The production of plastic profiles and film is carried out with highly developed dies in which the geometries are coordinated precisely to the flow properties of the plastics. This coordination often requires long iteration loops in simulation and experiment. These loops represent a considerable cost and time factor, and threaten the prospects of manufacturing in high-wage countries.  

Additively manufactured demonstrator die (© IKV/Fröls) 

Excellence Clusters Studies Additively Manufactured Extrusion Dies 

Additive Fertigung

Extrusionswerkzeuge

Extrusion

Werkzeug- und Formenbau

Technik Trend

kunststoffe-international.com

Fast Product Change in Extrusion  

In 2013, Reifenhäuser introduced the high-performance extrusion lines for PET thermoforming sheets with the patented mechatronic polishing stacks of the MIREX-MT-V design series. Now Reifenhäuser introduces the next generation of this line type. 

Reifenhäuser Combines Improved Components 

Industrie 4.0

Polyethylenterephthalat

Flachfolien- und Plattenextrusion

Folien

Verpackungsmaterial

New Generation of PET Thermoforming Sheet Lines 

Macchi presented at K the new Pod-Flex series for the production of seven-layer blown films with a net width of 2700 mm. The extrusion line can extrude laminate, barrier and biomaterials, since the new TES72 extrusion die, which is completely PVD-coated, can process both polyolefin and barrier-film formulations on the same line. 

Technical Advances in More Flexible Blow-Molding Lines  

Blasfolienextrusion

Higher Speed for Material Exchange 

In extruder construction the rotary joints are normally integrated in cramped installation situations. For that reason slender and compact sizes are called for. On the basis of the proven sealing system of its 7900 series, Haag + Zeissler Maschinenelemente GmbH, Hanau, Germany, has now developed a compact rotary joint, taking into account economic aspects. 

Quick-Change Cartridge System   

Extrusions-Zubehör

Rotary Joints Series 7950 

At the Fakuma 2017 trade show, Leistritz Extrusionstechnik GmbH based in Nuremberg, Germany, presented a novelty in the area of process monitoring. They showed an elongational rheometer that supplies solid data making it possible to prove even the slightest deviation in the production process. 

Elongational Rheometer for Fast and Efficient Process Monitoring 

Messtechnik

Inline-Messtechnik

Qualitätssicherung

Measuring Shearing and Stretching Viscosities Online  

The Davis-Standard Technical Center has announced two additions to its lab capabilities in Pawcatuck, Conn/USA. By the end of the first quarter, Davis-Standard will offer trials for its Davis-Standard Helibar groove feed extruder and the DS Activ-Check control system for continuous extruder monitoring. According to John Christiano, Davis-Standard’s Vice President of Extrusion Technology, both present new opportunities for customers to improve and strengthen processes. 

R&D Additions at Davis-Standard  

Steuerungen (Hardware und Software)

Trials for Extruder Equipment 

Luciano Anceschi, also known as President of Euromap, has found a new managing director for his family's company. 

The Company Develops Its Leadership with this Appointment 

Kunststoffverarbeitung: Maschinen und Komponenten

Spritzgießen

Blasformen

Stefano Venturelli New Tria CEO as of April 1 

The Institute for Plastics Processing in Aachen is drumming up support for an innovative event that will demonstrate diversity and present the unexpected. Even the event's initiator, Prof. Hopmann, is keyed up and can't wait to see what will be presented there ¿ as he divulged to us in an interview.  

IKV premiere will throw light on the fundamentals of plastics technology  

Faserverarbeitung

Lehrstühle und Institute

Call for papers for a symposium for lateral thinkers  

As already known since the previous K, “EVO Ultra Flat” from Reifenhäuser Blown Film GmbH, Worms, Germany, improves the flatness properties of blown film. A new laser-measurement system now enables the improvement to be quantified precisely: laminating and barrier films are up to 40  % flatter while sagging is reduced by up to 90  %. The measuring unit records the topography of the fine film web and then sets the correct production parameters. Reifenhäuser will be demonstrating at its booth how this ultra-flat measurement with integrated closed loop control functions. 

Reifenhäuser at K 2019 

Measurable Flatness, Increased Sustainability and Progressive Digitalization  

The Chinese global film supplier invests in two 7-m sequential film stretching lines for the production of BOPA films. 

Xiamen Changsu orders production line for BOPA film 

Brückner delivers sequential film stretching lines 

The EMVA announces that based on the high dynamics of the COVID-19 pandemic development the EMVA Business Conference 2020 in Sofia is cancelled.  

One-day Conference in Online Format is Planned for June 

Spritzgießmaschinen

Europa

EMVA Business Conference in Sofia is Shifted to 2021 

Recently, the first plant in the Middle East for producing composite pipes with diameters up to 1,200 mm was commissioned. Not only is the production line the first of its kind in the Middle East, but it is also noteworthy for the entire plastic pipe manufacturing business because of its specific properties and a throughput of up to 2,000 kg/h. 

High-Strength Pipes for Extreme Demands Coextruded from PE-RC Materials 

Polyethylen

Extruder

Rohr- und Profilextrusion

Kunststoff-Rohre

Bedded on Rocks 

In industrial production monitoring, fast, reliable results are required to evaluate product quality. Suitable test methods must be available for this purpose. The time-consuming method previously used to determine the degree of crosslinking of PE-X pipes can now be replaced by rapid rheological measurements.  

Rapid, Reliable Determination of the Degree of Crosslinking of Polyethylene  

Werkstoffprüfung, mechanisch

Quality Monitoring of PE-X  Semi-Finished Products 

Today, online measuring devices with controlling function are standard in extrusion lines. The used measuring devices include, amongst others, gauge heads, which measure the inner and outer diameter of the hose and tube during the extrusion process. Described are two product series based on laser technology for continuous online quality control. Operators can choose between classic and high-end orientated technologies. 

Online Diameter Control during Hose and Tube Extrusion 

Measuring the Diameter  

With the CTE 50 Plus Coperion Nanjing, China, launches its new CTE PLUS twin screw extruder series. The CTE Plus is equipped with a new gearbox engineered by Coperion GmbH, Stuttgart, Germany. 

Twin Screw Extruders Equipped with New Gearboxes 

CTE Plus Series 

Cracks often appear on screws and unsettle customers. The manufacturer EJS is often confronted with this effect and has got to the bottom of it. 

“Hardy, we received your screws. Are you sure your people have done the inspection? Look at the crack, I think any people will see this clearly. How can we install such a screw on our machine? How fast can you get us a new screw? We need it now. Please let me know. ” As a screw manufacturer, EJS often receives such complaints.

When the first 125 hard-facing screw was ready for inspection, the employees at E.J.S Industry Co., LTD, Ningbo/China (EJS), noticed that there were cracks on the screws. How could that happen? 
Was it caused by bad temperature control, or bad bimetallic alloy powder, or bad base steel, or process management? To find out why, a lot of tests were scheduled and a lot of labels were sticked on the product for later identification. After a lot of trial and error, EJS came to know WHO was the mother of cracks and their relationship. 

Hardfacing screws are normally processed by a PTA welding machine. The energetic plasma arc has a high temperature more than 1000℃ to melt the alloy powder, which is to be welded into the flight one by one until it’s completely finished. During this process, the thermal expansion and cold contraction happens inevitably and repeatedly due to the big difference between 1000℃ and the ambient temperature(5℃ to 40℃). 

Since 2015, EJS had a special furnace to keep the hardfacing screws warm for certain hours after PTA welding, which do help us to reduce the numbers of cracks. Unfortunately some cracks are still there, big or small, more or less. Is there any way to get rid of them? 

As a quality-oriented company, EJS tries everything to avoid cracks. However, it is not possible to completely exclude the possibility of cracks forming. The company consulted senior engineers, checked with experts, analyzed together with experienced production managers and sought advice from long-term customers in different countries. Finally EJS accepted the fact that cracks are inevitable for some alloys on big sizes, because no cracks means soft flights. There are some alloys which you cannot avoid micro cracks. They always exists. 

When the cracks are intense, AND the flights always stay - it is acceptable. When the cracks are long, AND the flights always stay - it is acceptable. When the cracks are wide, AND the flights always stay - it is acceptable. When the cracks are regular in one direction - it is acceptable. If the crack causes the peal-off -  it is NOT acceptable. 

Using these simple questions, customers can check whether their screws are OK or not. In case of doubt, the experienced EJS staff will be happy to help. 

<a href="http://www.ejschina.com">www.ejschina.com</a>

10597133 News Beitrag [Online] - EJS 1.4.2020

issue 03/2022

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issue 01/2022

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