SHEET EXTRUSION SYSTEMS

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Elvin Watkins
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1 SHEET EXTRUSION SYSTEMS

Davis-Standard s sheet systems are recognized around the world for reliability, accuracy, high outputs, and processing efficiency. Our process knowledge and experience is unsurpassed.

XP Express Series Processing capabilities include common packaging resins such as APET, CPET, PETG, high-density PE, PS, PP, PA, and any other extrudable thermoplastic materials.

2 Davis-Standard s sheet systems are recognized around the world for reliability, accuracy, high outputs, and processing efficiency. Our process knowledge and experience is unsurpassed. We manufacture equipment for foam, flexible and rigid sheet extrusion, and single and multi-layer coextrusion applications utilizing the latest feed block technologies available. XP Express Series Processing capabilities include common packaging resins such as APET, CPET, PETG, high-density PE, PS, PP, PA, and any other extrudable thermoplastic materials. We supply integrated systems and solutions incorporating single screw or twin screw extrusion technology, in single or multiple extruder arrangements, process optimized feedscrews, melt filtration systems, polymer melt-pumps, flat sheet dies, roll stands, hot melt laminating and protective substrate let offs, solution applicators, winders, shears, saws, online thickness measurement systems and more, so that you can rely on us for all of your sheet extrusion needs. We also focus on providing customers with versatile and cost-effective options with a fast delivery, as seen with our XP Express roll stand system. Whatever your requirement, we have the resources and expertise to engineer a solution. Single Source Responsibility We pride ourselves in supplying fully integrated sheet systems. Our single-source extrusion capability enables us to provide unsurpassed uniformity in system components and performance. We offer customers a sheet extrusion package with all major components such as extruders, roll stands, controls and winders manufactured in-house. All equipment not manufactured in-house is sourced from a reliable network of vendors. Customers look to us as their source for: Extruders Melt stream filtration systems Roll stands Winders Process control systems Feedscrews Coextrusion technologies Sheet dies Melt pumps Dual laminating pay-offs Auto reverse roll coaters Rotary shears Thickness measurement systems with thickness optimization

applications, high output capacity extrusion for end user inline thermoforming Fender liners, splash guards, truck bed liners, interior sound absorption Slip sheets,

3 Systems for a Variety of Applications Our customers produce a broad range of products for many different markets. Examples include: Packaging Automotive Dunnage Building Medical Custom Cups, plates, tubs, domes, frozen food, blister/point of purchase, extrusion for roll feed thermoforming applications, high output capacity extrusion for end user inline thermoforming Fender liners, splash guards, truck bed liners, interior sound absorption Slip sheets, thermoformed pallets, waste containers Wall partitions, interior/exterior lighting, drainage, pail liners Saline solution bags, instrument packaging Circuit breakers, geomembranes, tank liners, refrigerator liners, roofing membranes, carpet coating

6-inch (150mm) 30:1 Thermatic extruder Feedscrews Extruders and Feedscrews For over 50 years, the Davis-Standard name has been synonymous with quality extruders and feedscrews.

4 6-inch (150mm) 30:1 Thermatic extruder Feedscrews Extruders and Feedscrews For over 50 years, the Davis-Standard name has been synonymous with quality extruders and feedscrews. We view the extruder and feedscrew as the foundation of your sheet system. Our Thermatic extruders are built for high outputs, efficiency and years of trouble-free operation. The advanced technology and track record of our feedscrews is unsurpassed. Our goal is to provide you with the best extruder and feedscrew combination for your process(es). THERMATIC EXTRUDER ADVANTAGES All Thermatic models are built with rugged H beam steel construction to provide maximum stability and minimal vibration. Cast aluminum heaters are bolted together for better temperature control and longer life. Davis-Standard s horizontal, helical gearbox uses labyrinth seals to reduce leakage and maintenance. Standard units available as single motor input or synchronized dual motor inputs. Bearings are pre-loaded to generate a truer power transmission underload. A dual thermocouple micro-processor system provides anticipatory temperature control for high accuracy. Extruders are supplied with air-cooled or water-cooled systems depending on barrel cooling capacity. The motor is available in AC or DC variable speeds, externally vented or fan-cooled. FEEDSCREW ADVANTAGES Davis-Standard barrier technologies exceed the most sophisticated sheet process requirements for pressure stability and melt temperature uniformity while providing maximum productivity. Feedscrews are designed for consistently higher output rates, process stability, distributive and dispersive mixing properties, and minimal polymer degradation. Feedscrews are manufactured from a variety of metals for corrosion and wear resistance. R&D facilities in the United States and Europe enable us to research, test, and supply custom feedscrew designs. FLATPAK FOR TIGHT COEXTRUSION LAYOUTS This configuration is engineered specifically for plants with space limitations that inhibit the use of traditional fan design or straddle frames. Designed with a vertical gearbox that saves space through close coupling. Compact set-up can accommodate a common cooling manifold and heat exchanger for added efficiency. Access to individual machines for normal operation and routine maintenance is possible due to a sub-base mounting system with slide rails. Applications: Monolayer, Coextrusion, Roll Stock, Cut-to-length, and In-line Extrusion and Thermoforming

Controls, Dies, and Coextrusion Sheet extrusion often calls for complex systems capable of handling a range of processing requirements and resins.

We are well equipped in these areas to help you fine-tune your system.

5 Controls, Dies, and Coextrusion Sheet extrusion often calls for complex systems capable of handling a range of processing requirements and resins. This is where controls, dies, and coextrusion technology can lead to improved processes, greater efficiency, and processing versatility. We are well equipped in these areas to help you fine-tune your system. EPIC III High-Level Control Windows -based plant management and extension process control capabilities with adaptable and expandable touch screen displays. Supervisory features including event logging, customized reports, SQC, historical trending, maintenance/troubleshooting, pressure set-up and more. Partial and complete line overview, detailed extruder data, recipe creation/storage, etc. Connectivity solutions available for remote data access via laptop as well as network capability for remote monitoring of multiple systems. System includes Dynamic Data Exchange (DDE) and Object Linking and Embedding for Process Control (OPC). A multiple-level security system protects set-up functions and accessibility. DIE DESIGNS FOR EVERY NEED Die designs are engineered for monolayer and conventional coextruded structures up to twelve layers, and micro layer structures comprised of hundreds of layers. A broad range of dies are available from the widest to the narrowest application. Manual or automatic die lip adjustment is available as required and is integrated into the system. Computerized internal designs are used based on the rheology of the specific polymer and use. EPIC III controls with a sloped front console. Assembly and Test COEXTRUSION FOR BALANCE AND CONTROL Coextrusion capability for fixed-ratio coextrusion blocks to multi-adjustable ratio and distribution devices for complex barrier composites. Adjustment features for proper flow balance and distribution. Multi-manifold dies are supplied either as independent units or in conjunction with custom designed feedblocks. Barrier Coextrusion Sheet Systems

Superior Roll Stand Technology Our XP Express and EX-M-PLAR series roll stands are engineered to simplify and improve sheet processes across the board.

Roll stands can include three or more cooling rolls, as well as automatic drive controls and hands-free nip gap adjustment.

6 Superior Roll Stand Technology Our XP Express and EX-M-PLAR series roll stands are engineered to simplify and improve sheet processes across the board. These models are available in standard or customized versions in upstack, downstack, vertical, horizontal, offset top roll or offset bottom roll J configurations. Roll stands can include three or more cooling rolls, as well as automatic drive controls and hands-free nip gap adjustment. XP EXPRESS ADVANTAGES XP EXPRESS PS MODEL PACKAGING SHEET APPLICATIONS Standard features include: Individual roll drive for precise web tension control and optimized sheet polish Web cooling train sized for application with matched roll diameter and heat exchange system Dual flow rotary union design locates water on non-operator side of the machine Direct acting roll actuation to maintain precision roll gap Compact footprint for space challenged facilities

XP EXPRESS CS MODEL CUSTOM SHEET APPLICATIONS Same standard features as the PS model except the CS model utilizes an individual roll gear drive train system to facilitate quick embossing roll removal

Capabilities include production of polished or embossed roll stock and cut-to-length sheet or inline extrusion to thermoforming applications.

7 XP EXPRESS CS MODEL CUSTOM SHEET APPLICATIONS Same standard features as the PS model except the CS model utilizes an individual roll gear drive train system to facilitate quick embossing roll removal without disturbing the AC drive train mechanics and electronics. Both models are competitively priced and pre-engineered for a fast delivery. Capabilities include production of polished or embossed roll stock and cut-to-length sheet or inline extrusion to thermoforming applications. Each unit is supplemented with optional ancillaries such as laminating unwinds, solution applicators, cross-axis roll feature, integral air-knife assembly, auxiliary cooling, slitting and trimming, embossing, on-line annealing and protective film let offs. Equipped with high-speed features for thin gauge sheet applications with the heating and cooling capacities to match operating line speeds. Standard pressurized water systems up to 275ºF roll temperature set point, or optional oil heating systems for high temperature applications. Can be configured in upstack, downstack, and offset top or offset bottom arrangements with three primary cooling rolls and multiple supplemental cooling rolls. Easily accessible with operating features such as dynamic nip force (PLI) control or roll position control. Custom models available for sheet and packaging applications. EX-M-PLAR SERIES ADVANTAGES Robust design, engineered for the most demanding applications of superior sheet quality finish or those that require wide width and heavy gauge sheet. Features a heavy duty split arm roll actuation device, with standard straight bore bearings or a tapered bearing design for optimized tolerance control. Utilizes a coordinated AC drive system for each drive section throughout the line. Hands-free technology eliminates manual and mechanical operator adjustments of the flex lip die bolts via integration of an inline automatic lip profile control system, and closed loop roll gap control via a hydraulic jack closed loop controlled through a PLC unit to improve repeatability of machine set points and consistently produce sheet of minimal thickness variation. Capable of attaining a nip gap resolution of inches (0.0127mm) or less and feedback device resolution of inches ( mm). Processors can adjust the system while in operation under full pressure, make immediate set point changes, control the new gap set point, and reduce setup and job changeover time. Drive trains available in chain, gear, or as individual roll drives for optimized sheet tension control in the system. Configurations comprised of upstack, downstack, vertical, horizontal, orbital or angled at 45 can be customized to include four, five or more cooling rolls. Scrap Reclaim Extruder Heavy Gauge Sheet Roll Stand Configurations

that every square inch of your system is

8 Intergrated Ancilliary Equipment Ancillary Equipment Advantages Details are important to us and our customers. From the design of our roll stand rolls, to cooling and polishing units, to auxiliary equipment, we want to ensure that every square inch of your system is ready to meet or exceed your expectations. ROLL STAND ROLLS Available with pneumatic or hydraulic roll actuation. Automatic roll force control system minimizes roll deflection allowing processors to polish thinner gauge sheets than previously possible. A manually actuated worm-wheel, jack-screw device at the nip outlet provides consistent roll gap position. Rolls are constructed of a mild steel shell with a 400 series stainless steel overlay hardened to Rockwell C. Rolls are machined, chrome plated and polished to a matte or mirror finish quality with a standard 1-3 RA,.5 RA, or tighter, for optical grade sheet.

A standard high-pressure design utilizes shrunk fit outer shells to improve strength and minimize deflection. Optional rolls are available for embossing and other high-quality surface requirements.

COOLING AND POLISHING UNIT Features a modular design with side supports consisting of blanchard-ground side plates that are drilled and bored in pairs to align roll mounting and support girts for

9 A standard high-pressure design utilizes shrunk fit outer shells to improve strength and minimize deflection. Optional rolls are available for embossing and other high-quality surface requirements. AC roll drive system corrects speed differentials and eliminates need for four-speed transmission. COOLING AND POLISHING UNIT Features a modular design with side supports consisting of blanchard-ground side plates that are drilled and bored in pairs to align roll mounting and support girts for improved web guiding. Precise roll stand height adjustment by means of cross-shafted jacks to precisely position the melt curtain onto the rolls. Local HMI controls are fixed or pendant arm mounted. Fixed, collapsible, and rollover type conveyor designs available. Supplemental sheet cooling systems include controlled flow convective cooling air circuits, cooling cans, and quench systems. Annealing sections provide sheet stress relief. HEAT EXCHANGE SYSTEM Provides uniformity through proper temperature control during roll heating or cooling process with roll temperature tolerances within 1 to 3ºF. Consists of a centrifugal pump, tube, and shell heat exchanger, and an individual expansion tank sized for specific heat loads. Direct injection systems are also available for low temperature process applications. Common pressurized fill system with valving to each roll reduces maintenance and limits run disruptions. Gear Drive System EX-M-PLAR Roll Stand END-OF-THE-RUN TENSION CONTROL Standard haul-off system consists of two hardened neoprene rubber rolls. The nip gap is actuated by a straight-acting pneumatic cylinder and rolls are driven by an AC drive identical to the polish roll drive unit. AUXILIARY EQUIPMENT Options for slitters, laminating un-winds, specialized conveyors, water baths, thickness gauges, winders, and loading devices. Thickness measurement systems available with thickness optimization control for sheet from.008-inches (0.2mm) to over 1-inch (25mm). Packaging Sheet Line

Growing Process Technology We are always working to expand our processing technology to accommodate the changing needs of

A significant example of is the demand for PET processing technology, reflecting environmental concerns and the importance

Our PET capabilities include technology to process multiple materials such as recyclable PET in flake form, and low bulk

10 Growing Process Technology We are always working to expand our processing technology to accommodate the changing needs of the marketplace and the world. A significant example of is the demand for PET processing technology, reflecting environmental concerns and the importance of recycling. Our PET capabilities include technology to process multiple materials such as recyclable PET in flake form, and low bulk density PET ranging from 100 percent post consumer waste to virgin APET. This includes sheet structures for running monolayer, coextrusion and side-by-side sheet. Our customers have experienced ongoing business success using our systems for PET and other packaging material processes while reducing waste and helping the environment.

The Davis-Standard, LLC Difference There is a reason why our equipment is recognized as being among the best in the world our service and expertise is focused on supporting our customers investment.

Production scale and laboratory equipment is available to analyze various processes.

11 The Davis-Standard, LLC Difference There is a reason why our equipment is recognized as being among the best in the world our service and expertise is focused on supporting our customers investment. TECHNICAL CENTERS We have fully staffed Technology Centers in the United States and Europe, making our screw design and technical capabilities among the best in the world. Production scale and laboratory equipment is available to analyze various processes. A team of experienced and knowledgeable process engineers and screw design specialists collaborate with customers to evaluate process parameters and implement feedscrew technology best suited for specific applications. Each feedscrew is manufactured on the basis of individual customer parameters encompassing output rate, melt temperature, pressure requirements, output consistency of extruder stability, melt homogeneity, and melt quality. 24/7 CUSTOMER SERVICE/AFTERMARKET SERVICES We have service technicians available 24 hours a day, seven days a week, to handle parts inquiries and emergency service needs. Parts shipments, if in stock, can be shipped within one day. We maintain complete mechanical and spare parts inventories ranging from feedscrews and barrels, to thermocouples and motors. On-site service by a technician is also available. For parts and service call SHEET BUSINESS SERVICES Systems Engineering and Integration Davis-Standard provides the necessary mechanical/electrical engineering and integration to interface all sheet line components into a fully functional production line. On system orders, the project manager interfaces with the buyer s personnel to coordinate all aspects of the line being manufactured. Pre-Shipment Testing and Inspection We offer complete set up and electro-mechanical testing prior to shipment at our manufacturing facility. Customers are welcome to inspect their lines prior to shipment. Mechanical and Electrical Checkout Our process experienced engineers and technicians perform a thorough check of both mechanical and electrical functions of the entire line and any associated equipment supplied by Davis-Standard. PROCESS VERIFICATION AND OPERATOR TRAINING Davis-Standard personnel are available to train your operators in the use and operation of the line. CONTRACT INSTALLATION SERVICES We provide installation contract services for our supplied equipment when required. EXTRUSION LAB TESTING Extrusion lab testing at our facilities on a customer supplied resin formulation is available at an additional charge in accordance to fees in effect at the time the lab service is rendered. Our knowledgeable and experienced technical staff has solved many challenging extrusion process applications, improving productivity on many customer machines. Technology Center Spare Parts Black Clawson Converting Machinery Sterling Egan Hartig Our Brands Killion Extruders NRM Extrusion Get to Know Us ER-WE-PA Repiquet Johnson Merritt Extruder Goulding DS Brookes Davis-Standard has set the standard in sheet equipment and systems. We hope you will take the time to get to know us. Our capabilities go far beyond our equipment. They extend to our professional training experts, laboratory personnel, design engineers, and hands-on field engineers who will work with you every step of the way.

12 Davis-Standard Business Areas Aftermarket Services Blow Molding Systems Blown Film Systems Cast Film Systems Compounding Systems Elastomer Systems Extrusion Coating and Laminating Systems Fiber Systems Foam Systems Laboratory Equipment and Specialty Systems Liquid Coating and Laminating Systems Pelletizing Systems Pipe, Profile and Tubing Systems Process Control Systems Recycle/Reclaim Systems Sheet Systems Twin Screw Systems Unwinding and Winding Systems Wire and Cable Systems #1 Extrusion Drive Pawcatuck, CT USA Tel: Fax: Room 1007, Jing An China Tower 1701 Beijing (W) Road Shanghai P.R. CHINA Tel: Fax: Unit 33 Hainge Road Tividale, Oldbury, West Midlands B69 2NY UNITED KINGDOM Tel: Fax: North First Street Fulton, NY USA Tel: Fax: South Adamsville Road Somerville, NJ USA Tel: Fax: Mettmanner Strasse 51 D Erkrath/Düsseldorf GERMANY Tel: Fax: Davis-Standard, LLC. All Rights Reserved. JWRP5K1007

processor of wide ranges of polymers because it provides an external means of changing die pressure distribution.

processor of wide ranges of polymers because it provides an external means of changing die pressure distribution. Die Technology Cloeren dies feature the most advanced technologies. With more than 25 patents issued, and many more pending, Cloeren is the acknowl-edged leader in the industry. We understand the complexities