Combined de-airing extrusion units Futura II PZG/ E

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1 The experience gleaned from the supply of over 5,000 auger extruders and our systematic approach to the practical implementation of cutting-edge scientific insight are our main strengths. Not for naught are we a leader in extrusion technology. Combined de-airing extrusion units Futura II PZG/ E HÄNDLE GmbH Maschinen und Anlagenbau Mühlacker (Germany) Phone Fax [email protected]

2 HÄNDLE a leading global partner to the ceramic industry based in Mühlacker (Germany) HÄNDLE counts among the world's leading manufacturers of machines and equipment for the preparation and shaping of ceramic raw materials, particularly in the heavy clay sector. Offering the market premium, technically advanced products, HÄNDLE maintains its market position by also providing first-class customer services and spare parts of the highest quality. In-depth know-how, fast service and maximum reliability of spare and wear parts count among the capability characteristics for which HÄNDLE will continue to stand. We promise! Main merits at a glance Maximum throughput thanks to optimized filling of the de-airing chamber Laboratory and Pilot Plant Conveying and Storing Screening Superior durability and low maintenance requirement coupled with maximum operational stress tolerance thanks to robust gearing and minimized wear Low energy consumption coupled with (optional) permanent operating-data acquisition Feeding and Dosing Better-than-ever vacuum conditions thanks to large de-airing chambers Crushing Mixing and Homogenizing Shaping Extruding De-airing extrusion units Futura II Optimal "vacuum tightness" throughout the system, plus easy maintenance thanks to threadless mounting of barrel and body liners Uniform column advance thanks to optimized auger geometry Shaping - Molding Spare parts and Service PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 2

3 A Futura II combined de-airing extrusion unit comprising an MDVG 920f de-airing double-shaft mixer and a Futura II E 56a/50 extruder Benchmarking the state of the art: HÄNDLE's Futura II series HÄNDLE offers a complete line of combined de-airing extrusion units for a broad range of applications. Our units are of modular design, comprising extruders and de-airing mixers of various size. In designing the Futura II extruder, HÄNDLE systematically implemented the latest in mechanical- and process-engineering knowhow pertinent to extrusion technology and the resultant products boast accordingly favorable price-performance ratios and customer-benefit orientation. Futura II is available with barrel diameters of 200 to 750 mm, maximum extrusion pressures ranging from 20 to 50 bar and volumetric throughputs of 1.9 to 60 m³/h. An MDVG 1025 f de-airing double-shaft mixer accompanying a Futura II E 65a/56 extruder 3

4 Design Modularity Flexible combination of mixer and extruder Large de-airing chamber Optimal auger geometry Threadless wear-part fixation PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 4

5 Cutting-edge drive engineering and robust gearing Separate paddle drives The right vacuum extruder for the right products 5

6 Design Modularity Load- and function-appropriately engineered crucial components, e.g., gearing, coupling, thrust bearing, barrel and auger, all as part of an overall modular concept. Modularized extruder Cutting-edge drive engineering and robust gearing We incorporate the latest products of modern control technology and motive-power engineering. Continuous operating-data acquisition, energy conservation, equipment monitoring and protection, plus defined control response set new standards and blaze new trails for future shaping systems by HÄNDLE. HÄNDLE and its partners have developed for their newgeneration extruders.» Long service life and low maintenance requirement coupled with maximum loading capacity! Large dimensioned gears, maximized mechanical efficiency and easy installation + removal these are the crucial characteristics of the gearing technology that High-tech gearing with separate paddle drives PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 6

7 Separate paddle drives The modularity of the drive assembly with separate paddle drives yields a combination of easy maintenance and lower energy consumption. Extruder body In any extruder used for producing thin-walled holloware or tiles, dry particles and sizable surface-dry agglomerations are bound to increase the rejects rate. HÄNDLE, though, applies special coatings as a standard feature, effectively preventing material buildup and, hence, dry agglomerations. A look inside the extruder body Threadless wear-part fixation HÄNDLE's threadless wear-part fixation technique yields unparalleled "vacuum tightness" for the en-tire system plus quick & easy maintenance.» No dry particles, no false-air infiltration and no vacuum-related lamination A clamp-anchored barrel liner 7

8 Design Self-centering augers and Hirth coupling No matter what the load, the auger remains perfectly centered on the shaft thanks to its triangular polygon. This arrangement guarantees symmetrical power flow into the shaft. The self-centering Hirth coupling ensures optimal positioning of the front-end auger with respect to the rear-end auger (at 7 increments).» Fewer extrusion textures produced, and ideal shaping conditions in pressure head and die thanks to uniform advance of the clay column out of the front auger. Hirth coupling Optimal auger geometry The geometry of all augers, including the front-end auger, is always in balance with product and compound, hence guaranteeing flawless homogenization, plastification and de-airing in combination with high throughput. Diverse wear-prevention concepts all tailored to the respective product performance specification PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 8

9 Variable combinable augers and counter knives Barrel, auger and body can all accommodate supplementary pairs of counter knives. Depending on the extrusion compound, the envisaged product and the targeted throughput rate, made-tomeasure solutions are possible. Very sticky clay, for example, can be adequately de-aired and readied for untextured extrusion. A built-in triangular auger shaft and pair of counter knives De-airing double-shaft mixer Modularity Modular design of double-shaft mixer with long compression zone A de-airing mixer upstream of the extruder serves as a connecting component between body prepara-tion and the actual shaping process. Together, they form a multifunctional system for attending to the material's mixing, kneading, shredding, de-airing, wetting, steam-heating, etc. The homogeneity of the body, as a prerequisite for good shaping, is decisively determined by the de-airing mixer. 9

10 Function De-airing double-shaft mixer with front-end suspension Some 2/3 of the overall homogenization achieved in a de-airing double-shaft mixer takes place in the closed compression section. High pressure in the compression zone is essential to excellent vacuum, just as infinitely adjustable mixing paddles are essential for perfect mixing. The more homogeneous the compound, the better (and more economical) the extrusion. A large-volume de-airing chamber facilitates maintenance and helps achieve better vacuum conditions. HÄNDLE has put all these scientific insights into practice by extending the compression zones of our de-airing double-shaft mixers and enlarging the volume of their de-airing chambers. A look inside the mixing trough PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 10

11 NEW Mixing-trough cleaning ports To facility quick & easy maintenance for applications involving frequent changes of extrusion compound, we are now offering supplementary cleaning ports for the mixing trough of MDVG 715d double-shaft mixers. Mixing trough with cleanout and cleaning ports Flexible combination of mixer and extruder Cross or longitudinal configuration Just when and where any particular configuration should be considered depends on the case-by-case, projectspecific situation.» Separately driven paddles for guaranteed optimal, energy-saving feeding of the "open auger" in the de-airing chamber no matter what the configuration. Cross configuration Longitudinal configuration 11

12 Possible combinations The right vacuum extruder for the right product Our extruders combine with horizontal de-airing doubleshaft mixers and vertical primary pug mills. The following table illustrates the most commonly employed combinations. Vertical single-shaft mixers are unbeatable for feeding tile, facade-element and panel extruders.» Maximum accessibility, simple cleaning and state-ofthe-art drive mechanisms as these machines' distinguishing features. The latest model to join HÄNDLE's Futura II extruder series: a type E 40b/40 in combination with a type-ms 40a vertical primary pug mill, used for extruding facade elements and panels EXTRUDER TYPE E 25a PZG 35c PZG 40c E 40b E 56a E 65a E 75a MS 40a VACUUM MIXER TYPE MS 50a MH 25a MDVG 715d MDVG 920f MDVG 1025f MDVG 1220c PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 12

13 Technical data EXTRUDER TYPE Barrel diameter mm Extrusion pressure 1 max. bar Volumetric throughput 2 m³/h compact Throughput capacity 2 t/h wet Power requirement kw E 25a/20 E 25a/25 E 40b/35 E 40b/40 E 56a/45 E 56a/50 E 56a/56 E 65a/56 E 65a/60 E 65a/65 E 75a/65 E 75a/70 E 75a/ ,2-1,9 0,5-3, ,3-3,3 0,8-6,2 3,5-24,5 5, DE-AIRING DOUBLE-SHAFT MIXER TYPE Barrel diameter mm Mixing-trough width/ length mm Volumetric throughput 2 m³/h compact Throughput capacity 2 t/h wet Power requirement kw MDVG 715d / MDVG 920f / MDVG 1025f / MDVG 1220c / VERTICAL PRIMARY PUG MILL TYPE Barrel diameter mm Volumetric throughput 2 m³/h compact Throughput capacity 2 t/h wet Power requirement kw MS 40a MS 50a HORIZONTAL PRIMARY PUG MILL TYPE Barrel diameter mm Volumetric throughput 2 m³/h compact Throughput capacity 2 t/h wet Power requirement kw MH 25a 250 0,2-3,5 0,4-6, Extrusion pressure = axial pressure 2 Volumetric throughput and throughput capacity dependent on extrusion compound, speed and cross-section of column Subject to technical modification due to ongoing development. 13

14 Options Oil supply system Keeps oil cool and in circulation for optimal operation of planetary gearing Pressure-head swiveling unit For quick exchange of pressure head/ die combinations Lifting and lowering system For fast, precise adjustment of the de-airing extruder's installation height PRODUCT INFORMATION DE-AIRING EXTRUSION UNITS FUTURA II 14

15 Practical examples Futura II de-airing extrusion unit, employed for multiple-column extrusion of roof tiles, comprising an MDVG 1025f de-airing doubleshaft mixer and an E65a/60 extruder. Throughput capacity: 55 t/h wet Futura II de-airing extrusion unit, serving in the production of masonry bricks and drop-in ceiling bricks, comprising an MDVG 1025f de-airing double-shaft mixer and an E 75/70v extruder. Throughput capacity: 65 t/h wet Futura II de-airing extrusion unit, used for extruding panels, comprising an MDVG 715d de-airing dou-ble-shaft mixer and an E 56a/45 extruder. Throughput capacity: 17 t/h wet 15

16 HÄNDLE GmbH Maschinen und Anlagenbau Industriestrasse Mühlacker (Germany) Phone +49 (0) Telefax +49 (0) hour Service Helpline +49 (0) / 2012