Strictly-Extrusion

A new patent-pending valve from Guill Tool and Engineering Co., the Multiflow valve, offers outstanding productivity and cost-savings benefits to manufacturers that require the extrusion of complex multi-layer tubing. The Multiflow valve allows extruders to manufacture either three-layer or up to five-layer tubing products with the use of fewer extruders. In the three-layer configuration, the proprietary valve is designed for use with all ABA crossheads or inline dies. Using this superior technology, plastic or rubber material is fed from the ‘A’ extruders and divided inside the manifold in order to form both the inner and outer layers of the final product. “The obvious cost savings are considerable,” said Jim Prue, Chief Design Engineer for Guill. “For example, a manufacturer is now able to make a three-layer product by using only two extruders, saving substantially on required outlays for capital equipment.” Other advantages include; the abilitiy to change layer-wall thickness without shutting down the extruder; eliminates ‘dead’ areas in the manifold that would lead to degradation of the material and contamination of the tubing; and it allows a wide range of wall thicknesses.

Beta LaserMike is a global organisation committed to innovate, manufacture and service precision measurement and control systems for the wire and cable, pipe/profile/tube, and piece part inspection markets. As one of the world’s first automatic set-up ultrasonic measurement and control systems for wall thickness and concentricity, Beta LaserMike’s new UltraScan system offers unmatched performance and virtually eliminates operator influence providing tube, pipe, conduit, packaging, vinyl siding and other extrusion manufacturers with on-line measurement capability to improve product quality, increase throughput and decrease costs. Beta LaserMike’s GraviScan weight and throughput measurement system is an essential element to extrusion manufacturers looking to maximise their extrusion process by continuously monitoring the extrusion process during the fill, empty and refill process. When coupled with a process controller, manufacturers can control line speed, monitor the extrusion screw’s RPM, communicate through standard field-bus interfaces and develop quality documentation as printed reports or exported data.

Davis-Standard recently supplied all extrusion system components, extruders through downstream equipment, for a high-level microlayer film processing project. The multi-layer configuration included extruders ranging in sizes from 40 to 115 mm, feedscrews, enhanced cooling equipment, an online thickness measuring gauge, a rollstack and conveyor, and complete system control via the EPIC III supervisory control system. The line also utilises an innovative feedblock technology for extruding films with hundreds of layers but with the thickness of a typical multi-layer film. Films being processed on the new line have 50 to 100 layers using four different high barrier film materials. The films are 6 mil thick with layers as thin as 0.002 mm. Extrusion of films with microscopic layers improves stress-cracking resistance and overall barrier properties. Markets for these films include retail products, food and medical packaging.

During the ISH in Frankfurt , which is being staged from 25th until 29th March 2003, Henco will be on hand to showcase the company’s innovative Henco sandwich multi-layer pipes, Henco screw fittings, press fittings and other heating and sanitary accessories.

Priding itself on being a flexible company, Henco is quick to anticipate market trends by offering innovative top-quality products. Apart from various official seals of approval, such as DVGW, ATG, KIWA, KOMO, ÖNORM and WRC, Henco also enjoys ISO 9001 certification. About 80% of the company’s output are exported to 60 or so countries: outside Europe the main markets served are Asia and the Middle East.

Henco now manufacturers about 1.5 million metres of compound tubing a week, which equates to 60,000 km a year, or enough to circle the earth!

Henco sandwich pipes

The basic product is Henco’s sandwich multi-layer pipe: a flexible compound tube made from cross-linked polyethylene and a layer of aluminium. This tube offers all the advantages of metal and plastic. It is used for heating elements, collectors, sanitary systems, drinking water systems and - last but not least - floor heating systems.The cross-linking procedure that involves electronic beam processing is of vital importance for guaranteeing top-quality Henco compound tubes.Polyethylene comprises chains of interconnected molecules. With electronic beam processing, the tube is exposed to intense electronic rays which displaces the atoms and alters the structure of the plastic.
The hydrogen atoms receive these electrons and leave links in the carbon atoms in the molecular chains free. Two carbon atoms belonging to seperate molecular chains and having a free link bond and thus link two chains. The links between the chains form a web-like structure, which is called cross-linking.

Henco fittings

Henco fittings complement Henco multi-layer tubes perfectly. Made from top-quality plastic and steel, these environmentally friendly fittings can be attached in a seconds with mains and battery-powered press tools and jaws. As they generally consist of plastic, they are resistant to corrosion and may be recycled.

Screw fittings

Henco has a complete range of compression fittings. The metal fittings with Eurocone connection are suitable for all common types of nipples with Eurocone connection and guarantee a triple seal. The special design of the fitting eliminates torsion. Henco screw fittings are suitable for all systems using Henco sandwich tubes.

Press fittings

Henco’s metal press fittings are made with electrical Power-Press jaws. One press on the button and the connection is completed within seconds. These non-detachable press couplings are resistant to torsional strain and tension load.

New: Henco floor heating

Henco manufactures its own floor heating system using its patented multi-layer pipes.This system not only makes it possible to promote rational energy use, it also guarantees the longevity of the system by eliminating oxygen absorption. Other advantages of Henco floor heating include pleasant radiant heat, less air circulation and hence less dust deposits, less invasion of space etc.Furthermore, Henco lends support to installation engineers by offering a professional design service. We offer calculations free of charge for floor heating equipment based on four systems: pipes fastened to studded plates, to metal mesh reinforcement, to clip rail or fastened by stapling. Customers also receive a CAD layout free of charge with their order.

A major development in 2003 is the production of larger pipe sizes. During ISH 2003 visitors will have the opportunity to see the 40 Ø. Owing to its overwhelming success in various countries we have opted for a comprehensive PVDF system for this new product. Currently Henco produce in-house 30,000 PVDF fittings per day and production capacity will be increased during 2003 by a further 50%!

For further information: pay a visit to the Henco team, at stand N° 6.1A60
Website: www.henco.be

Noveon, Inc. announced that it had purchased sheet extrusion technology and other assets from SJM Eurostat S.A. (SJM). The purchase price was not disclosed. SJM, headquartered in Point-de-Poitte, France, is a leading supplier of static control products to the electronics industry in Europe.
Under the terms of the purchase agreement, Noveon will immediately begin servicing all existing SJM electrostatic discharge (ESD) sheet customers with SJM toll-producing extruded sheet products for sale exclusively by Noveon. The sheet extrusion technology acquired by Noveon includes carbon-filled HIPS, ABS/PC, HDPE and EVA. Noveon will also introduce a new dual-layer HIPS product which combines the conductive, carbon-filled technology from SJM with a layer of dissipative, Stat-Rite® polymer technology from Noveon.
‘This purchase supports Noveon’s strategy of offering a comprehensive line of ESD sheet and compound products to meet the performance needs of our global customer base,’ said Tim Fahey, Global Business Director of Noveon static control product lines. ‘Acquiring this technology from SJM Eurostat expands our sheet product portfolio and immediately enhances our ability to serve thermoforming customers as well as the electronics industry in Europe,’ Fahey said.
For more information about this Noveon acquisition, please visit the Noveon static control products website at www.stat-rite.com .

SMS Folientechnik, a market leader in foam extrusion lines, has developed a new improved process for manufacturing foamed film and sheet with high performance and top quality output. The key feature of this new technology consists of two cooling extruders in parallel configuration, providing a cost-efficient solution to the ever-increasing demand for higher cooling capacity – especially for manufacturing foams with alternative foaming agents. In the new process offered by SMS Folientechnik, patent pending, the cooling of the melt is taken over by two extruders in parallel configuration. Upon leaving the primary extruder, the melt is divided into two part streams, optimally cooled by means of the specially designed ExCool screws in the cooling extruders, and then the two separate streams are re-united. This solution opens a completely new perspective in manufacturing foam sheet: products with different colours, densities and other varying properties, providing access to numerous new fields of application. The first XPS foam sheet line equipped with this new technology has just been delivered. This line is designed for an output of 1,500 kg/h and equipped with a 180 mm melting extruder. Through the two parallel cooling extruders, each with a 200 mm screw diameter, the melt is optimally processed and homogeneously cooled, then it passes into the die for manufacturing foam board at up to 200 mm thickness.

Uponor Oyj has today divested its shareholding in Uponor ETI Company, a U.S.-based municipal water and sewer systems subsidiary, to PW Eagle Inc., based in Minneapolis, MN. The deal, valued at USD 30-34 million, is part of Uponor’s strategy to reduce exposure to commodity business.
The deal is a major step forward in Uponor’s strategic transformation, releasing capital for the development of the company’s core business, housing solutions. Uponor already offers North America’s leading brands in domestic radiant floor heating and plastic plumbing systems. Uponor ETI holds a strong position in the U.S. municipal pipe markets east of the Rocky Mountains. The company employs a staff of 300 and generated annual net sales of USD 90 million in 2002. Uponor ETI runs four manufacturing facilities in the eastern and central parts of the country.
PW Eagle is a leading U.S. supplier of municipal pipe systems. Its business, focused mainly in the western parts of the country, is well complemented by that of Uponor ETI. PW Eagle’s net sales totalled USD 251 million in 2002. The company is listed on the NASDAQ.
Uponor’s Municipal Americas division will continue to market gas pipe systems in the U.S. and South America.

For the first time, the six-layer polycarbonate sheet from Makroform, in the sheet thicknesses 16 mm und 20 mm, is available on the market under the names Makrolon®multi longlife 6/16-20 and Makrolon®multi longlife 6/20-20. These high quality sheets combine excellent heat insulation with extremely high stiffness and a good cold-bending radius. This results in outstanding value for money.Furthermore, the two six-layer sheets offer impressive levels of extremely high impact resistance and light weight. This last point in particular guarantees easy installation even with large areas and “light” substructures, which have a major impact on the ensuing construction costs. Like all products with the longlife protection from Makroform, the new sheet is absolutely weather-resistant. It therefore recommends itself primarily for the roofing of private and industrial buildings.
Due to the unique geometry and unmatched combination of properties, the new sheet from the innovative i-LINE from Makroform is suitable for the most demanding of applications. Günther Winnerl, Segment Manager for Building at Makroform, anticipates a lively demand for this product of superior quality. “Our new six-layer sheet displays an extraordinary property profile oriented towards the increasing demands of the construction market. Like all products from the i-LINE, our seal of quality for a new generation of improved quality products guarantees innovative and intelligent top-of-the-line solutions even for the highest construction requirements.“
Further information on the Makroform range of products can be found on the Internet at: www.makroform.com

Cabot has launched its website with new navigation and graphic design, which creates a Dedicated Masterbatch Page. The new navigation allows visitors to control the content they see on screen, using a series of filters. The information on masterbatch is now presented as a separate product line, that can also be selected from the ‘Products & Markets’ category of the global navigation. To access this page, just click here: http://w1.cabot-corp.com/controller.jsp?entry=product&N=23+1001+4294967063

The purchase of a Davis-Standard sheet system has proven to be a valuable investment for the Pawling Corporation of Pawling, New York. A diversified supplier of custom rubber, thermoplastic and building protection products, Pawling installed the turnkey system in 2002 to support its Architectural Products Division and to bring its custom sheet extrusion in-house. The system was designed to process 400 to 450 pounds of PVC per hour, but has exceeded expectations with outputs consistently doubling that amount. In addition to impressive processing rates, Pawling has more control over production of specific sheet quantities and color matching of extruded parts, critical for architectural applications. The company has also improved customer service with faster lead times. Pawling can deliver custom extruded sheet in two to three weeks versus four to six weeks offered previously.

“This was the first sheet system purchased by our company and we’ve been extremely pleased with its performance,” said Robin Ringler, business unit manager of Pawling’s sheet products. “We did a considerable amount of work up front with Davis-Standard’s engineers and the line’s impressive outputs are indicative of that. We appreciate how they collaborated with us on the design, and their service was first-rate for a smooth start-up and installation.”

The line, extruder through conveyor, is used primarily to extrude sheet for Pawling’s new PRO-TEK™ wall covering panels and for Pawling’s custom sheet extrusion business. It is capable of extruding roll sheet from .030 to .060 inches
(.8 to 1.5mm), flat sheet up to .125 inches (3.2mm) and in widths up to 50 inches (1,270mm). The system is equipped with a fast gap die feature and “hands off” rollstack technology for added efficiency. The fast gap device enables Pawling to make die adjustments simultaneously rather than manually adjusting 50 individual screws, typical on most dies. The hands-off rollstack eliminates manual and mechanical operator adjustments of the roll gap and improves repeatability of set points and sheet consistency. The position of the moveable roll is controlled relative to the stationary process roll to regulate the nip gap. A sensor continuously monitors the nip gap and volumetric control of hydraulic fluid maintains the position of the nip rolls. The gap is sustained through a full range of nip pressures, including compensation for change in roll temperatures.

“The die and rollstack technology have simplified the line operation while providing excellent sheet quality and minimal downtime,” added Ringler. “I’ve been working with Davis-Standard equipment for 30 years and have always been impressed by the reliability of their technology. All of our new machines are Davis-Standard.”
In addition to the sheet line, Pawling operates two Davis-Standard silicone extruders, two NRM rubber extruders, two NRM plastic extruders and six Davis-Standard Thermatic® extruders. These machines support Pawling’s Architectural Products Division as well as the PRESRAY/Pawling Division. The Architectural Products Division supplies entrance mats and grating, impact protection, and recreational and athletic flooring. The PRESRAY/Pawling Division encompasses custom mixing and extrusion, inflatable seals and flood protection products. Approximately forty percent of Pawling’s extrusion operation supports internal product manufacturing while the other 60 percent supports external business including the supply of gaskets, bumpers, trim strips and basic profiles.
Markets served include the aerospace, automotive, building/construction, landscaping, mass transit, medical/pharmaceutical, military and solar energy industries.
For more information about Pawling, visit www.pawling.com. For more information about Davis-Standard sheet systems, contact Al Chrisbacher at achrisbacher@davis-standard.com.