Strictly-Extrusion

Berstorff supplied two complete compounding lines of time and cost-saving modular design to the leading Russian chemical company KuibyshevAzot. Both lines have recently been commissioned at the new production location in Shanghai. For the time being, an output rate of approx. 10,000 tonnes/year of glass fibre reinforced polyamide 6 for the Chinese and Southeast Asian markets is produced.
In this project, Berstorff acted as a turnkey system supplier. The lines mainly comprise the complete material handling and metering system, a ZE 60 A x 44 D UTX and a ZE 40 A x 44 D UTX twin-screw extruder, a strand pelletising unit with downstream cooling section, silos for the final product and sacking systems. The lines are designed for output rates of 1000 and 300 kg/h, respectively. Both lines are also suited for reinforcing polypropylene and already comprise the appropriate equipment for this application.
Particular benefits are offered by the modular plant concept: both lines could be preliminarily mounted in Hannover with first tests being carried out together with the customer. The customer was thus given a first impression of the dimensions and the functioning of the line at an early stage. The installation of the lines at the place of destination was completed within less than eight weeks.
Roman Meytis, General Director of KuibyshevAzot Engineering Plastics in Shanghai, is convinced of Berstorff’s modular concept: ‘In my opinion, the idea that led to the development of modular lines is simply unique. The advantages we gained from this concept are considerable savings in time and total cost. The easy installation and rapid commissioning were of decisive importance in this context’. He was also extremely satisfied with the performance of the Berstorff staff. ‘In view of the perfect organisation of the work involved from the order placement right through to the commissioning, the efficient local service and advice as well as of the competence in realising technically sophisticated and complex solutions within a minimum of time, we consider Berstorff as a leader in the compounding line sector.

US firm Xaloy has moved from its Heilbronn premises, in Germany, to a larger site in nearby Neckarsulm. A manufacturer of screw and bimetallic barrels, Xaloy has started production of screen changers and melt pumps at the new location. Ralf Hilbert, sales manager for Xaloy Europe, said it would not have been possible to continue the company’s “expansive business policy” from Heilbronn, since “in the long term, we would not have satisfied the continually growing demands and number of customers from that location”. Particular attention will now also be given by the company to expansion of its replacement parts business, supplying customers throughout Europe from Neckarsulm.

The Klöckner Pentaplast Group announced plans to build a manufacturing plant in India in Aurangabad. Recognized as the world’s leading producer and preferred supplier of films for pharmaceutical, medical device, food, electronics, and general-purpose thermoform packaging, the company plans to invest in excess of USD 20 million in the first phase of its manufacturing facility that will produce films for pharmaceutical and food packaging, as well as specialty technical films. kp will furthermore install the first centre of excellence for pharmaceutical films in India at this location for all of Asia, to pursue process development, technology transfer from other kp excellence centers, best practice implementation, and special services to the pharma industry. Serving customers in India and across Middle Eastern geographies, the state-of-the-art manufacturing plant, with a capacity of 15k tons/p.a. at start-up, will be operational by early 2008 and is expected to generate employment for over 90 employees.
Present on the occasion, Joachim Kreuzburg, President & COO, Klöckner Pentaplast, Europe and Asia, said ‘We are committed to manufacturing excellence and delivering ‘best-inclass’ solutions to all our customers and the Aurangabad manufacturing facility in India is in line with this philosophy. Our customer focused approach and expertise in specialty films combined with emphasis on the high quality of our products, will enable us to offer consistent value to customers in the country, as well as across the Middle East. We are also committed to further investments in India.’

The SIG140 BW can be retrofitted to any blown film line and combines a fast acting bubble width control system with the conventional thickness control system. The width control sensors are ultrasonic and situated 120? apart on a hexagonal ring around the bubble, usually positioned just above the freeze line. The SIG140 calculates the signals to a single lay-flat width measurement. The control system compares the width signal against target and inflates or deflates the bubble to achieve correct width. The SIG140 also has a reportedly unique feature — an eccentricity measurement showing any displacement of the bubble and its direction relative to the die-bolts on the die. This enables the operator on start-up to adjust the die-bolts to give a concentric bubble with the most uniform thickness profile.

A new-generation device for feeding colorants and additives into plastics processing machines combines the low cost of a volumetric feeder with the superior precision, consistency, and data generation of a gravimetric metering system, NOVATEC, Inc. announced at Plastec West (Booth 3939). The new feeders are manufactured by Maguire Products, Inc. under a cooperative agreement with NOVATEC, which is backing the equipment with a five-year warranty.
The enhanced accuracy of new MGF Series gravimetric feeders enables molders and extrusion processors to reduce color and additive consumption, increase control over product quality, and document color usage for each production run, according to Tony Crook, product manager, blending systems. The feeders are available with throughput capacity of up to 35 lb. (16 kg) per hour and can be mounted directly to the throat of most molding machines or extruders.
While NOVATEC and Maguire ship a combined total of hundreds of volumetric feeders each year, the new MGF Series feeders are their first gravimetric systems. ‘Until now, gravimetric feeders have been specialty devices available from a few suppliers and costing 40% more than our volumetric equipment,’ said Tony Crook. ‘All that changes with the MGF feeder, which provides processors with the cost-reducing accuracy of a gravimetric feeder for the price of a volumetric model.’
While an MGF feeder is mounted on the processing machine exactly like its volumetric counterpart, there are two major differences between the systems:
• The MGF feeder has two load cells which accurately monitor the loss in weight of colorant in the hopper as the material is fed into the processing machine by an auger. The hopper and auger tube are mounted atop the load cells.
• The MGF feeder has an easy-to-use microprocessor controller with backlit display. The controller allows all dispensing parameters to be easily entered. Automatic adjustments are made when 20 grams of accumulated error is detected.
The loss-in-weight operation adds a new dimension of accuracy. ‘Volumetric feeders do not monitor the weight of colorant as it is fed to the processing machine and thus generate no data about how much of the material is actually consumed from moment to moment,’ Crook said. ‘Because a gravimetric system generates a wealth of data on color consumption, it adjusts color metering far more accurately to account for process variations and to compensate for vibrations on fast-cycling molding presses.’
New Gravimetric Feeders Readily Adjust for Process Variations
The controllers for the new MGF feeders have a digital counter that the operator uses to pre-set the precise amount of color to be added. This parameter is translated into the required degree of auger rotation.
In injection molding, the operator inputs the shot size and letdown ratio for the specific application. The auger doses color as the screw in the molding machine retracts, and the auger motor shuts off when the required amount has been supplied. Drawing on information fed back from the injection machine, the controller adjusts for screw slippage or changes in rate.
In extrusion, the operator inputs throughput rate and letdown ration. The controller regulates auger motor speed to automatically adjust for changes in screw torque, plant voltage, or raw material.
By tracking and adjusting for actual colorant consumption, the MGF feeders not only provide even greater accuracy and consistency but also make possible detailed documentation of the entire production run, according to Tony Crook, including a shot by shot account of color dosing in injection molding. The new feeders can be linked in a plant-wide network.
The MGF feeders also retain the user-friendliness of the volumetric feeders. For example, every component that comes into contact with colorant is easily removed for fast cleaning.

At a time of continued growth for the high barrier films market, the leader in supplying equipment for the production of these specialized products has launched an innovative improvement. Working from the traditionally reliable Battenfeld Gloucester barrier blown film die designs, BGE has added new technology to improve temperature, flow rate and gauge uniformity and control. As a result a manufacturer of specialty high-barrier film & bags located in Miami, Florida recently purchased a Battenfeld Gloucester Engineering 5-layer retrofit blown film line and a complete 7-Layer blown film line to increase their capacity. Seeing a growing demand for custom high barrier multilayer film and bags has also meant an expansion for the company with a new plant underway in the southern states.
After 20 years of production only a hurricane can stop a Battenfeld line
After 20 years of outstanding production and only after damage incurred from Hurricane Rita the company is upgrading their 5layer line. The line retrofit includes all new ContraCool® extruders, dies, air ring and an Autoprofile® control package as well as a new Extrol® 6032 Microprocessor Control System.
‘Gloucester Engineering is well known for its innovative designs and robust manufacturing,’ states Carl Johnson, Blown Film Senior Group Product Manager. ‘We have numerous lines installed in the 1980’s that still offer high production and superior quality film for our customers.’
High demand for high barrier calls for new designs to improve efficiency and quality
According to the Freedonia Group, the US barrier film market will continue to grow at a healthy rate. It is expected that demand for barrier films reaches $3.7 Billion in 2010 which represents a 5.5% annual growth from 2005 levels.
Responding to this growth and always concerned about customer’s profitability and quality of products, Battenfeld Gloucester has included its new Encapsulated Feed Technology (EFT) in the new die designs. According to Johnson, EFT enhances the overall die performance by streamlining flow passages; it allows quicker cleaner changeovers when changing resins or colors.
At the end of the day and with the current cost of raw materials, this represents more efficiency, less downtime, cost reduction and increased profits for film producers.
With demand for multilayer products growing the customer also needed to add new equipment to their plant. The 7-Layer turn key system from Battenfeld Gloucester includes a 12′ 7-Layer Optiflow LP® Non-Rotating Radial Fed IBC Die offering advanced stiffness and thermal homogeneity. The result is a uniform die temperature, flow rate, and gauge control with very tight layer and film thickness control. The computer modeled flow channels provide low residence time, high shear rates, and maximum versatility. The 12′ UltraCool 900 Series Patented Dual Lip Air Ring design provides converging air flow between the bubble and forming cone for increased output and reduced film chatter. Its design offers finished internal flow surfaces for lower pressure drop, less heat generation and quieter operation.
The system also includes an Extrol 6032 Microprocessor Control System, 50mm Gravimetric Feed Hopper ContraCool® Extruders, a 12′ Internal Bubble Cooling (IBC) Air Exchange System, and the Digisonic® IBC Layflat Control System with the patented use of non-contact sonic sensors for measuring all types of film with accurate control under the most demanding circumstances. Also included in the system are a Layflat Bubble Cage and Guide Assembly, a Collapser, Traversanip® (Oscillating Primary Nip Roll Assembly), the Tower and a Model 1001-D Dual Turret High Speed Shaft Type Winder with Automatic Indexing and Cut-Off.
‘Our business philosophy is really quite simple offer machinery that consistently delivers superior performance and at a competitive price. Our customers include some of the very largest film and bag manufactures in the world. Our ability and willingness to ‘custom tailor’ our equipment around their particular needs brings a tremendous value-added benefit to them,’ states Johnson. ‘Battenfeld Gloucester is an integral partner to our customers supporting their growth and ability to provide the highest level of customer service.’

Extrusion Dies Industries, LLC, has opened a wholly-owned subsidiary in Shanghai, China to provide technical support, rework service, and spare parts for flat extrusion and coating dies built by EDI in the US. The new company, EDI Precision Dies (Shanghai) Co., Ltd. is being formally introduced at Chinaplas 2007 this month. The Shanghai operation can carry out both standard rework procedures like cleaning, lip sharpening, and refinishing and major upgrades such as converting a die from a manual gauge profiling system to an automated one using EDI’s Autoflex technology.

Guill Tool & Engineering, a leader in the design and manufacturing of extrusion tooling worldwide, has announced the posting of its new expanded and enhanced website. The new site, www.guill.com, provides a complete range of information about Guill’s products, capabilities and history, as well as press releases and articles covering new products and developments at the company. The new Build Your Product section of the website adds interactivity, and will act as a resource for customers. The aim is to support Guill’s relationship with its customers, by making it easier to communicate with the company; request product information, estimates (quotes) and troubleshooting assistance, along with referencing available resources, charts, tables and information on product care and cleaning. Guill serves the medical, wire and cable, plastics and rubber, tubing and pipe, automotive, electronics, chemical, cosmetics and food processing industries, as well as the defense industry. The Industries section of the new website provides details on the company’s involvement in all of these sectors. The Products segment of the new website provides details on the broad categories of products the company manufactures, including crossheads, in-line heads, rotary heads, tooling, heaters and accessories, as well as details on its various product series and on its quick colour and material changeover capabilities. The Engineering Resources portion of the website offers a variety of calculators, charts and tables, engineering capacities, as well as troubleshooting and R&D capabilities. The Defense section of the website discusses Guill’s work in providing components for the defense industry, including Electric Boat Corp. and Northrup Grumman Newport News, among others.

For the production of plastic jacket pipes for district heat transport, Battenfeld, Bad Oeynhausen, has recently installed a complete large-diameter pipe extrusion line to produce pipe up to 1,600 mm in diameter at MosFlowline, Moscow. MosFlowline, considered one of the country’s largest manufacturers of PUR-insulated pipe, is now operating the largest pipe extrusion line in Russia. The Russian processor and the German machine manufacturer can look back on many years of successful partnership. With the installation of its first two complete pipe extrusion lines in 1989 to manufacture pipes up to 800 mm in diameter, which are still in trouble-free operation today, MosFlowline set a milestone. With the new line, the processor intends to continue its expansion, adding larger pipe dimensions to its product range. The plastic jacket pipes, also called “capped pipes”, are ideally suited to the transport of water heated to temperatures between 130 and 150?C, since they are extremely easy to lay and to service at low cost, have a long life cycle and are highly resistant to chemicals and salts, physical impact and, above all, corrosion. However, their greatest advantage compared to conventional pipes is their excellent insulating property. Plastic jacket pipes consist of an inner steel pipe and an outer pipe made of PE. Applicable to all complete production lines from Bad Oeynhausen, this recently delivered large-diameter pipe extrusion line from Battenfeld Extrusionstechnik is perfectly synchronised, beginning with the extrusion die, through the cooling section and haul-off to the cutting saw and control unit. In addition to the extruder, which is required to ensure high output with optimised product homogeneity, the extrusion die and the complete downstream equipment must also be optimally laid out for large diameters between 710 and 1,600 mm. MosFlowline uses this line to manufacture the outer PE pipes with diameters of up to 1,600 mm and wall thicknesses of up to 30 mm.

Year 2006 was a record one for Maillefer and the strong growth continues into 2007. The company fully recognises the confidence that customer’s place in its leading technology, reliable products and dedicated project management. Figures show total sales in 2006 well exceeding €100 million. A healthy order backlog at this years end confirms the trend forecasted a year ago. Deliveries are booked throughout the entire year ahead and leading into 2008. Total sales for 2007 are expected to clearly surpass that of the previous exercise. Much activity is from demands in modernising or expanding the power grids in industrialised nations. That is leading to investments across the entire energy distribution network. While in pipe applications, the climbing copper prices are accelerating the switch from all metal to alternative plastic pipe (eg. PEX and composite PE Al PE). Neighboring Europe continues to remain a loyal ground for Maillefer. The mature industries lead with rationalisation, expansion and new technology projects. In regions beyond, the company is seeing significant expansion and new growth projects in Russia, China and the Gulf states.