SHEETS, TUBES, PROFILES, BOARDS, BEADS. XE Schaumex and Schaumtandex Lines

Transcription

1 SHEETS, TUBES, PROFILES, BOARDS, BEADS XE Schaumex and Schaumtandex Lines

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White goods Construction Medical / pharmaceutical 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 Moulding Technology Division supplies machines and systems for standard and special applications, very large machines and fully automated solutions. Our main markets are in the automotive, packaging, electrical, electronics, medical technology and consumer goods industries. Our Reaction Process Machinery Division supplies machines and complete systems for processing polyurethanes and other reactive materials. Completing our product portfolio, Tooling Technologies supplies foam moulds, 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 over 3,000 people worldwide. Our sales and service network keeps us close to all our customers around the world.

3 Secure your competitive edge in foaming with Schaumex and Schaumtandex XE lines Packaging For decades, we have designed and built innovative and yet proven technological foaming systems from foam extruders to complete foaming lines. Thanks to their sophisticated design, our Schaumex and Schaumtandex XE lines are perfectly suited to meet the most varied demands in physical foaming. These lines give a unique edge to your production: PS, PE and PP can be processed without any changes of the screw and barrel configuration, environmentally compatible blowing agents can be used and start-up material, edge trimming and scrap web are easily recycled. In addition, our XE lines feature outstanding productivity, high operational reliability and top product quality. These lines are also particularly suitable for processing high-temperature resistant polymers such as PET, PEI, PES, etc.

4 Schaumtandex ZE110/KE400 PRODUCT INFORMATION IN DETAIL Schaumtandex ZE/KE lines for high quality requirements and extreme troughput rates Stepping up efficiency in foam extrusion Schaumtandex ZE/KE throughput rates The Schaumtandex ZE/KE combination (comprising a twin-screw extruder for compounding and a single-screw extruder for cooling) is our response to exacting requirements on the mixing efficiency in high-throughput foaming processes. This trend-setting configu- 2,000 Throughput (kg/h) ZE50 / KE120 ZE60 / KE150 ZE75 / KE250 ZE90 / KE250 ZE90 / KE400 ZE110 / KE400 ZE130 / KE400 ration incorporates our comprehensive expertise in single- and twin-screw extruder design and 1,500 physical foaming processes. It combines the outstanding mixing efficiency of a twin-screw 1,000 extruder and the excellent cooling characteristics of a single-screw extruder in a single line Page 4 XE Schaumex and Schaumtandex lines

5 Schaumtandex ZE60 /KE150 Schaumtandex ZE/KE benefits excellent size-output ratio with high output rates proven mixing efficiency of the ZE-UT series scalability with a view to future requirements, thanks to modular design of the twin-screw extruder s barrel and screw elements use of standard elements from the proven ZE-UT series high process flexibility through variable screw speed and filling degree excellent cooling characteristics of single-screw extruder through the use of barrels with wet liners and pressurised water for temperature control Schaumtandex ZE/KE lines suitable for a wide range of raw materials, high blowing agent content, throughput rates up to 2,000 kg/h Product information in detail Page 5

6 Schaumtandex KE/KE throughput rates Throughput (kg/h) KE90/KE120 KE120/KE150 KE150/KE250 1, Schaumtandex KE120/KE150 PRODUCT INFORMATION IN DETAIL Schaumtandex KE/KE lines the cost-effective solution for output rates of up to 900 kg/h Proven technology for medium throughput rates Our Schaumtandex KE/KE combination (comprising a single-screw extruder for compounding and a second single-screw extruder for cooling) provides proven technology along with an exceptionally sturdy machine design. Schaumtandex KE/KE lines are a cost-effective solution for throughput rates of between 250 and 900 kg/h. Schaumtandex KE/KE The cost-effective alternative for technologically mature processes with throughput rates of up to 900 kg/h Page 6 XE Schaumex and Schaumtandex lines

7 Schaumex 90 ISO-TUBE PRODUCT INFORMATION IN DETAIL Schaumex lines maximum productivity combined with minimum space requirements System variants Schaumex throughput rates The Schaumex line concept for the entire foaming process: compounding, injection and incorporation of the blowing agent and melt cooling all in a single extruder with thoughput rates of up to 320 kg/h. 1,000 Throughput (kg/h) Schaumex 60 Schaumex 90 Schaumex 120 Schaumex Schaumex lines: compact and sturdy machine design Product information in detail Page 7

8 Active melt seal Schaumex patent no. DE STANDARD FEATURES Active melt seal, excellent cooling characteristics and constant solids feeding the KE single-screw extruder Active melt seal Schaumtandex extruders equipped with the patented active melt seal (ASD) set new standards of reliability for sealing the processing section at the gear box end. Sensitive foaming processes using liquid or gaseous blowing agents, sometimes in high concentrations, plus high system pressure, call for constant operating conditions, which we support with our active melt seal. The active melt seal essentially consists of an additional barrel element with oil temperature control and an additional screw section. A small amount of pellets is introduced into the barrel section by a separate metering unit with cooled feed pipe. The screw element provides for melting and pressure build-up by constant renewal of the melt pool and maintaining the necessary difference in pressure between the active seal and the processing unit. Excellent cooling characteristics To ensure high melt quality, absolutely reliable temperature control is a must. This calls for efficient cooling of the melt in the extruder. With our barrel sections and wet liners we offer an optimum system that provides for high heat removal rates and maximum cost effectiveness. Cooling rates of up to 110 kw/m 2 K are achieved through the use of Pressurised water Wet liners A special screw profile Reliable feeding A water-cooled liner with spiral grooves allows pellets of varying size to be fed without difficulty into the feed barrel section of Schaumex and Schaumtandex lines. Constant feeding is thus ensured throughout the entire speed range. Page 8 Standard features

9 Twin-screw extruder STANDARD FEATURES Modular design, special screw elements and optimum processing sections the ZE twin-screw extruder Modular design In the design of the screw elements and barrel units of our ZE extruders we have applied a strictly modular concept. This supports an almost unlimited range of variants and options to choose from for a screw-barrel configuration that precisely matches your process requirements. The right turn Our range of screw elements comprises: Conveying elements in various lengths and pitches, multi-flighted, closely intermeshing with self-sealing profile, or with flight edge profile and increased free screw volume Mixing elements in various lengths Kneading elements in various lengths and with kneading disks at various offset angles Blisters and returning elements The optimum processing section The processing section of the twin-screw extruder is configurable to match individual foaming processes. There are barrels in 4D and 6D lengths in open or closed design. 4D side-feed barrels and 6D combined barrels. All barrels for foaming processes are gas-tight and can be fitted with spacer rings for injection of the blowing agent. Screw elements and barrel unit Multi-spline shaft Kneading elements and kneading disks

10 PRODUCT INFORMATION IN DETAIL Top quality film and sheets for any application produced on Schaumex and Schaumtandex ISO-PAC and ISO-TUBE lines Whether expanded polystyrene, light polyethylene foam, heavy polyethylene or polypropylene foam Schaumex and Schaumtandex ISO-PAC lines produce the right sheet for any application: packaging material, especially for food and electrical appliances building material, especially for impact sound insulation technical articles such as seals, edge protection strips, and cover seals roof linings, seals, armrests, and impact protection for the automotive industry and products for countless other applications Depending on the starting material and process used, the film produced can have a wide variety of properties, all meeting the highest quality standards, thanks to the fine-step temperature control in our extruders. Schaumex 120 ISO-PAC Page 10 XE Schaumex and Schaumtandex lines

11 Foam insulation tubes made of PP, PE, and PE/EVA have firmly established themselves in the area of heating, sanitary, and air conditioning installations. Foamed edge protection sections are widely used in the furniture industry. Foamed fun articles for swimming pools are made in a wide range of types and shapes. All these products, and many more, can be produced in consistently high quality using our ISO-TUBE Schaumex and Schaumtandex lines. The four-die tube head specially designed for the ISO-TUBE line provides for reduced line speed at constant output rate. There is no need to interrupt production when changing the extrusion dies because the flow channels can be individually shut off or adjusted. This means tubes, profiles, and rods in varying dimensions can be simultaneously extruded. Machine size The optimum line for any application Max. output (kg/h) for film and tubes PE PS Schaumex Schaumex Schaumex Schaumex Schaumtandex KE90 / KE Schaumtandex KE120 / KE Schaumtandex KE150 / KE Schaumtandex ZE50 / KE Schaumtandex ZE60 / KE Schaumtandex ZE75 / KE Schaumtandex ZE90 / KE250 1,000 ISO-TUBE density 25 g / l 40 g / l diameter 10 mm 200 mm blowing agent butane Expanded PE tubes and profiles: tubes for heating and air conditioning installations, edge protection sections used in the furniture industry, fun articles for swimming pools Light PE foam: impact sound insulation material, packaging film density 20 g / l 150 g / l diameter 1.5 mm 16 mm, width 2,200 mm max. blowing agent butane density 250 g / l 400 g / l diameter 1 mm 3 mm, width approx. 1,000 mm blowing agent CO 2 Heavy PE foam: seals for glass container lids ISO-PAC density 60 g / l 150 g / l diameter 1.5 mm 5.5 mm, width 2,000 mm max. blowing agent butane Expanded PS film: food packaging containers, wall and ceiling insulation material, thermal packaging material for pharmaceuticals, graphic boards density 50 g / l 350 g / l diameter 1.5 mm 5 mm, width approx. 1,500 mm blowing agent butane Expanded PP film: automotive industry, microwaveproof food packaging Product data may vary depending on m achine size. Product information in detail Page 11

12 The special mechanism of the blown film die provides for easy gap adjustment during production. PRODUCT INFORMATION IN DETAIL Special design for optimum film production extruder downstream equipment Custom-tailored ancillary units Our XE Schaumex and Schaumtandex lines are complemented by ancillary equipment of our own design that we either produce at our own facilities or subcontract to specialist suppliers. Blown film die Our blown film die provides high flexibility in the production of film with various thicknesses. A special mechanism allows the die gap to be easily adjusted during the production process. In addition, three independent oil units heat and cool the die head offering a very precise temperature control from the head up to the discharge from the die. This is particularly important for PP foam, since the processing parameters of PP are decisively more limited than those of other polymers. Film calibration unit Page 12 XE Schaumex and Schaumtandex lines

13 ISO-TUBE four-die head Benefits: Thanks to the reduced line speed at constant output, the cooling bath length can also be reduced. Die changes can be made without interrupting production, because the flow channels can be individually shut off via a directional valve. As die changes are simple and straightforward, the production of profiles and rods poses no problem. PP, PE, and PE/EVA blends can also be extruded. The multiple-die heads boost productivity to high output rates. Thanks to the simple die change, sections and rods can be easily produced Product information in detail Page 13

14 Option Page 14 XE Schaumex and Schaumtandex lines

15 LINE CONCEPTS Transparent technology: Schaumtandex ISO-PAC and ISO-TUBE lines The layout shows a complete ZE 60/KE 150 Schaumtandex line comprising: Gravimetric metering system with suction conveyor 20 ZE 60x30D-UTX twin-screw extruder 25 KE 150x30D single-screw extruder 30 Temperature control units (oil and water) 40 Blowing agent metering pump 50 Electric control system 60 Blown film die with air cooling ring 70 Calibrator 80 S-wrap 90 Automatic double turret winder 100 Double tube die 110 Cooling unit 120 Take-off and cutting unit 130 Discharge unit Preline Page 15

16 PRODUCT INFORMATION IN DETAIL Perfectly suited for the sophisticated production of XPS boards - the Schaumtandex ISO-BOARD lines The production of XPS boards is defi nitely one of the most challenging tasks in foam extrusion. Besides the high technical requirements specified for the end products, processes, and production equipment, statutory requirements with regard to permitted blowing agents have time and time again stimulated the search for new solutions. We see ourselves as a reliable partner in this complex scenario. Our expertise in the areas of singlescrew extruders, twin-screw extruders, and foam extrusion enables us to contribute decisively to new solutions for this demanding task. KraussMaffei Berstorff has many years experience in the construction of complete production plants. This experience is also available in the area of foam extrusion. In addition to the extruders and equipment produced by us, we also offer complete material handling systems, ancillary equipment, chip and offcut handling, right through to factory hall construction. Throughput rates of ISO-Board lines 10 Throughput [kg/h] Schaumtandex KE90 / KE120 ZE50 / KE120 Schaumtandex KE120 / KE150 ZE60 / KE150 Schaumtandex KE150 / KE250 ZE75 / KE250 Schaumtandex ZE90 / KE250 Schaumtandex ZE90 / KE400 Schaumtandex ZE110 / KE400 Schaumtandex ZE130 / KE400 2,000 1,500 1, Page 16

17 Production of XPS boards the supreme discipline in foam extrusion. The layout shows a ZE 75/KE 250 Schaumtandex line with a throughput capacity of 900 kg/h. It comprises the following units: 10 Gravimetric metering system with suction conveyor 20 ZE 75x30D twin-screw extruder 25 KE 250x30D single-screw extruder 28 Static mixer 30 Temperature control units (oil and water) 40 Blowing agent metering unit 50 Electric control system 60 Slot die 70 Board calibrator 80 Roller take-off unit 100 Board milling and stacking unit 110 Packaging system 120 Suction system with silo 130 Shredder Option Preline Page 17

18 PRODUCT INFORMATION IN DETAIL Schaumex BEADS lines for the cost-effective production of high-quality expanded pellets With our Schaumex BEADS lines we are setting trends in machine design. These lines produce high-quality expanded pellets (EPP) for the cost-effective production of sophisticated returnable packaging, elastic impact protection elements for cars, and technical articles for industrial applications. The distinguishing feature in the production of PE and PP beads is that the extrudate leaving the extruder is cut directly at the die plate by means of rotary knives. The pellets expand under the effect of the sudden pressure drop and cool down as they enter the water flow. Schaumex 120 BEADS EPP beads for further processing to various moulded parts Page 18

19 Preline Page 19

20 Clearly arranged central operating panel PRODUCT INFORMATION IN DETAIL Automation and control practice-oriented, easy to operate and flexibly scalable The process data management systems employed by KraussMaffei Berstorff are based on the Windows operating system and include: Line visualisation with fully graphic and tabular representation, input monitoring, and data logging Long-term data filing offering the possibility of external data storage (network, tape, CD-ROM, etc.) Trend display of recorded data of variable configuration Recipe management of all process parameters (upon request also in MS-Access) Filing of fault and warning messages for subsequent control, optical representation of faults in the process images Full support of Windows network functions Easy integration of standard software Optional production planning several batches can be pre-set and processed one after the other. Optional computer coupling: upon request, recipe data, trend and production planning data can be converted and made available to other systems via network (in-plant network, control centre, etc.). Page 20 XE Schaumex and Schaumtandex lines

21 The process data management systems used are based on the Windows operating system and offer a multitude of convenient functions and additional options Practice-oriented control systems The standard equipment includes all control and visualisation functions and features flexible scaling according to the specific requirements and the design of the machine. Process survey, large-scale display of key parameters Access via different authorisation levels MDA (optional, on separate PC): our measuring data acquisition system based on Windows includes trend display, long-term data acquisition and recipe management. Easy to operate and flexible with PLC and process data management system With PLC and process data management system. Depending on the process task and appropriate machine configuration, the control system is designed to meet individual requirements. All PLC components applied for this purpose correspond to the state of the art. Programming in accordance with IEC Modular design Networking of peripheral equipment Coupling to the master system Remote assistance via modem Product information in detail Page 21

22 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 or 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 production. 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 in Germany and USA fitted with the latest machinery and equipment. We can run trials 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 Berstorff machines. A well-structured training program produces skilled operators and technicians, which will positively impact your uptime and productivity.

23 Worldwide hotline numbers KraussMaffei Berstorff GmbH Hannover, Germany Customer Service Phone: Phone rubber technology: Phone plastics technology: Phone service hotline: Krauss Maffei Italiana S.r.l. Rezzato, Italy Phone: Fax: Krauss Maffei Corporation Florence, USA Phone: Fax: BKM Servicegesellschaft OOO KraussMaffei Berstorff Moscow, Russia Phone: Fax: Krauss Maffei Mexico Mexico City, Mexico Phone: Fax: Krauss Maffei do Brasil Ltda São Paulo, Brazil Phone: Fax: KraussMaffei Co., Ltd. Shanghai, China Phone: Fax: Krauss Maffei Asia Pacific Pte. Ltd. Singapore 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: Customer Service KraussMaffei Berstorff GmbH An der Breiten Wiese Hannover Germany

24 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. Thanks to their sophisticated design, our Schaumex and Schaumtandex XE lines are perfectly suited to meet the most varied demands in physical foaming. These lines give a unique edge to your production: PS, PE and PP can be processed without any changes of the screw and barrel configuration, environmentally compatible blowing agents can be used and start-up material, edge trimming and scrap web are easily recycled. In addition, our XE lines feature outstanding productivity, high operational reliability and top product quality. These lines are also particularly suitable for processing high-temperature resistant polymers such as PET, PEI, PES, etc. 1.5 GB.2ndedition 03/08. EXTH 001 A PRO 09/2007 ENG KraussMaffei reserves the right to make technical changes. KraussMaffei Berstorff GmbH An der Breiten Wiese Hannover Phone Fax