SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES. Sheet extrusion of polyolefins and engineering thermoplastics

Transcription

1 SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES Sheet extrusion of polyolefins and engineering thermoplastics

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 Integrated system solutions for a huge range of PO sheet products Packaging The use of polyolefins has been growing steadily for decades and the trend continues. One important growth area is in extruded sheet. KraussMaffei Berstorff s 36D single-screw extruders are ideal for extruding polyolefin sheet both compact and foamed. We ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It s all at your service.

4 TRANSPARENT TECHNOLOGY Take a tour of a possible configuration for a sheet extrusion line Crosscut saw or router with servo-drive Haul-off Single- or double-strand hauloff, pneumatic positioning of the rubber-covered rolls, adjustable speed differential to polishing stand Swarf extraction Stacker with roller table Roller cooling section Edge trim hacker Longitudinal parting saw with servo-drive, pneumatic positioning of the cutting blade and the swarf extraction unit

5 Optional system components Screen changer Melt pump Static mixer Protective film above and/or below Laminating unit Embossing unit Corona treatment Thickness monitoring Other options on request Radiant heater Combination of area and point heaters, adjustable zone regulation Polishing stand with high-gloss, chrome-hardened rolls, individual servomotor drives and planetary gears, nip monitoring via electronic sensors, constant temperature profile over the whole width of the roll Pressure roll for optimizing flatness (temperature control and drive optional) Temperature-control unit uses water or oil as medium Slit die Single-screw extruder KME B/PL for PO with gravimetric material feed (one to four components) Extruder shown without switching cabinet or C5 control unit

6 Detailed product information Benchmarks for PO sheet production with 36D single-screw extruders Many market segments and application areas are turning increasingly to polyolefin sheet: Be one step ahead of the competition with KraussMaffei Berstorff. Complete system solutions from the world s leading system supplier KraussMaffei Berstorff has long been a worldleading system supplier of PVC sheet extrusion lines. In recent years, we have systematically expanded our product portfolio. We offer complete system solutions for processing different PO sheet grades and custom PO materials. Our machinery and process know-how can give you a decisive competitive advantage, because we configure and supply complete sheet extrusion lines using high-quality components and extensive automation. The advanced screw geometries are a hallmark of our 36D single-screw extruders. The screws maintain the constant pressure, high output and uniform temperature profile essential for the process. The extruder can also be operated without a melt pump. Dedicated systems for foamed PO sheet Chemically foamed PE and PP sheet is finding a lot of new applications, and it is also helping to cut the cost of raw materials for products that are already on the market. To meet high quality specifications, the extruded foam must have a homogenous internal structure and smooth outer surfaces. For the best foam quality, the melt must leave the extruder as a highly homogenous compound with the blowing agent (added as microgranules) uniformly distributed. The melt, which is under pressure, expands immediately on exiting the die. 36D single-screw extruders are ideal for extruding foamed PO sheet. Such sheet has a closed pore surface while the internal core cross-section has a homogeneous, cellular structure. Foam formation is triggered by subjecting the blowing agents to heat. The complex combination of the formulation, the plasticizing process and the special geometry of the slit die lips produces foamed sheet with far lower density than compact sheet. Raw materials consumption is reduced in proportion. KraussMaffei PO sheet die Adjustable coextruder adapter Fast gap and deckling systems Page 6 Sheet extrusion of polyolefins and engineering thermoplastics

7 Berstorff supplies a dedicated extrusion unit for this foaming process: it consists of a 36D single-screw extruder with grooved bush and barrier screw, a screen changer (option) and a slit die specifically designed for foamed PO sheet. Output in sheet extrusion [kg/h] Extruder type HDPE PP KME B/PL KME B/PL KME B/PL KME B/PL KME B/PL KME B/PL KME B/PL KME B/PL on request on request Detailed product information Page 7

8 TRANSPARENT TECHNOLOGY Meet the machine: take a tour of a 36D single-screw extruder Eccentric feed Avoids turbulence and maximizes output Rugged gearing Long life, lowest maintenance costs and space savings (gearbox and motor form a U)

9 Gravimetric material weighing system Deep-nitrided grooved bush Outstanding cooling performance, lowest cooling water consumption, steady material feed independent of counterpressure and selfcleaning Bimetallic barrel Lowest wear rates Barrier screw For thermal and materially homogenous melt and low melt temperatures Optimal drive dimensions DC (standard) or AC (option), air-cooled (standard) or water-cooled (option)

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 Page 11

12 APPLICATIONS AND CUSTOMER BENEFITS All set for the markets of the future tap into lucrative potential with new applications No matter how varied and specialized your PO sheet production needs may be, KraussMaffei Berstorff s 36D single-screw extruders are more than equal to the job. Processing materials for a broad product range The screws in our 36D single-screw extruders have been engineered to deliver decisive advantages in terms of product quality, productivity and costs. With KraussMaffei Berstorff sheet extruders, you can process materials for a whole range of products, especially those used to make water tanks and acid tanks. HDPE sheet unbeatable advantages in countless applications HDPE sheet resists stress cracking, has low-temperature impact resistance, very good energy absorption, high stress resistance, outstanding corrosion and abrasion resistance, low water absorption and very good electrical isolation properties. With a property profile like this, it s the material of choice for a broad range of applications. Here are some of the products that can be made of HDPE: Rotor blades Roller bearing bodies Storage containers Shuttering Wash basins Machine parts Seating Medical prostheses Chopping boards for the food processing industry Shipbuilding HDPE sheet is used in shipbuilding Acid tank made from PP sheet Page 12 Sheet extrusion of polyolefins and engineering thermoplastics

13 Your benefits at a glance: Conveying behaviour independent of counter-pressure at all speeds Low melt temperature levels due to high specific throughputs Excellent plasticizing performance Gentle melt processing and optimal homogeneity Long life through optimized pressure profiles and low wear rates Clear reduction in cooling water consumption for the grooved bush Low-maintenance drive in proven U arrangement Compact machines with a small footprint Outstanding price/performance ratio PP sheet attractive advantages for many applications PP is light, offers optimum abrasion resistance, has excellent electrical characteristics, withstands long-term exposure to temperatures up to 90 C, has a high surface hardness, can be nailed and welded, and is thermoformable. It can be used in a broad range of applications. Here are some typical products: Battery housings Acid tanks Liners Laboratory dishes Mechanical components Shuttering Transport pallets Kitchen equipment Sterilizable components Various kinds of extruded PO sheet, mono or coextruded in multiple layers PP-H dialysis boards Applications and customer benefits Page 13

14 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. Page 14 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.

15 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 Page 15

16 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. The 36D single-screw extruders from Krauss- Maffei Berstorff are ideal for extruding polyolefin sheet whether compact or foamed. We ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It s all at your service. 1.0 WE. 3rd edition 06/10. EXT 035 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