The world leader for proven processing solutions. Flat Dies and Feedblocks for the Extrusion Industry

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1 The world leader for proven processing solutions. Flat Dies and Feedblocks for the Extrusion Industry

2 1 What We Offer Maag has been providing high quality extrusion line equipment and systems for more than 25 years. Now we can provide sheet and film processors a complete package from the extruder outlet that includes the screen changer, melt pump, mixer, and die. With all that we have to offer, partnering with Maag has never made more sense. Maag offers a full line of film, sheet, foam sheet, and double wall dies, and associated feedblocks. Our TruFlow products are engineered and constructed to world class standards, typical of what you ve come to expect from Maag. Dies are available for producing single and multiple layer output, including foam and corrugated layers. Capacities include: Up to 6,600 lb/hr Up to 315 in. wide Up to 1.18 in. thick Up to 9 layers A variety of manual and automatic lip adjustments are available, including adjustments without production interruption, as well as internal and external deckling arrangements. Whether provided individually, or as part of a complete package with melt pump, screen changer, and/or static mixer, you get the quality and lasting value that has made Maag one of the most trusted names in extrusion today. Typical Products Handled PC PMMA PA PP PE, HDPE, LDPE, LLDPE PS, HIPS PVC PET PVB ABS TPU EVOH Cellulosic plastic A TruFlow model C2-1 quick adjusting die with automatic fine gauge control and feedblock incorporated into a system with melt pump and screen changer.

3 2 TruFlow Product Overview Maag offers dies to suit most applications, such as: Film and sheet Coating and laminating Coextrusion Specials, including dies for foam sheet and double wall products Standard construction features include: Premium steel construction with hardness of RC for bodies and RC for lips Surface finish for flow channels is 4-6 RMS and 2-3 RMS for lips Chrome plated internal ( in.) and external ( in.) surfaces One inch center distance for thickness adjustment screws All dies and feedblocks have computer optimized flow channels for consistent residence time and residence time distribution. State of the art 3- and 5-axis machining centers are used to produce the complex channel designs. Thorough lab testing ensures performance objectives are met. More than 8,000 die installations worldwide attest to their superior design and craftsmanship. Maag TruFlow dies are available in 18 standard designs for a wide variety of extruded products. Computer modeling is used to optimize flow channels in TruFlow dies and feedblocks.

4 3 TruFlow Film and Sheet Dies Models A1 & A3 Cast Film Dies Thicknesses to in. The A1 is equipped with manual push thickness control and fixed lower lip for close contact with the casting rolls. The A3 adds automatic gauge control. Upper lip adjustment is provided by thermal expansion bolts, which are heated via closed-loop control using data collected from a gauging system immediately downstream of the die. The bolts are insulated to eliminate thermal influence between the bolts and die lips. Outputs to 2,200 lb/hr ( 3,950 lb/hr for A3) Widths in. (217 in. for A3) Thicknesses in. Upper lip adjustment: 45 manual push Upper bonding bolt Installation: vertical Internal or external deckling system (20 in. max adjustment each side) Models A2 & A2-1 Film / Sheet Dies Thicknesses to in. For film and light gauge sheet. The upper lip is adjustable by manual push and the lower lip is adjustable or exchangeable, for a wide range of thickness adjustment. Outputs to 3,950 lb/hr Widths in. Thicknesses in. Upper lip adjustment: 45 manual push (push and pull for A2-1 model) Lower lip : adjustable or exchangeable Upper bonding bolt Installation: horizontal, vertical, or 45 Internal or external deckling system (20 in. max adjustment each side) Model C2-1 Quick Adjusting Die Thicknesses to in. This innovative die allows lower lip adjustment without process interruption. Outputs to 3,300 lb/hr Widths 8 80 in. Thicknesses in. Upper lip adjustment: 45 manual push Lower lip: quick adjustable Lower bonding bolt Installation: horizontal or 45 Choke bar External deckling system Our automatic cast film die maintains precise gauge control without operator intervention. The C2-1 s quick adjustment feature allows changing gauge thickness online in under 2 minutes.

5 4 Models C1 & C2 Sheet Dies Thicknesses to 0.59 in. C1 and C2 dies are for light to heavy gauge sheet production and include a choke bar to promote uniform melt flow across the die width. The C2 further offers higher precision output. Outputs to 1,320 lb/hr Widths in. Thicknesses inches Upper lip adjustment: 45 push Lower lip: fixed or adjustable Choke bar: 45 Lower bonding bolt Installation: horizontal or 45 External deckling system Model B Sheet Die Thicknesses to 1.18 in. For heavy gauge sheet. Outputs to 4,400 lb/hr Widths in. Thicknesses in. Upper lip adjustment: push, 45 push and pull fine adjustment, 90 adjustment for >0.6 in. thickness Lower lip: adjustable up to 0.08 in. thickness, exchangeable up to 0.24 in. Choke bar: 45 for in. thickness, 90 for thicker material Lower bonding bolt Installation: horizontal or 45 External deckling system Model C2-2 Sheet Die Thicknesses to 1.18 in. For extra heavy gauge sheet. Outputs to 6,600 lb/hr Widths in. Thicknesses inches Upper lip adjustment: 90 push and pull, changeable Lower lip: exchangeable Choke bar 90 Upper bonding bolt Installation: horizontal or 45 External deckling system TruFlow dies are precision built from high quality steel with all surfaces hard chrome plated and polished.

6 5 TruFlow Coating and Laminating Dies Models A1-1 & A1-2 Coating, Laminating, and Oriented Film Dies The A1-1 is equipped with internal deckling with thick edge reduction. The A1-2 model adds automatic gauge control. Upper lip adjustment is provided by thermal expansion bolts which are heated via closedloop control using data collected from a gauging system immediately downstream of the die. The bolts are insulated to eliminate thermal influence between the bolts and die lips. Outputs to 1,100 lb/hr (2,200 lb/hr for A1-2) Widths in. (217 in. for A1-2) Thicknesses in. Melt indexes <8 Upper lip adjustment: push Lower lip: fixed Installation: horizontal, vertical, or 45 TruFlow coating and laminating dies include internal deckling as standard. This external deckling system allows width adjustment without production interruption.

7 6 TruFlow Specialty Dies Model C2-3 Polystyrene Foam Sheet Die Specially designed for polystyrene foam applications. Each lip features independent oil temperature control. Outputs to 1,100 lb/hr Widths in. Thicknesses in. Upper lip adjustment: push, 45 push and pull fine adjustment Lower lip: adjustable or exchangeable, depending on thickness Choke bar: 45 Installation: horizontal, vertical, or 45 External deckling system Models D1-1 & D1-2 PVC Foam Sheet Dies The D1-1 model is for free foam and the D1-2 model is for Celuka foam. Each lip features independent oil temperature control. The D1-2 model has two independent channels, each with choke bar, which provide minimum polymer residence time and precision flow control. This model also has separate oil temperature control for the die body. Outputs to 1,750 lb/hr Widths in. Thicknesses (free foam) in.; (Celuka foam) in. Upper lip adjustment: 45, 90, fine adjustment (exchangeable on the D1-2 model) Lower lip: adjustable or exchangeable, depending on thickness Choke bar: 45 or 90, depending on application Upper or lower bonding bolt Installation: horizontal Model I Double Wall Die This dual channel design produces double wall PP and PC sheet for a hollow material that is rigid, yet lightweight. A special version is available for applying a UV resistant layer with the addition of a feedblock. Outputs to 1,100 lb/hr Widths to 138 in. Thicknesses (PP) in., (PC) in. Upper lip adjustment: 90 fine adjustment Lower lip: 90 fine adjustment Choke bar: (PP) 90 in both channels Installation: horizontal Examples of internal structure patterns used in double wall sheets. The round holes are compressed air outlets. A typical TruFlow foam die

8 7 TruFlow Coextrusion Dies and Feedblocks Model D Dual Manifold Sheet Die For handling two different polymers. It features two independent channels, each with temperature control system, to provide minimum polymer residence time and precision flow control. Outputs to 3,300 lb/hr Widths in. Thicknesses to in. Upper lip adjustment: 45 fine adjustment Lower lip: adjustable or exchangeable, depending on thickness Choke bar: 45 on upper channel, lower channel if needed Lower bonding bolt Installation: horizontal, vertical, or 45 Internal or external deckling system Model DF-1 Triple Manifold Film / Sheet Die For film and light gauge sheet using three or more different polymers. It features three independent channels, each with temperature control system, to provide minimum polymer residence time and precision flow control. Outputs to 3,300 lb/hr Widths in. Thicknesses in. Upper lip adjustment: 45 fine adjustment Lower lip: adjustable or exchangeable, depending on thickness Choke bar: 45 on upper channel, other channels if needed Lower bonding bolt Installation: horizontal, vertical, or 45 Internal or external deckling system Model E Triple Manifold Sheet Die For medium to heavy gauge sheet using three or more different polymers. It features three independent channels, each with temperature control system, to provide minimum polymer residence time and precision flow control. Outputs to 3,300 lb/hr Widths in. Thicknesses in. Upper lip adjustment: 45 fine adjustment, 90 available Lower lip: adjustable or exchangeable, depending on thickness Choke bar: 45 or 90 on upper channel, other channels if needed Lower bonding bolt Installation: horizontal, vertical, or 45 External deckling system A TruFlow coextrusion die with external deckling.

9 8 Model F Integral Die and Feedblock Combination Our coextrusion dies can be integrally combined with one of our feedblocks for easier installation. Dependent upon the die chosen Internal or external deckling system Model G Fixed Geometry Feedblock Designed for 2, 3, or 4-layer sheet production, the layer configuration can be changed via use of different flow selection cartridges. Layer percentages can be adjusted by adding or removing flow channel modules. Maag TruFlow die Model H Variable Geometry Feedblock Designed for 5- to 9-layer sheet production, this type of feedblock allows layer percentage control externally, using flow control pins or adjustable vanes for each layer. The layer configuration can be changed via use of different flow selection cartridges. Maag TruFlow die A seven channel variable geometry feedblock with control pin type layer adjustment. The flow selection cartridge (attached to the top of the inlet section) allows flexibility in layer configuration. A three channel variable geometry feedblock with vane type layer adjustment.

10 9 Package Systems In addition to dies and feedblocks, Maag offers the following extrusion optimization products: Melt pumps: for higher line throughputs with better gauge control and lower overall energy consumption. Screen Changers: in a variety of continuous, semi-continuous, and non-continuous configurations for increased product quality and protection of downstream equipment. Static mixers: for uniform mixing and temperature distribution with low pressure losses in a compact inline design. Maag can provide a complete engineered package that combines the die and/or feedblock with: Screen changer Melt pump Static mixer Hydraulic power units Sensors, instrumentation, and controls Adapters and connectors Motors, gear reducers, and drives Shafts, couplings, and guards Base plates, support frames, and carts Benefits When you buy a packaged system from Maag, you realize the benefits of: Single source responsibility An integrated system where all components are designed to work together Simpler procurement Melt Pump Screen Changer Static Mixer Inlet Pressure RPM Pump Drive Die Drive Control Current Speed control Master Discharge Pressure Drive Control Typical schematic of Maag extrusion optimization equipment. Melt Temperature

11 10 Standard Die Selection Die Type Thickness (in.) Cast Film Heating Zones in Body Heating Power (KW) Die width (in.) < Output (lb/hr) A A1/A ,100 A1/A3 Model Number 650-1,500 A1/A A3 1,100-3,300 A3 1,500-4,000 A3 Film / Light Gauge Sheet Sheet Coating / Laminating A2/A A2/A ,100 A2/A ,500 A2/A , 200 C2-1 1,100-3,300 C2-1 1,500-4,000 A2/A C1/C , , ,300 C2-2 1,100-4,400 1,300-6, A A A ,100 A ,550 A ,750 A1-2 1,100-2,200 A1-2 The selection guide and all other representations presented in this brochure are for standard dies only. We can also supply custom dies built to specific customer requirements. Consult Maag for more information.

12 USA Maag Pump Systems Inc Continental Blvd. Charlotte, NC USA Tel Fax Switzerland Maag Pump Systems AG Aspstrasse Oberglatt Schweiz Tel Fax Germany Maag Pump Systems GmbH August-Kümpers-Strasse Wettringen Deutschland Tel Fax Italy Maag Pump Systems S.r.l. Viale Romagna Rozzano (M) Italia Tel Fax Singapore Maag Pump Systems Pte. Ltd. 25 International Business Park German Center Singapore Tel Fax France Maag Pump Systems SARL 111, Rue du 1er Mars Villeurbanne France Tel Fax China Maag Pump Systems Shanghai Room 1204A, Silver Tower 218 South Xi Zang Road Shanghai, China Tel Fax

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