Your Global Partner in Extrusion, Coextrusion, and Converting

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1 Your Global Partner in Extrusion, Coextrusion, and Converting

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3 Our name says it all. Extrusion Dies Industries, LLC designs and builds flat extrusion dies and coating heads for plastic processors and web converters. This was our mission back in 1971, when EDI started out as a machine shop of four people in a small town in the U.S. Midwest. Now we are a global force a leading international manufacturer of flat dies and the field s technological partner. But our sole business is still the same: to provide producers of film, sheet, coatings, and laminates with value, quality, and dependable service. To help our customers innovate and grow, we are constantly developing new die systems with enhanced capabilities. EDI s initial innovations were the Autoflex and Ultraflex dies, now worldwide industry standards in gauge control. Today we are the only flat die builder whose manufacturing capabilities are totally three-dimensional, from initial concepts through engineering to the cutting of tool steel. This enables us to produce dies with flow-channel geometries that used to be impractical, if not impossible, to achieve. The result: dies that provide better product quality, greater raw-material economy, and higher productivity than ever before. Chippewa Falls, Wisconsin, U.S.A. remains our world headquarters, but we also serve customers through our European and Asian subsidiaries, EDI GmbH, in Reichshof-Wehnrath, Germany and EDI China, in Shanghai P.R. China. In Latin America, Europe, Asia, and Australia, our extensive network of agents provides comprehensive sales and technical support. EDI s dedicated remanufacturing facilities in Chippewa Falls, China and Germany along with licensed rework technology in Japan help customers protect their investments in EDI equipment by returning dies to original specifications and upgrading them with advanced systems. Besides innovation and worldwide access, EDI helps processors and converters succeed by assuring them of dies that arrive on time, start up quickly, and run reliably for years to come. Some of our original dies, in fact, are still in full production. Our design and manufacturing operations are ISO 9001:2000-compliant, and our commitment to quality embraces not only performance but service before, during, and after the sale. This is what brings customers back to EDI time and again. 1

4 Cast Film Oriented Film Sheet Extrusion 2

5 S Y S T E M S F O R E V E R Y F L A T - D I E P R O C E S S, A N Y W H E R E I N T H E W O R L D Chicago, Milan, Sao ~ Paulo, Beijing EDI dies are hard at work wherever manufacturers process polymers or coatings. EDI has been a leading supplier of flat die systems in the U.S. for over three decades all the while winning customers in every other part of the world. Today more than half of the dies and feedblocks we produce are delivered to customers outside the U.S. To help customers succeed no matter where they do business, we have an international support network that provides rapid access to sales services, technical assistance, spare parts, and die rework. Besides supplying die systems directly to customers, we also design and build them for turnkey processing lines supplied by the world s major OEM s. Every die from EDI is a custom-engineered product. Working with each customer, our engineers determine the manifold design, die body materials, flow surfaces, temperature controls, thickness adjustment, deckling and other basic elements that best meet the needs of the application. EDI coextrusion systems range from feedblock-fed single-manifold designs to multi-manifold dies for seven layers or more. Our coextrusion feedblocks provide precise on-line adjustment of layer thickness and sequence. Deckling options span a wide range of internal and external systems. EDI systems have been installed for every flat-die extrusion and converting technique: Cast film. Our proprietary manifold designs and gauge profiling systems provide tight control over material consumption, increase product consistency, and prevent defects and roll distortions. Specially designed dual-chamber vacuum boxes ensure stable, uniform roll development. Oriented film. Lip-adjusting technology developed for this application ensures critical gauge control for the downstream tentering process. Sheet. EDI builds dies for applications that range from stress-free optical sheet to thick, heavy-duty products, and from narrow strips to multi-meter-wide geomembranes. Rapid width and thickness adjustment features provide production versatility for custom processors. Extrusion coating. Dies are available with edge profile control, full internal/external deckling, and motorized deckles that permit fast adaptation to changes in web width. Fluid coating. Inherently more productive than roll coaters, EDI s slot die coating heads can be configured with internal deckling and automated thickness control. Coating Fluid Coating 3

6 H E L P I N G C U S T O M E R S T O S U C C E E D In extrusion processing and web converting, technology is the most powerful force for success. Many EDI customers are engaged in competitive markets where even a slight saving in raw material cost or a marginal increase in throughput can yield a significant advantage. EDI is a reliable technological resource for these companies, providing a steady stream of innovations with real benefits. Often these competitive advantages are neither slight nor marginal but dramatic and decisive. Here are some examples: Higher Productivity. Our proprietary three-dimensional flow-simulation software optimizes flow surfaces in Multiflow manifolds and Ultraflow feedblocks. And the Autoflex automated gauge control system provides greater adjustability, shorter response times, and finer resolution than competitive equipment. Material Cost Savings. Manufacturers large and small cut resin consumption and reduce scrap with EDI s Ultraflex manual and Autoflex automated gauge control systems, and Edge Profile Control TM (EPC) dies for edge-bead reduction in extrusion coating. Reduced Downtime. EDI technologies for quick on-line product changeovers make flexible manufacturing practical. These include: FastGap systems for changing product thickness, Accuflow TM online-adjustable coextrusion feedblocks, and Fast Deckle TM to vary product width without stopping production. To reduce downtime for maintenance, EDI has developed Autoflex VI gauge-control modules, Multiflow manifold designs that prevent polymer degradation and plateout, and Ultracart rapid die servicing systems. Enhanced Product Quality. Multiflow manifolds provide precise melt flow distribution and layer-to-layer uniformity in coextrusion. Ultracoat slot die coating heads eliminate the airborne contaminants (and throughput limitations) of roll coating. EDI s advanced engineering and machining capabilities, combined with a company-wide quality assurance system, result in high-precision dies that meet exact product specifications year after year. Process Laboratories. The company s Technology Center can be used to test drive virtually any extrusion or coating process that involves flat dies. Not far from EDI world headquarters in Chippewa Falls, WI, the Center includes multiple selfcontained process laboratories that companies can rent for product development and process testing. Recognizing that our customers seek to maximize production of saleable goods, EDI has established the process labs as a way for them to explore all alternatives without incurring the high material costs and lost output of trial runs on their own commercial-scale production lines. 4

7 S A L E S A N D S U P P O R T A R O U N D T H E G L O B E To provide customers with comprehensive sales assistance and technical support anywhere in the world, EDI has established an extensive sales network of U.S. offices and international agents. This global force, combined with specialists at our U.S. headquarters, EDI GmbH, and EDI China gives customers access to: Experienced sales engineers who consult with customers to identify the best die systems for their specific end-product requirements. Since virtually every EDI die is built on a custom basis, sales engineers play a crucial role. Skilled technicians who provide customers around the world with on-site startup assistance and troubleshooting. Extensive spare parts departments in the U.S., Europe and Asia that maintain inventories of most standard parts and ship them within a day. Elsewhere, EDI agents stock frequently requested components and instantly refer special orders to the U.S. headquarters. With direct access to customer engineering records, EDI can quickly produce custom parts to get lines back up and running. In addition to supporting European and Asian agents by providing technical service and spare parts, EDI GmbH and EDI China manufactures die components to meet regional standards and expectations. The ultimate goal of this EDI whollyowned subsidiary is to produce completely European and Asian dies for European and Asian customers. 5

8 Using proprietary software, EDI engineers can model in three dimensions the flow of molten polymer through a manifold (shown here) or feedblock. Five-axis machining center at EDI's headquarters can produce complex, streamlined flow surfaces that previously were too costly or even impossible to manufacture. Controls for EDI's computerized machining centers are linked to the company's simulation software, making possible fully three-dimensional die production, from initial concepts to the cutting of steel. 6 In manufacturing dies, EDI combines extensive computerized automation with skilled metal-working craftsmanship, such as that required for hand-polishing all die surfaces. For die surfaces that must be exceedingly smooth and flat, EDI operates a climate-controlled micro-grinding plant and a laser system (shown here) for sub-micron measurement of flatness.

9 C O M P A N Y - W I D E F O C U S O N Q U A L I T Y Quality assurance plays a central role in EDI s entire enterprise. From the moment we start work on an order, our objective is to design and build a die that is complete in every detail, arrives on schedule, starts up trouble-free, meets end-use product specifications, and runs efficiently and consistently. Quality also means assuring customers that, long after the sale, they can maximize productivity by readily accessing technical support, spare parts, and remanufacturing services. Key capabilities of our ISO-9001:2000-compliant design and manufacturing operations include: Custom engineering. Our experienced engineers design dies that exactly meet specifications for polymer types, throughput rates, number of layers, and other parameters. Using resin data from our rheology lab and advanced flow simulation software, EDI engineers determine optimal flow paths for manifolds and feedblocks. Our company-wide intranet gives instant access to design standards for all die components. Precision manufacturing. Divided into focused manufacturing cells to speed workflow and maximize quality, EDI s production facilities employ CNC milling machines capable of producing dies with widths from 15 cm to 10 m (6 in. to 33 ft.). Skilled craftsmen hand-polish all die surfaces. For critical-performance dies with exceedingly smooth, flat surfaces, EDI operates a climate-controlled micro-grinding plant containing super-precise surface grinders and a laser system for sub-micron measurement of flatness. Fully 3-D machining. EDI s fully three-dimensional production system begins with unique software for 3-D modeling of polymer flow through a die. This proprietary software is directly linked to computer-controlled milling centers, enabling us to machine complex surfaces rapidly and within extremely narrow dimensional tolerances. The two 5-axis machining centers for flat-die production represent a further leap forward in our 3-D manufacturing capabilities. These advanced systems, first used in the aerospace industry, machines along two more axes than conventional milling centers. It reduces the number of times that a die must be re-oriented beneath cutting heads before milling of all surfaces is complete, enabling us to produce new dies in less time. The additional axes also increases EDI s capabilities to produce complex, streamlined flow surfaces that are too costly or even impossible to manufacture with conventional technology. Extensive rework services. In the U.S., Germany, and China, EDI operates dedicated remanufacturing cells for EDI dies and ones produced by other suppliers. A licensee of our unique rework technology operates a plant in Japan. These facilities enable customers to protect their investments by repairing and refurbishing weary dies, returning them to original or even better performance. We can also redesign flow surfaces, install new-generation technology, or add new capabilities like automated gauge profiling. 7

10 SERVING EVERY FILM, SHEET, AND COATING MARKET The breadth of EDI s expertise in matching dies to specific applications can be seen in the thousands of our dies operating worldwide. Customers range from custom processors to multinational corporations. Installations range from small shops to mass-production plants to clean-room operations for transdermal medical patches or optical films. Major markets for the film, thermoformable sheet, and coatings processed with our dies include: Packaging and disposables: bags and wraps; barrier films; retort containers; see-through windows; dairy tubs and lids; blister packs; ovenable trays; meat, produce, and cookie trays; egg cartons; clamshell containers; coatings on paperboard milk cartons; plates and cups; stretch wrap. Building and construction: vinyl siding; glazing; vapor barriers; pool and pond liners; geomembranes; insulation board; flooring; wallboard; specialty tapes; window film; door shells; shutters; corrugated panels; shower-stalls and sanitaryware. Durable goods: refrigerator and other appliance liners; luggage shells; housings and enclosures; sporting goods; pallets. Transportation: windshield interlayers; mud flaps; camper tops; panels and housings; fuel tanks. Medical patches Appliance liners Shelf-stable juice boxes Containers & Optical Film Solar Panels Medical: blood and solution bags; disposable and surgical kit trays; transdermal patches; adhesive liners; hospital hygiene products; pharmaceutical and device packaging. Sustainable Energy Technology: hybrid automobile batteries; rigid and flexible photovoltaics solar cells; optical films; water filter membranes. Flexible packaging Capacitor film Coatings on paperboard Vinyl siding 8

11 lids Barrier Technology Medical blood & fluid bags Spas & hot tubs Package windows Electronic packaging Auto windshield interlayers Disposable dinnerware Battery Technology Produce packaging Bubble Wrap Stretch wrap Foam Board Blister packaging 9

12 A CATALOG OF EDI DIE SYSTEMS, COMPONENTS, AND ACCESSORIES EDI designs and manufactures a wide spectrum of flat-die extrusion and coating equipment from leading-edge technology for ultra-precise applications to workhorse systems proven in thousands of installations worldwide. Our team of seasoned sales engineers and exclusive agents around the globe can guide you through the sometimes complex process of choosing the right die system. With a thorough understanding of your company s needs and expectations, they can quickly provide you with the best possible system. In many applications the solutions are simple. Yet in others there are routes to success not readily apparent even to process engineers with decades of experience. Many times, investing right from the start in a flat die system with greater capabilities results in process flexibility and productivity that yield better products and faster payback. Here is an overview of EDI s flat-die equipment and systems. In virtually all cases, dies, feedblocks, and other critical components are custom engineered for specific customer requirements. EXTRUSION AND COATING SYSTEMS EDI supplies equipment for the full range of mono- and multi-layer flat-die processes: film, sheet, and extrusion coating. Our dies are also used widely to produce extruded webs for the manufacture of biaxially oriented polypropylene (BOPP), polyester (BOPET), and nylon (BOPA) products, as well as oriented polystyrene (OPS). EDI slot-die systems are installed for coating a wide range of polymeric and non-polymeric substances onto paper, film, and many other substrates. Flat dies from EDI range from widelyused industry workhorses to specialty types like this die for twin-wall sheet. Regardless of type, all EDI dies are custom-engineered. ULTRAFLEX DIES Our Ultraflex system is the industry-standard flat die, a workhorse used by thousands of processors and converters around the world. Each Ultraflex die incorporates a flexible-lip adjustment system for controlling profile thickness and ensuring consistent, defect-free products. Contributing to the precision of the die is the close spacing and steady compression of the adjusting bolts on the flexible lip. (EDI dies with Autoflex automatically adjustable thickness control are described in a later section.) Ultraflex dies feature streamlined flow surfaces for long production runs. Their basic two-piece design simplifies disassembly, cleaning, and other routine maintenance. Specially designed endplates simplify maintenance of end seals. Die-body geometry is customized to minimize the air gap between the die exit and roll. All Ultraflex dies can be provided with coextrusion capability. Die bodies are produced from enhanced high-purity alloy tool steel (exceeding AISI P20 specifications) through-hardened for extended die life. Flow surfaces are plated with industrial hard chrome at an average thickness of to in. (25 to 38µ) and polished to a mirror finish. Exteriors are flash chrome-plated for ease of maintenance and rust prevention. Dies are supplied completely wired with cartridge heaters. 10

13 THE ULTRAFLEX SERIES INCLUDES: Lightweight and laboratory dies (L40 series) for low-pressure and narrow-web use. Standard dies (U40 series) for extrusion coating, film, and thin sheet. Heavyweight versions with bigger, stronger die bodies to handle higher throughput rates, wider viscosity ranges, and greater product widths. Models range from light-heavyweight (LH series) to heavyweight (H series) to extra-heavy weight (HM series). Restrictor-bar models for sheet production, which provide uniform melt distribution over a wide range of material viscosities and throughput rates. EDI restrictor bars are machined from hardened, corrosion-resistant stainless steel. These dies feature the patented Krupa stud adjusting system, which permits on-the-fly stud replacement in minutes. Restrictor bars can be at 45, 70, or 90 degrees. HEAVY DUTY AND MAGNUM SHEET DIES Designed for products with thicknesses ranging as high as in. (17.8 mm), Heavy Duty and Magnum dies are sheet-industry workhorses, widely used by custom processors. Sliding upper lips provide gauge versatility while replaceable lower lips afford versatility in gap opening and land length. Lip lengths from 3.0 to 6.0 in. (7.6 to 15.2 cm) are available. Restrictor bars are typically at 90 degrees. Heavy Duty TM Sheet Die Magnum TM Sheet Die 11

14 DIES TYPICALLY RECOMMENDED FOR SPECIFIC APPLICATIONS (Recommended options: Edge Profile Control (EPC) internal deckling) 12

15 L40 U40 LH40 H75 LR100 R100 RC100 HR100 HRC100 HRMC

16 AFVI IV H75 AUTOFLEX DIES WITH AUTOMATED GAUGE PROFILING Installed on more than 2000 dies worldwide, EDI s Autoflex automatic thickness control system is the premier technology for precisely controlling the thickness profile of film, thin sheet, and coatings. In addition to making possible higher-quality, more accurate products, the Autoflex system can generate substantial raw material savings compared to conventional manual adjustment. All Autoflex systems center on a series of closely spaced thermally-actuated adjuster blocks arrayed along the flexible lip of the die. These blocks operate in response to feedback from computerized downstream gauging systems. When a thicker-than-target area is detected in the extrudate, power to the cartridge heaters at corresponding points in the lip is automatically increased; this causes the blocks to thermally expand, which tightens the lip gap in the area. Conversely, thinner-than-target areas are addressed by a reduction in power. All Autoflex systems have forced-air cooling to optimize response times. The industry-standard Autoflex IV system is used widely in film and extrusion coating applications, making possible corrections within the +/- 200µ (0.008-in.) range. Dies in the more widely adjustable Autoflex VI series nearly double the range to +/- 380µ (0.015 in.). In addition, the gauge-profiling system in the Autoflex VI-R model is a module that can be readily disengaged from the die for fast and easy maintenance. Also available, for applications where ultra-fine gauge-control may be required, are specially designed Autoflex VI models with This cast film system includes Autoflex die and Accuflow feedblock. Microflex TM technology, which incorporates reduced adjusting-block centerlines and other measures to increase resolution. CONTOUR DIE FEATURE The uniquely sculplted geometry of the Contour Die assuring uniform dynamic die body deflection across the die width, reducing the time required to adjust the die to within target parameters. Unlike conventional constantdeflection dies, however, the Contour Die has a coathanger manifold that provides streamlined flow allowing for a significant reduction in scrap. As a result of these features, processors may be able to increase throughput, within the production capabilities of their extrusion equipment. FASTGAP SYSTEM World renowned for the manufacturing flexibility and streamlined maintenance it provides, EDI s patented FastGap FastGap system available for most Autoflex and single-point Ultraflex dies permits processors adjustment to vary the lip gap within a range of in. system (6.4 mm) without taking a die off line. A single-point (shown here adjustment mechanism allows operators to quickly on an change thickness settings for new runs, and return to Autoflex die) previous settings after purging or die lip cleaning, saving valuable production time and reducing scrap. possible makes it Now installed on many EDI dies, FastGap to vary the operates by means of separate lip responsibilities, lip gap within a wide with gauge profile control carried out by the flexible top range without lip and gap adjustment by the operation of the taking the die FastGap system on the movable lower lip. EDI s off line. Advanced Lip Technology (ALT TM ) system can be used in conjunction with FastGap to further increase production flexibility. It employs interchangeable lip land inserts that permit the processing of a wide range of products on the same die. 14

17 MULTIFLOW MANIFOLD DESIGNS The heart of an extrusion die, the manifold is the flow channel machined into the die body that distributes molten polymer from an extruder into the required endproduct width and thickness. EDI supplies a range of Multiflow manifold designs to meet the specific requirements of different materials and applications. Some of the designs are: Multiflow I, a standard coathanger design whose teardrop-shaped cross section provides streamlined flow suitable for all polymers. Applications include mono-layer products, as well as coextruded structures of heat-sensitive materials. Multiflow I-R, whose almost completely rounded back wall provides processors of heat-sensitive resins with the highest degree of protection from polymer degradation. Multiflow II, a standard coathanger manifold whose elongated-teardrop crosssection minimizes interface deformation in coextrusions of polymers with differing rheological properties. Multiflow II-G, center of channel has an elongated teardrop shaped diminishing cross section coathanger for optimal coextrusion performance. Each die end is of constant cross section to allow for streamlined full manifold internal deckling. Multiflow IV, a T -shaped design with an elongated-teardrop cross section whose volume is constant. Widely used in mono- and multi-layer extrusion coating, this design is the basis for EDI s Edge Profile Control TM system for reducing or eliminating edge-bead formation when product widths are changed frequently. The design features full internal manifold plug deckling and deckle blades, which can be quickly adjusted for different widths, rates, and materials. Multiflow V, an advanced design with an elongated-teardrop cross section (similar to that of Multiflow II) whose aspect ratio increases towards the ends of the die and whose backline is parallel to the die lip exit. By placing all body bolts at the same distance from the exit, this configuration minimizes differential die body deflection. The complex cross-sectional design promotes the lowest degree of interface deformation possible in coextrusion on a single-manifold die. The curved preland provides uniform distribution of the polymer across the die width, addressing the phenomenon of M and W patterns. STRAND PELLETIZING Used by compounders, EDI strand dies have high-quality chrome-plated steel bodies, stainless steel strand plates, and manifolds designed for specific polymers and melt flow behavior. Each die is a custom product that comes with a wide range of options, like low-wear strand plates, explosion-proof and high temperature-resistant wiring, liquid temperature control, and manifold designs incorporating restrictor bars. Multiflow I Multiflow I-R Multiflow II In these cross sections, with manifold back walls at top and die exits at bottom, colors represent polymer speed. Dark blue is slowest, orange is fastest. Multiflow I is standard coathanger design for all polymers, including heat-sensitive materials used in coextrusion. Multiflow I-R is a streamlined manifold whose rounded back wall helps eliminate degradation of heat-sensitive polymers. Multiflow II is an advanced design that minimizes die body deflection, as well as interface deformation in coextrusion. DIES FOR FLUID COATING ULTRACOAT PRECISION SLOT DIE COATING HEADS For applying low-viscosity coating materials, Ultracoat dies provide a high precision coating system. Since all of the coating material is applied to Ultracoat adjustable dies and the substrate in a metered fashion, significant savings in raw materials Liberty fixed lip dies are used for applying can be realized. EDI s manufacturing capability ensures die flatness, and low-viscosity or wet coating materials. optimum coat weight uniformity. Ultracoat dies incorporate a flexible lip feature to refine coat weight distribution across the substrate and are available with manual or automatic lip adjusting mechanisms (application specific lip face designs are available). Ultracoat dies incorporate corrosion-resistant body materials, removable lip inserts, and computer-engineered coathanger manifolds. The Ultracoat Die Support System positions the coating die at the best possible angle and proximity to the roll. This provides the accuracy and repeatability that are essential, given the tight operating windows for backup roll applications. LIBERTY FIXED LIP SLOT DIE EDI s Liberty fixed lip slot dies are precise coating devices that are used for a wide range of products in the paper industry, medical field, electronics, solar panels and flat panel displays. When surrounded by the proper equipment, Liberty dies yield excellent coating results. By using an internal shim to establish the slot gap our dies can handle fluid viscosity from 1 to over 100,000 cps. The coating thickness can be as low as 1 micron ( ) to as much as 1.27mm (0.050 ) making the fixed lip slot die a very versatile tool. 15

18 COEXTRUSION SYSTEMS EDI is your international partner in coextrusion technology. Whether your product is multi-layer stretch film, thermoformed rigid packaging, biaxially oriented film, or specialty coatings, we have the right equipment to cost-effectively manufacture high-quality products. In addition to manifold designs optimized for coextrusion in single-manifold systems (see the section on Multiflow manifolds above), we offer a wide range of other system components to fit specifications and budgets. EDI feedblocks include Accuflow TM systems that are fully adjustable on-line; Ultraflow fixed-geometry models; designs that permit rapid changes in the sequencing of layers; and simplified general-purpose types. Multimanifold dies are available for structures of up to seven layers. And for specialty coextrusions such as those with multiple colors or stripes in the machine direction, EDI develops a variety of die designs on a custom basis. EDI FEEDBLOCK SYSTEMS Feedblocks are a critical component of coextrusion systems. They shape each molten polymer into a layer, and then combine all layers into a single sandwich structure that is distributed by the die manifold into film, sheet, or coating. This centimeters-wide structure requires extraordinary dimensional precision as it will be distributed into a meters-wide end product. Paired with Multiflow manifolds, EDI s Accuflow and Ultraflow feedblocks can be used for the full range of two- to seven-layer coextrusion applications with multiple advantages versus other systems. All have totally stainless steel construction, easy to clean split-body construction, and optimal melt streamlining to prevent the formation of gels and other defects. Both Accuflow and Ultraflow feedblocks can be designed to incorporate EDI s I-S series of interchangeable flow spools, which make it possible to change the sequence of material layers without having to block off flow channels or disassemble the feedblock (see photo next page). This feature provides versatility for processors who periodically switch material from the core layer to the skin layer, for example, or from the inside skin to the outside skin. At top is assembled Accuflow feedblock for five-layer (ABCBA) coextrusion. Rectangular exit from feedblock channel is at front. Entry from primary (core-layer) extruder is at back, not visible. In exploded view at bottom, one of two black-colored spools has been removed from top half of feedblock. At right is an adaptor that feeds skins to each side of core. Visible in bottom-half spool is a taper at its front surface, which is adjusted to vary width of skin layer. 16

19 ACCUFLOW PATENTED FEEDBLOCKS The patent-pending Accuflow adjustable feedblock redefines flat-die coextrusion technology as the first feedblock to provide precise on-line control over the quality and consistency of multi-layer film, sheet, and coatings with up to seven layers. Conventional fixed-geometry feedblocks can be modified to accommodate variations in product requirements by changing flow inserts, but making these changes involves downtime or longer startups. By fine-tuning the transverse thickness profile of coextruded products during production, Accuflow adjustable feedblocks accelerate line startups, simplify repeat runs, and boost productivity. While conventional feedblocks incorporate solid metal spools or other devices that create dead spots and stagnate polymer flow, Accuflow feedblocks employ highly streamlined, combining spools to minimize the potential for degradation and permit finer adjustment of layers as they are combined. Each feedblock contains one fewer combining spool than the total number of layers in a given product (i.e., two spools for a three-layer product, six for a seven-layer structure). In operation, combining spools consecutively add layers to each side of a central core layer. In a five-layer A-B-C-B-A structure, for example, the B sub-skin layers would first be added to the C core layer, followed by the A skin layers. Accuflow feedblocks can also be equipped with heating elements that refine the dimensions of the combined structure by controlling viscosity at points along the width of the feedblock channel. The precision and repeatability of the adjustments afforded by the Accuflow system make it possible to obtain levels of product quality and consistency not achievable with conventional feedblocks. Specific improvements include: Finer layer and thickness adjustment, resulting from fast, accurate changes in the height and width of the channel for each layer at the point in the feedblock where layers are combined. Elimination of viscous encapsulation, which occurs when a less viscous polymer becomes thicker toward the sides of the die by encapsulating a more viscous core layer. This is especially troublesome when the coextruded skin layers are very thin. To correct viscous encapsulation, the combining spools can be rotated to make the exit gap smaller and narrower. With thicker skins, where viscous encapsulation is less likely, the spools can be opened to allow for increased melt flow. Prevention of M or W flow patterns that result in non-uniform layers and defective products. These irregularities can be removed by coupling the adjustments of the combining spools with profiling of the miniature heaters in the feedblock channel. ULTRAFLOW FEEDBLOCKS Unlike the adjustable Accuflow system, the Ultraflow I feedblock is a fixed-geometry unit. In most applications, machined flow inserts-small distribution manifolds-permit the melt flow of each polymer to be fine-tuned prior to the combining point in the feedblock. These inserts can be easily changed to accommodate more or fewer layers without disassembling the feedblock or adaptor network. The Ultraflow II-C feedblock is designed for production lines running dedicated coextrusion structures at low to moderate throughput rates. The simplicity of its captured-insert design renders the feedblock compact and affordable. Since the inserts are captured within the feedblock body, full disassembly is required to exchange the flow distribution inserts. For less demanding coextrusion applications (i.e., well matched viscosities or thick skin layers), this simple, clean design is highly effective. Ultraflow I-S feedblock enables coextrusion processors to quickly change the sequencing of layers by changing flow spools, an example of which is the cylindrical component at left in photo. 17

20 MULTI-MANIFOLD DIES An alternative to feedblock technology, Isoflow multi-manifold dies from EDI provide more precise control over polymers with different viscosity ratios, accommodate critical processing parameters, and eliminate viscous encapsulation in wide webs. With Isoflow multi-manifold dies, coextruded layers are combined before the die lip land for unsurpassed layer distribution. Ultraflow feedblocks can be incorporated into these multi-manifold dies to feed multi-layer structures into different manifolds in the same die. The dies can also be engineered to include EDI s fixed restrictor bars in one or more manifolds to provide ultra-precise skin-layer distribution. Autoflex VI-R die shown here is a five-manifold system. EDI s multi-manifold die technology provides precise control over polymers with different viscosity ratios, accommodates critical processing parameters, and eliminates viscous encapsulation in wide webs. POLYSIDE TECHNOLOGY Polyside coextrusion dies make it possible to produce side-by-side structures typically different colored stripes-or a combination of side-by-side and multi-layer structures. Available in single or multi-manifold versions, they create new design opportunities. Customized side-by-side striping dies from EDI can produce webs with from two to several hundred machine-direction stripes of varying colors and layer configurations. 18

21 SUBSYSTEMS AND ACCESSORIES DUAL VACUUM BOXES EDI s unique dual vacuum boxes provide better stabilization of extruded film than alternate web-impingement devices. In operation, the pre-sweep chamber removes entrained air between the casting roll surface and the film. A second chamber develops a higher vacuum to stabilize the film forming area, reduce neck-in, and control film edge movement. Constructed of stainless steel, EDI s dual vacuum boxes feature swing-out, split chambers that simplify cleaning, maintenance, and installation. Various blade configurations which are adjustable at the pre-sweep section and between pre-sweep and primary chambers can be supplied. More effective than alternate web-impingment devices, EDI s proprietary vacuum box technology removes entrained air from between film and roll, then uses high vacuum to stabilize film. DECKLING SYSTEMS Deckles are adjustable devices that vary end product width by blocking off portions of the die slot from both ends of the die. EDI offers a wide range of external and internal types. External systems available from EDI include: fixed-side deckles, flex-side deckles, sliding cantilevered wedge-style deckles, and EDI s Fast Deckle. Internal deckling systems offered by EDI include: EPC TM full-bore internal/external deckle with edge profile control. EPC-R TM partial internal deckles (lip-land blades) for edge profile control. Gull-wing deckles in Multiflow V-G manifolds, with specific design enhancements customized for each application. All of the above internal deckling options are available in motorized systems. Fast Deckle TM External Deckling System EPC TM Full-Bore Internal/External Deckle with Edge Profile Control EPC-R TM Partial Internal Deckle for Edge Profile Control Motorized EPC TM Deckling System 19

22 SUBSYSTEMS AND ACCESSORIES ULTRACART DIE SERVICE SYSTEMS Ultracart die handling systems enhance worker safety, reduce downtime, simplify die disassembly and reassembly, and help prevent costly damage to critical die surfaces during maintenance. With these systems, die halves are easily rotated to access flow surfaces and streamline cleaning procedures. While basic Ultracart systems are for use with single-manifold dies, the Ultracart Rapid Servicing System is especially designed for triple-manifold coextrusion dies. Fully mechanized, the system can be wheeled to the processing line for off-loading of the die and moved to a workplace for die cleaning and maintenance. Technicians can offload, disassemble, clean, reassemble, and return the die to operation all without removing die components from their secure mounting on the cart. Designed for rapid maintenance of triple-manifold coextrusion dies, EDI s Ultracart Rapid Servicing System makes possible full mechanization of die handling, from taking the die off line, through disassembling and cleaning, to returning the die to operation. ADAPTORS AND MELT FEEDPIPES In designing and manufacturing these ancillary components, EDI pays the same attention to detail as it does for dies and feedblocks, whether the customer requires small transition plates, sophisticated distribution blocks for routing multiple flow streams to multi-channel dies, or lengthy feedpipe networks. Our key design criteria are flow streamlining and engineering safety factors. Adaptors and melt feedpipes are machined from high-quality steel forgings and are beautifully polished. 20

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24 Extrusion Dies Industries, LLC 911 Kurth Road Chippewa Falls, Wisconsin USA Tel: (715) Fax: (715) EDI Precision Dies (Shanghai) Co., Ltd. 99 Zhongde Road Songjiang Science & Technology Park Songjiang, Shanghai P. R. China Tel Fax EDI GmbH Kastanienweg Reichshof-Wehnrath, Germany Tel: Fax: info@edi-gmbh.de Designers and manufacturers of high performance die systems