Efficiency in a class of its own - the MAS Recycling Compounder
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1 PRESS RELEASE from MAS Maschinen- und Anlagenbau Schulz GmbH Pucking near Linz / Austria, Photo: Author Fig.1: Processing film flakes and additives to high-quality compounds on one system and in a continuous process, is at the focus of the FAKUMA Fair presentation of the machine manufacturer MAS from Upper Austria. Core component of the compounding system is the patented MAS Extrusion System with co-rotating, conical dual screws. Efficiency in a class of its own - the MAS Recycling Compounder The extrusion machine manufacturer MAS-Maschinen- und Anlagenbau Schulz GmbH from Upper Austria presents a new application option for its dual screw extruder with co-rotating conical screws. It is the resources and energy saving version of in-line film recycling and compounding, which can be perfectly implemented with the conical co-ration system. In addition to the compact design, the MAS System offers an extremely non-destructive material plastification and homogenisation at to date unparalleled low energy consumption values, as well as the best system requirements
2 Efficiency in a class of its own - the MAS Recycling Compounder - Page 2 for processing materials with low bulk density, e.g. film flakes, but at the same time also with high bulk density, e.g. filler materials (Fig.1). Conical co-rotating dual screw extruders were not on the market before The MAS- Maschinen- und Anlagenbau Schulz GmbH from Upper Austria closed this gap with the MAS extruder conceptualised on the basis of own patents and developments. It offers a series of advantages which crucially expand the application fields for dual screw extruders. The MAS Extruder is available in 6 sizes with outputs from 200 to 1800 kg/h (Fig.2). The system advantages of the MAS extrusion system The new MAS extrusion system combines the known good plastification and homogenisation of a parallel screw extruder with the specific advantages of the conical dual screw system. These are, in particular, the good feeding option through the large infeed opening of the design and the correspondingly large intake volume. The range of advantages is supplemented by the excellent conveying characteristic with simultaneous stable melt pressure and last, but not least, the to date unparalleled low energy consumption values. A comparison with conventional single screw extruders customarily used in recycling systems reveals that the co-rotating dual screw system offers superior homogenization. The favorable infeed behavior and nondestructive material handling features are also very impressive. There is minimal breakdown of the polymer structure, and the physical characteristics of the starting materials, such as elongation at tear and tensile strength, remain largely unchanged. In addition, the greater homogenization of the plastic melt enables highly effective melt filtration and degassing, which makes it easier to process recycled material. Recycle Films and Add Value by Compounding The large infeed opening makes the MAS extruder a perfect recycling machine (Fig. 3). Materials with a low bulk density, such as film flakes, can easily be fed in. They do not have to be compressed beforehand using special devices. Additives such as hydrated magnesium silicate (talc) or calcium carbonate, stabilizers, or dyes can be metered into the film flakes and fed into the system at the same time. Side feeders do not have to be used. The comparatively large contact surface of the screws with the material allows a large amount of energy to be conveyed to the plastic. This enables the plastic to be melted quickly over a short path and also enables a compact
3 Efficiency in a class of its own - the MAS Recycling Compounder - Page 3 design, especially in comparison to single screw recycling systems. Kneading elements integrated into the screws support homogenization. The large overlap of the screw profiles increases the delivery rate and stabilizes the melt pressure. A melt pump for building up and stabilizing pressure is therefore no longer required. It is worth mentioning that the conical screws of the modular system can be fitted for the specific task, which allows them to quickly and easily be adapted to various uses as needed. Low Energy Consumption from Start to Finish The compact MAS extruder is the key element of this integrated recycling and compounding system in the form of a cascade extruder. The MAS extruder is combined with a MAS melt filter system (for continuous filtration with a planar array filter) and a downstream single screw degassing extruder (Fig. 4). The cascade extruder supplies a granulation system. The overall efficiency of the system is highly impressive. In compounding mode with a supply of 60% PP film flakes and 40% powdered additives, a specific energy consumption of only 0.24 kwh/kg was measured! Further information: Ing. Stefan Lehner Sales Manager at MAS GmbH lehner@mas-austria.com Website: Author: Reinhard Bauer - TECHNOKOMM office@technokomm.at
4 Efficiency in a class of its own - the MAS Recycling Compounder - Page 4 about MAS Maschinen- und Anlagenbau Schulz GmbH MAS was founded by Ing. Helmut Schulz in He can look back on more than 40 years experience in plastics machine construction and holds numerous area-specific patents. The MAS service portfolio covers planning, design, manufacture and sales of polymer processing machines and systems for recycling, refining and extruding plastics/compounds. MAS core competences are: > The MAS extruder is the worldwide first dual screw extruder with conical, co-rotating screws for processing plastics and plastic compounds. > Systems for dry preparation of recycling plastics with the DRD System (Double Rotor Disc). 20 patents are evidence of the innovative powers of the company which generates a turnover of around 9.0 million EURO (2011) with a head count of 25. Address: Hobelweg 1 A 4055 Pucking, Austria
5 Efficiency in a class of its own - the MAS Recycling Compounder - Page 5 Figures: Photo: MAS Maschinen- und Anlagenbau Schulz GmbH / Pucking Fig.2: The NCT (New Conical Technology) Extruder from MAS has a modular design and is available in six sizes for outputs of 200 to 1800 kg/h, here equipped with Flake feeding unit. Photo: MAS Maschinen- und Anlagenbau Schulz GmbH / Pucking Fig.3: The MAS Extruder offers the system-specific advantage of a dual screw extruder in the form of a large infeed opening, which allows efficient feeding in of raw material with low bulk density. The high-performance plastification of the co-rotating screws delivers a highly homogenous plastic melt which can be degassed optimally. (Vakuumentgasung: Vacuum degassing, Beschickungsöffnung = Infeed opening, Druckaufbau = Pressurization, Mischen Homogenisieren = Mixing Homogenizing, Plastifizieren = Plastification
6 Efficiency in a class of its own - the MAS Recycling Compounder - Page 6 Fig.4: System example of a cascade extruder, which can be used to compound recycling material directly. In this case the conical co-rotating extruder from MAS is combined with the new MAS melt filter system and a single screw degassing extruder. (Beschickungsöffnung = Infeed opening, atmosphaerische Entgasung, atmospheric degassing, Schema MAS Kaskade = Scheme MAS cascade, CDF kontinuierlicher Schmelzefilter = CDF continuous melt filter, Granulierung = Granulation)
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