum reliability. Your components and systems are tailored to your exact requirements, thus optimizing production efficiency from the very start. Your system is installed and put into service by our own qualified engineers. maag components and systems are designed to work together perfectly and built to ensure long, trouble-free operation, thus yielding excellent production economics and reliable operation long into the future. We provide you with a single comprehensive source to furnish and maintain all your production equipment, thus reducing the cost and administrative burden associated with purchasing, operation and maintenance and eliminating the finger pointing among different individual providers. You can count on fast, guaranteed repair and maintenance service from our experienced, highly trained specialists. Because your production availability depends on getting critical parts quickly, our global service network puts our spare parts and accessories close to your doorstep. We offer training for your staff on your premises, or in our service centers helping you to motivate your employees while maximizing operational efficiency, thus ultimately lowering production costs. Our technical support is ready to assist you, or to answer your questions, quickly and unbureaucratically, saving you time and money. Among our application-related services are viscosity measure ments and flow simulations by our experienced application engineers, bringing process transparency to help you (and us) perform better. Switzerland Oberglatt Germany Grossostheim Russia Moscow India Mumbai USA Charlotte France Lyon Italia Milano China Shanghai Taiwan Taipei Brazil Sao Paulo Malaysia Kuala Lumpur Singapore Singapore 18

19 Maag has business roots extending back more than 100 years. The foundations for today s Maag Pump Systems AG were laid by Max Maag in the year 1910, beginning with gear manufacture. The business grew, and in 1928 the company s factory in Zurich shipped its first gear pump. In the decades to follow, Maag engineers developed ever more sophisticated and capable gear pumps. Today, these process pumps are in operation around the world, serving customers in the plastics, chemical, petrochemical and food processing industries. At the start of the new millennium, Maag Pump Systems expanded its product range to include high-performance screen changers and large-area filtration units so that, since this time, it has been able to offer complete systems. After more than six decades serving the plastics industry, it is hard to even imagine this market without pelletizing systems from Automatik Plastics Machinery. Originally founded in 1947 as Automatik Apparate- und Maschinenbau GmbH, the company began developing strand pelletizing systems from its earliest days, bringing the first automated strand pelletizer to the market in the 1960s. The 1970s saw a further burst of innovation, particularly the company s launch of the first underwater strand pelletizer in the middle of that decade. In the late 1990s, Automatik went on to bring its unique drop pelletizing system for low-viscosity products to the market, filling yet another industry need. The company completed its product portfolio in 2003 with the introduction of its SPHERO underwater pelletizing technology. Since this time, Automatik has offered solutions covering a comprehensive range of pellet shapes, operating throughputs and production requirements. The paths of these two extraordinary companies have crossed many times over the years, as both have long been providers of complementary, superior quality systems and components to the plastics processing industry. With their merger in 2010, Maag Pump Systems and Automatik Plastics Machinery were brought together under the umbrella of Maag, offering complete and highly efficient pro duction solutions from a single source. Maag has been a part of Dover Corporation, a U.S. industrial conglomerate, since

20 Switzerland Maag Pump Systems AG Aspstrasse Oberglatt Switzerland P F Welcome@maag.com Brazil Maag Automatik c/o Dover do Brasil LTDA Av. Prefeito Luis Lattore Jundiai SP Brazil P InfoBrazil@maag.com Italy Maag Automatik s.r.l. Viale Romagna Rozzano (MI) Italy P F MaagItaly@maag.com Germany Maag Automatik GmbH Ostring Grossostheim Germany P F Info@maag.com China Maag Automatik c/o PSG (Shanghai) Co., Ltd. Unit F, CITIC Shenhong Plaza. No. 1350, North Si Chuan Rd Shanghai China P F MaagChina@maag.com Malaysia Automatik Plastics Machinery Sdn Bhd ( M) 14 Jalan PJU 1A/8 Ara Damansara Petaling Jaya Selangor Malaysia P F InfoSEA@maag.com France Maag Pump Systems SAS 111, Rue du 1er Mars Villeurbanne France P F MaagFrance@maag.com Singapore Maag Systems Singapore 25 International Business Park No German Center Singapore Singapore P F MaagSingapore@maag.com India Maag Automatik c/o PSG India A-93, OPW Building Rd No.16, Kisan Nagar, Wagale Industrial Area Thane (West) Mumbai India P /13/14 F MaagIndia@maag.com Taiwan Automatik Plastics Machinery Ltd. Room 619, 6F., No.6 Hsinyi Rd., Sec. 4, Da-an District Taipei City 106 Taiwan P F InfoTaiwan@maag.com USA Maag Automatik Inc Continental Boulevard Charlotte, NC USA P F MaagAmericas@maag.com Z_05_EN_2015/03