FLAT DIES AND FEEDBLOCKS

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1 FLAT DIES AND FEEDBLOCKS For the extrusion Industry maag has been providing high quality extrusion line equipment and systems for more than 30 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. Your 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

2 What we offer Typical Products Handled PC PMMA PA PP PE, HDPE, LDPE, LLDPE PS, HIPS PVC PET PVB ABS TPU EVOH Cellulosic plastic maag offers a full line of film, sheet, foam sheet, and double wall dies, and associated feedblocks. Our TruFlow TM 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. A TruFlowTM model C2-1 quick adjusting die with automatic fine gauge control and feedblock incorporated into a system with melt pump and screen changer. 2

3 TruFlow TM 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. Computer modeling is used to optimize flow channels in TruFlow TM dies and feedblocks. maag TruFlow TM dies are available in 18 standard designs for a wide variety of extruded products. 3

4 TruFlow TM Film and Sheet Dies Models: A1 & A3 Cast Film Dies Thicknesses to in. A2 & A2-1 Film / Sheet Dies Thicknesses to in. C2-1 Quick Adjusting Die Thicknesses to in. Standard Specifications: The A1 is equipped with manual push thickness control and fi xed 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 infl uence 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 For fi lm 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 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 Options: Internal or external deckling system (20 in. max adjustment each side) Internal or external deckling system (20 in. max adjustment each side) Choke bar External deckling system The C2-1 s quick adjustment feature allows changing gauge thickness online in under 2 minutes. Our automatic cast film die maintains precise gauge control without operator intervention. 4

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

6 TruFlow TM 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 closed-loop control using data collected from a gauging system immediately downstream of the die. The bolts are insulated to eliminate thermal infl uence between the bolts and die lips. Standard Specifications: Options: 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: fi xed Installation: horizontal, vertical, or 45 This external deckling system allows width adjustment without production interruption. 6

7 TruFlow TM Specialty Dies Models: C2-3 Polystyrene Foam Sheet Die D1-1 & D1-2 PVC Foam Sheet Dies I Double Wall Die Standard Specifications: 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 fi ne adjustment Lower lip: adjustable or exchangeable, depending on thickness Restrictor bar: 45 Installation: horizontal, vertical, or 45 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 restrictor bar, which provide minimum polymer residence time and precision fl ow 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, fi ne adjustment (exchangeable on the D1-2 model) Lower lip: adjustable or exchangeable, depending on thickness Restrictor bar: 45 or 90, depending on application Upper or lower bonding bolt Installation: horizontal 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 fi ne adjustment Lower lip: 90 fi ne adjustment Restrictor bar: (PP) 90 in both channels Installation: horizontal Options: External deckling system A typical TruFlowTM foam die Examples of internal structure patterns used in double wall sheets. The round holes are compressed air outlets. 7

8 TruFlow TM Coextrusion Dies and Feedblocks Models: D Dual Manifold Sheet Die DF-1 Triple Manifold Film / Sheet Die E Triple Manifold Sheet Die Standard Specifications: For handling two different polymers. It features two independent channels, each with temperature control system, to provide minimum polymer residence time and precision fl ow control. Outputs to 3,300 lb/hr Widths in. Thicknesses to in. Upper lip adjustment: 45 fi ne adjustment Lower lip: adjustable or exchangeable, depending on thickness Restrictor bar: 45 on upper channel, lower channel if needed Lower bonding bolt Installation: horizontal, vertical, or 45 For fi lm 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 fl ow control. Outputs to 3,300 lb/hr Widths in. Thicknesses in. Upper lip adjustment: 45 fi ne adjustment Lower lip: adjustable or exchangeable, depending on thickness Restrictor bar: 45 on upper channel, other channels if needed Lower bonding bolt Installation: horizontal, vertical, or 45 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 fl ow control. Outputs to 3,300 lb/hr Widths in. Thicknesses in. Upper lip adjustment: 45 fi ne adjustment, 90 available Lower lip: adjustable or exchangeable, depending on thickness Restrictor bar: 45 or 90 on upper channel, other channels if needed Lower bonding bolt Installation: horizontal, vertical, or 45 Options: Internal or external deckling system Internal or external deckling system External deckling system A TruFlowTM coextrusion die with external deckling. 8

9 TruFlow TM Film and Sheet Dies Models: F Integral Die and Feedblock Combination G Fixed Geometry Feedblock H Variable Geometry Feedblock Standard Specifications: Our coextrusion dies can be integrally combined with one of our feedblocks for easier installation. Dependent upon the die chosen Designed for 2, 3, or 4-layer sheet production, the layer confi guration can be changed via use of different fl ow selection cartridges. Layer percentages can be adjusted by adding or removing fl ow channel modules. Designed for 5- to 9-layer sheet production, this type of feedblock allows layer percentage control externally, using fl ow control pins or adjustable vanes for each layer. The layer confi guration can be changed via use of different fl ow selection cartridges. Options: Internal or external deckling system maag TruFlow TM die maag TruFlow TM die A three channel variable geometry feedblock with vane type layer adjustment. 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. 9

10 Package Systems 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 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. Melt Pump Static Mixer Screen Changer Drive Control Inlet Pressure RPM Current Speed control Master Discharge Pressure Melt Temperature Pump Drive Drive Control Die Typical schematic of maag extrusion optimization equipment. 10

11 Standard Die Selection Heating Zones in Body Heating Power (KW) Die width (in.) < Die Type Thickness (in.) Output (lb/hr) Model Number Cast Film Film/Light Gauge Sheet Sheet Coating/ Laminating A A1/A ,100 A1/A ,500 A1/A ,200 A3 1,100-3,300 A3 1,500-4,000 A A2/ A2-1 A2/ A2-1 A2/ 450-1,100 A ,500 A2/A ,200 C2-1 1,100-3,300 C2-1 1,500-4,000 A2/A C1/C ,300 C1/C ,750 C ,300 C2-2 1,100-4,400 C2-2 1,300-6,600 C 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. 11

12 Global contacts, see Contact us at The data and illustrations refer to the date of printing. Necessary changes can be made at any time without special notice. maag s products and processes are protected by IP rights. D_01_EN_2015/02

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