Cost-effective system solutions. Film and sheet extrusion lines

Transcription

1 Cost-effective system solutions Film and sheet extrusion lines

2 IN PARTNERSHIP WITH INDUSTRY KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide Automotive White Goods Construction Life Sciences Electrical / Electronics Whatever you aim to achieve in plastics or rubber processing, KraussMaffei is your partner. We are the only company with intensive expertise across the three main engineering fields. And we have a strong track record in integrating this expertise to develop new processes and systems. Ready for any challenge Our Injection Molding Machinery Division supplies machinery and systems from 35 to 4,000 tonnes for standard applications and for all processing variants, together with fully automated solutions. We have a strong customer base in all the relevant industries worldwide. Our Reaction Process Machinery Division supplies machines and complete systems for processing polyurethanes and other reactive materials. Completing our product portfolio, Automotive Component Systems supplies foam molds, cutters and routers. Our customer base is wide, with a focus on the automotive, construction and white appliances industries. Our Extrusion Technology Division supplies machinery and systems for compounding, for pipe, profile and sheet extrusion, physical foaming, and the production of technical rubbers and intermediates for tire production. Machinery from the company s range from single extruders to complete extrusion lines is used in many industries, including chemicals, pharmaceuticals, automotive, construction, furniture and packaging. People for Plastics We are the people for plastics. We are your partners from the first exploratory discussion, through development to commissioning, servicing and operating your system, and final disposal. At all times, you are assured of outstanding competence in planning and engineering, as well as reliable and fast spare parts, service and support. Adding value for customers We put our expertise to work for your success. With machine ranges engineered for modularity, we can deliver application-specific solutions based on our wide range of standard modules and specially engineered solutions. This strategy offers customers technical and cost advantages. Close to customers around the world As an international company, KraussMaffei has a presence in all the major markets for the plastics and rubber processing industries and employs around 3,000 people worldwide. Our sales and service network keeps us close to all our customers around the world.

3 Producing cost-effective high-quality plastics film and sheets has never been easier! Packaging It couldn t be easier in its capacity as a system provider, KraussMaffei Berstorff offers all services involved in manufacturing high-performance extrusion lines from plant logistics, engineering and actually building the line up to operator training and production assistance. It couldn t be cheaper with ZE twin-screw extruders polymer melts can be processed and shaped in a single cycle on the basis of favourably priced raw materials and at increased output rates. Recycling of edge trimming and web scrap additionally contributes to greater efficiency and increased profits. It couldn t be better equipped with reliable single and twin-screw extruders that are combined with tailored smoothing units, KraussMaffei Berstorff lines offer ideal conditions for the production of high-quality plastics film and sheets.

4 System solutions System provider for optimum results Single- or two-stage process uncompromising flexibility. Better quality, improved production reliability, higher cost-effectiveness... KraussMaffei Berstorff s tailor-made technology is the ideal solution for producing high-quality plastic film and sheets. Apart from extrusion lines equipped with singlescrew extruders, KraussMaffei Berstorff also offers extrusion systems with twin-screw extruders for in-line production, where compounding and film or sheet extrusion are combined to form a continuous process. These twin-screw extrusion systems have been specially developed for formulations rich in additives. Both machine concepts provide central control, monitoring and logging of all critical process parameters so that you always know exactly what is happening. Today, central control features are an absolute must in any quality-oriented production system. Numerous examples of innovative end products made of plastic film or sheets can be found in the furniture, packaging and automotive industries. Special styling wishes of designers, exacting functional requirements of safety engineers or excellent user-friendly handling features can all be easily satisfied with KraussMaffei Berstorff s extrusion systems. Innovation comes from experience. In order to compete successfully in a global market, the plastics industry needs innovative yet experienced partners. Access to new markets for innovative plastics products is only possible with state-of-the-art processes and machinery. And they have to be reliable from the very start! KraussMaffei Berstorff regards itself as a system partner providing optimum cooperation with the customer, progressive concepts and highly dedicated project implementation. Benefit from KraussMaffei Berstorff s in-depth competence and let us design and build your film and sheet extrusion lines according to your specific requirements. We draw on an invaluable fund of know-how gained from our in-house development of all the components that constitute a complete extrusion line from the extruder to the downstream equipment. Page 4 System solutions

5 PRoDuCt information in DetAil Optimum production sequence with alternatives for the individual process stages single- or twin-screw extruders. When configuring your film/sheet extrusion or laminating line, you can rely on KraussMaffei Berstorff to have the extruder best suited to your specific product and your production process: from singleand twin-screw extruders right up to or mono- or co-extrusion systems. KraussMaffei Berstorff single-screw extruders are primarily used for processing materials such as PC, PMMA, PA, ABS, PE, PP and dried PET without additional additives, i.e. especially in the production of standard thermoforming sheet with output rates of over 500 kg/h. When used for these applications, single-screw extruders exhibit excellent pressure and temperature profiles to ensure an optimum melt quality. Other beneficial features of KraussMaffei Berstorff single-screw extruders include their simple yet sturdy machine design and low maintenance requirements. KraussMaffei Berstorff ZE co-rotating twin-screw extruders are used for the production of high-quality thermoforming sheet at throughput rates exceeding 1,000 kg/h, especially for processing undried PET, for the production of engineering film and sheets and for extrusion and lamination lines. With laminating lines, the benefits of this extruder series are of particular importance especially when in addition to high output rates in-line compounding contributes to an increased cost-effectiveness of the entire process. Owing to the modular configuration of the processing section, KraussMaffei Berstorff can target the right solution for any process task. KraussMaffei Berstorff twin-screw extruders are also available in an Ultra-Glide version for rapid screw replacement. This version includes a mechanical slide which allows the entire extruder drive to be moved sideways for rapid screw change. KraussMaffei Berstorff twin-screw extruders of the KMD series are the ideal solution for the production of high-quality roofing sheets on the basis of PVC dry blends. The optimized screw geometry combined with perfect temperature control ensures unparalleled melt homogeneity. Single-screw extruder Twin-screw extruder Product information in detail Page 5

6 Single-screw extruder Co-rotating twin-screw extruder Counter rotating twin-screw extruder Polishing calender Downstream equipment KraussMaffei Berstorff extruders are always the right way to maximise process flexibility. Thanks to the great variety of series and versions available in sizes ranging from 45 to 150 mm for single-screw extruders and from 25 to over 200 mm for twinscrew extruders, KraussMaffei Berstorff can always offer a system solution tailor-made to your specific product and process requirements. Polishing calenders: two systems many variations. KraussMaffei Berstorff polishing calenders are available with various roll arrangements and always offer an optimum cost-effective solution for your film and sheet production applications. The polishing calender technology established for decades and subject to ongoing improvement provides excellent film and sheet quality at the highest throughput rates. KraussMaffei Berstorff polishing calenders set new standards with features such as: rigid frame and roll construction, individually designed temperature control systems, high-precision independent drive units for each individual roll, horizontal, inclined or vertical roll arrangements. Polishing calenders are available in two forms: a) Fixed roll arrangement (horizontal, inclined or vertical) b) PlanetCalander with variable roll arrangement. Page 6 Extrusion lines for film and sheets

7 Polishing calender with fixed roll arrangement PlanetCalander with variable roll arrangement 3-rolls polishing calender Patented PlanetCalanders.....are the ideal polishing calenders for producing crystal-clear sheets and film from PMMA, PC, PETG and SAN with excellent optical properties. Owing to the variable arrangement of rolls 1 and 3, the calender unites all the process engineering benefits offered by the standard horizontal, inclined or vertical roll arrangements. The entire frame of this calender can be turned to optimize the melt feed angle. Moreover, the melt residence time on the central roll 2 can be controlled by adjusting the position of roll 3 relative to roll 2. This provides optimized cooling conditions for the most diverse material types and thicknesses. The melt residence time on roll 2 can be adjusted to suit the material and the sheet thickness. The melt feed angle, which is determined by the weight and elongation of the melt, can be changed by adjusting the position of the first roll. The PlanetCalander provides another major advantage for the production of embossed sheets: the central roll can be replaced in as little as 30 minutes. This shortens down-times and saves costs. Downstream equipment: winding or stacking? Every single component in the downstream equipment of our film and sheet extrusion lines has been designed to meet the needs of the future: state-ofthe art technology yet sturdy, reliable and designed for maximum throughput rates. Depending on the material type and thickness, the extruded film or sheet is calibrated in the polishing calender and then cooled, laminated, edge-trimmed and reeled or stacked. Various types of winders are available for film winding, from simple jumbo roll winders to fully automatic turret winders. When producing stackable sheets, an appropriate cooling roller section is included downstream of the polishing calender. If a PlanetCalander is being used, the position of the roller section is automatically adjusted to the position of the last polishing roll. After completion of edge trimming and cross-cutting, a vacuum stacking system loads the cut-to-size sheets to pallets. Depending on the given requirements, various additional units can be integrated into our film or sheet extrusion lines. Product information in detail Page 7

8 Standard thermoforming sheets Simple implementation, compact design and fast amortisation Extrusion with single-screw extruders and selected modules You do not need a degree in rocket science to figure out why KraussMaffei Berstorff s standard thermoforming sheet lines are so cost-effective. The four modules that make up the thermoforming sheet line are perfectly matched and based on a modular principle as standard. Rapid commissioning Compact design and functional checks prior to delivery ensure rapid commissioning. It will not take you long to realize how easily and quickly your standard thermoforming sheet production can be improved or modernized. Moreover, a second extruder can be easily connected to the coextrusion adapter to realize co-extrusion applications and the production of multi-layer sheets for much less than you thought. KraussMaffei Berstorff standard thermoforming sheet lines are available in three different sizes for throughput rates from 550 kg/h to 1,500 kg/h and sheet widths between 400 and 2,000 mm. Typical materials: PS, PP, PET Typical products: cups, bowls, plates, blisters, etc. 1: Main extruder with screen changer, melt pump and wide extrusion die with co-extrusion adapter 2: Three-roll polishing unit, cooling rolls, temperature control unit and take-off unit 3: Winder with accumulator and edge trimmer 4: Co-extruder with screen changer and melt pipe (option, not shown in figure) Options: Thickness gauge (for module 2) Page 8 Extrusion lines for film and sheets

9 State-of-the-art thermoforming sheet line reliable, long lasting and cost-effective 1 1 Feeding system 2 Single-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 3 3-rolls polishing calender 4 Post-cooling section with thickness gauge and take-off unit 5 Accumulator and winder Standard thermoforming sheets Page 9

10 High-quality thermoforming sheet lines Optimized production lines with customized equipment Meet the best... for quantity with quality KraussMaffei Berstorff thermoforming sheet lines for in-line compounding of thermoforming sheets offer unparalleled cost-effectiveness in the production of high-quality sheets for the most diverse packaging applications. The twin-screw extruders of these lines are designed to combine the originally separate production steps of compounding and sheet extrusion into a continuous process. Additional benefits include: cost-savings resulting from the use of raw materials (pellets, beads, powder, chips) instead of pre-compounded pellets, less capital tied up in materials flexible recipe change-over, 100% use of reclaimed material (edge trims, start-up scrap, web scrap), gentle raw material compounding, compact, space-saving design. Uncompromising performance. The prime strength of KraussMaffei Berstorff s thermoforming sheet line is that sheets with a filler and reinforcing material content of up to 70% can be manufactured in thicknesses between 150 and 2,000 µm. Typical products include margarine tubs, yoghurt pots, coffee cups, flower pot and structural automotive parts. Typical materials: LDPE, HDPE, PP, PS, ABS Page 10 Extrusion lines for film and sheets

11 Twin-screw extruder with slot die and smoothing unit for the production of highquality thermoforming sheets 1 1 Differential metering station with gravimetric feeders 2 Twin-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 3 3-rolls polishing calender 4 Post-cooling section with thickness gauge and take-off unit 5 Accumulator and winder 2 High-quality thermoforming sheet lines Page 11

12 Fabric-reinforced sheets Cost-effective lines for lamination on one or both sides Comprehensive solution even with in-line compounding. KraussMaffei Berstorff extrusion and lamination lines always offer an optimum cost-effective solution for your sheet production requirements. They have proved their worth in the daily production of the most diverse fabric-reinforced sheets for a wide spectrum of applications in structural and civil engineering projects. Thanks to the great variety of available extruders and calenders, extrusion lamination lines can be designed to meet the most diverse requirements. KraussMaffei Berstorff s proven and sheet extrusion lines with their innovative technologies, such as the modular configuration of twin-screw extruders and the five variations of our polishing calenders, provide maximum reliability and excellent sheet quality. Extrusion laminated products with a filler and reinforcing material content of up to 80%, thicknesses between 250 and 3,000 µm and widths of up to 3,600 mm can be produced with this equipment at throughput rates of up to 4,5 tonnes per hour. Perfection in every single layer! KraussMaffei Berstorff extrusion and lamination lines combine all production steps into a single process. From raw materials feeding and extrusion of different materials for both product sides, to coating, embossing, cooling, edge trim reprocessing and winding on big rolls or rolls designed for short web lengths. Typical materials: LDPE, HDPE, PP, PPVC, TPO, TPU Typical products: roof coverings, swimming pool and pond linings, sealing membranes for rain-water reservoirs and landfill sites, foundation linings, floor coverings Page 12 Extrusion lines for film and sheets

13 Extrusion and lamination line 1 Unwinder 2 Differential metering station with gravimetric feeders 3 Twin-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 4 3-rolls polishing calender 5 Lamination equipment 6 Post-cooling rolls with thickness gauge and take-off unit 7 Accumulator and winder 6 7 Fabric-reinforced sheets Page 13

14 film AND SHEET The tailor-made system solution for any product and process KraussMaffei Berstorff s engineering film and sheet extrusion lines are tailor-made to specific customer and process requirements. They allow the most diverse types of film or sheets to be produced, e.g. for the automotive industry and its suppliers, the building industry, civil engineering and for a variety of other engineering applications. The KraussMaffei Berstorff twin-screw extruders of these lines are designed to meet your specific product and process requirements. They combine compounding and film or sheet extrusion into a continuous process. Optimized polishing calenders are available to suit various process- or product-related requirements. When the PlanetCalander is used, the arrangement of the polishing rolls can be infinitely varied within a generous adjustment range. Your one-stop solution! Perfectly tailor-made complete efficient. Engineering film or sheet extrusion lines allow products with a filler and reinforcing material content of up to 80% to be manufactured in thicknesses between 150 and 3,000 µm. Typical materials: LDPE, HDPE, PP, PPVC, PS, ABS, PC, PMMA, TPO, TPU, PVB Typical products: Automotive film and sheets for passenger compartments, instrument panels and door panels, decorative film and sheets for furniture, diverse types of film or sheets for civil engineering applications. 5 4 Page 14 Extrusion lines for film and sheets

15 Customer and process-specific design: line for the production of engineering film 1 1 Differential metering station with gravimetric feeders 2 Twin-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 3 3-rolls polishing calender 4 Post-cooling section with thickness gauge and take-off unit 5 Accumulator and winder 3 2 Engineering film Page 15

16 Plastics sheets Sheet extrusion lines made to measure for any product measurements Efficiency beyond compare. KraussMaffei Berstorff offers sheet extrusion lines designed for the production of the most diverse types of high-quality plastic sheets. The thermoforming process, for example, allows the manufacture of low-cost components for apparatus or wall cladding panels. Innovative applications include the production of optical elements for monitors or vehicles. KraussMaffei Berstorff s response to these manifold product and process requirements is its uncompromising customer-centered flexibility in the design of the extrusion system. Owing to its sound knowledge of the extrusion and polishing processes and the availability of analysis methods that allow even the last detail to be accurately designed, you can rely on KraussMaffei Berstorff to provide the best extrusion system for any sheet extrusion application. Unparalleled productivity and flexibility. When used for sheet extrusion applications, optimized single-screw extruders and high-performance twin-screw extruders are suitable for both mono- and co-extrusion processes. The downstream polishing process can be accomplished in polishing calenders with a fixed roll arrangement or with the highly flexible PlanetCalander. Optimal control of sheet quality and cooling capacity is guaranteed. With this configuration, sheet extrusion lines offer high extrusion capacities along with excellent dimensional accuracy of the extruded sheets. Additional benefits include the user-defined sheet path and high productivity for sheets with a filler and reinforcing material content of up to 80%, thicknesses up to 65 mm, widths up to 4 m and throughput rates up to 3,000 kg/h. 5 4 Page 16 Extrusion lines for film and sheets

17 3-rolls polishing calender for sheet manufacture Typical materials: LDPE, HDPE, PP, PS, ABS, PC, PMMA, SAN, PET-G Typical products: crystal-clear sheets, sheets for applications in the chemical industry, sheets for tank construction. 1 1 Feeding system 2 Single-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 3 3-rolls polishing calender 4 Roller section for sheet cooling or heating/ cooling with thickness gauge and take-off unit 5 Cross-cutter and stacking device 3 2 Plastics sheets Page 17

18 Optical clear plastic sheet Sheet and board extrusion lines with crystal-clear results Innovative ideas merge with mature technology to give maximum efficiency and reliability. KraussMaffei Berstorff sheet extrusion lines are in a class of their own in terms of quality and productivity levels that can be achieved in the production of crystal-clear plastic sheets. They meet all requirements for easy operation, short product changeover times and maximum machine availability throughout all production stages, from polymer compound processing to finished sheet stacking. KraussMaffei Berstorff offers uncompromising flexibility in equipment planning and design to cater for the variety of customer-specific product properties and process conditions. Thanks to its in-depth knowledge of the entire production process, KraussMaffei Berstorff is a dependable partner in the production of crystal-clear sheets. Its sheet extrusion lines are tailored to specific customer needs and output rates and can be equipped with a singleor twin-screw extruder and flexible planet calender (PlanetCalander ). The twin-screw extruder / planet calender combination, for example, is ideal for output rates of over 1000 kg/h thanks to the low raw materials and energy costs it involves. So KraussMaffei Berstorff sheet extrusion lines meet virtually all needs of a modern production facility, no matter which materials need to be processed. They set high benchmarks in all areas of sheet production today and in the future. 5 4 Page 18 Extrusion lines for film and sheets

19 Sheet extrusion line PlanetCalander with roller section Typical materials: PC, PMMA, PETG, APET, PS, SAN Typical products: Sliding roofs, rear windows, TV screens, communication system displays, helmet visors, sunglasses, skylights, safety windows, protective covers. 1 1 Feeding system 2 Single-screw extruder with screen changer, melt pump, wide extrusion die and feedblock 3 PlanetCalander 4 Roller section for sheet cooling or heating/ cooling with thickness gauge and take-off unit 5 Protective film laminator 3 2 Optical clear plastic sheet Page 19

20 Laboratory flat film Test it in our technical centre before using it in your laboratory! Benefit from our expertise and experience! Let us join forces. Benefit from our well-equipped process laboratory in Hanover and Florence, Kentucky use our single- and twin-screw extruders, various smoothing units and downstream equipment to perform your tests. Film, sheets and laminated products can be produced in widths of up to about 1,100 mm. KraussMaffei Berstorff will help you optimize your process well before your production line is commissioned. With the assistance of our qualified personnel, you can test and optimize any process step, any screw geometry, any barrel configuration and any film or sheet fabrication process under real production conditions using your own materials. Laboratory extrusion line with twin-screw extruder and PlanetCalander Page 20 Laboratory flat film

21 EXTRUSION PROCESS CONTROL Easy process control and monitoring Central operation and visualization of the entire extrusion process The intelligent process control system provides for costeffective operation of the extrusion line. Peripheral systems and downstream equipment such as material conveying and metering systems, screen changer, melt pump, smoothing unit and winder are all integrated by standardized interfaces. All data can be accessed from the central control station and support the different functions of the visualization system. Our complex control systems are tailored to individual customer requirements and based on Siemens Simatic S7 and WinCC. Control systems on different hardware platforms are available on request. Operation and visualization All line components and the relevant operating status are visualized on clearly arranged screen pages. Fault alarm system The fault alarm system detects malfunctions at an early stage and thus avoids machine downtimes. Each alarm is displayed and archived with the corresponding status, time-stamp and plain text. Trend data Stored actual values can be displayed in any combination. The data can also easily be stored in an external data memory for quality documentation. Recipe management The recipe management comprises all process parameters. The values are loaded and stored during operation by means of the teach-in function of the recipe editor. Thanks to the download function, the values can be recalled at any time. Process Control Advanced Page 21

22 SERVICE WORLDWIDE Service, support and spare parts when you need them, where you need them Rely on us for a fast and competent response to all your service needs anywhere in the world. Whatever you need from troubleshooting and training to spares or repairs we re on the job. We re dedicated to supplying service quality on a par with the outstanding quality of our machines and systems. We offer far more than spare parts and hotlines. We ll work with you to choose the best and most cost-effective solution for your operation. We ll help you test new applications and we ll plan customized service packages. All-round service Our service offering is broad. We ll configure your system, install and commission it, train your staff, plan measures to minimize your downtime risk and maximize productivity, and carry out maintenance, repairs and upgrades. You ll find us fast, reliable and competent. Our hotline is manned by highlytrained and experienced service technicians. If necessary, we ll get a technician to you quickly. Remote diagnosis, interfacing directly with your machine s control system, can be a practical alternative. Spares for all important wear parts are available at short notice. We re continuously expanding our service network to speed up spare parts shipment. Talk to us about the right service solution for your business. Customer trials and prototyping in our test lab The Extrusion Division operates a test lab fitted with the latest machinery and equipment. We can run trials, produce prototype parts and fine-tune processes on your behalf. We can work with you to test and evaluate processes, machines and equipment in order to identify the best approach for a particular project. Our highly-qualified application engineers are there to help you. Training with high hands-on content Courses are held in our lab and training centre, or, optionally, on your premises. We offer clearly-structured basic and advanced training in operation, process control and maintenance for KraussMaffei extrusion systems. On request, we ll plan and hold special courses on topics of your choice. All participants spend a high proportion of their training working hands-on with original KraussMaffei machines. A well-structured training program produces skilled operators and technicians, which will positively impact your up-time and productivity.

23 Worldwide hotline numbers KraussMaffei Berstorff GmbH Hannover, Germany Customer Service Phone: Phone rubber technology: Phone plastics technology: Phone service hotline: Krauss-Maffei (U.K.) Ltd. Warrington, Great Britain Phone: Fax: Krauss Maffei Italiana S.r.l. Rezzato, Italy Phone: Fax: Krauss Maffei Corporation Florence, USA Phone: Fax: BKM Servicegesellschaft OOO KraussMaffei Berstorff Moscow, Russia Phone: Fax: Krauss Maffei Mexico Mexico City, Mexico Phone: Fax: Krauss Maffei do Brasil Ltda São Paulo, Brazil Phone: Fax: KraussMaffei Technologies India Pvt. Ltd. Pune, India Phone: Fax: KraussMaffei Co., Ltd. Shanghai Phone: Fax: Contacting us by post If you need to contact any of our international service or spare parts teams by post, use this address: Customer Service KraussMaffei Berstorff GmbH An der Breiten Wiese Hannover Germany

24 KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide. KraussMaffei machines and systems are used wherever plastics and rubber are converted into products. As a knowledge-driven technology company, we build on many decades of experience and a strong commitment to research and development. When using film and sheet extrusion lines, your production concept determines your production results. Made-to-measure lines and complete system solutions supplied by KraussMaffei Berstorff produce high-quality films and sheets, improve quality, enhance production reliability and optimise cost-effectiveness. Our extrusion lines equipped with high performance single- or twin-screw extruders provide outstanding flexibility in the production of thermoforming sheets, PET film, fabric-reinforced film, laboratory flat film or plastic sheets at low operating, raw material and production costs. 1.0 WE. 1. 2nd Auflage edition 09/07. 06/08. EXTH 003 XXX A PRO A PRO 09/ /2007 DE GB Technische KraussMaffei Änderungen reserves vorbehalten. the right to make technical changes. KraussMaffei Berstorff GmbH An der Breiten Wiese Hannover Phone Fax