Manufacturers of standard extruders sometimes incorporate oversized drives into their machine designs in order to be able to cover a wide range of requirements. In times of high energy prices, however, this is no longer economical. An extruder should be equipped with a drive package that is matched to the gearbox and the processing unit. But what are the requirements governing the design of the drive system?

Drives on the test bench: this type of motor test bench is used by Veka to collect experience about the operation of some 700 twin-screw extruders and 300 single-screw extruders used in production facilities worldwide at the most favorable operating point

Process-Oriented Design of the Main Drive for the Extruder

Extrusion

Kunststoffverarbeitung: Verfahren

Elektrische Antriebe

Antriebe

PVC-Profile

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Flachfolien- und Plattenextrusion

Extruder

Kunststoffverarbeitung: Maschinen und Komponenten

Extrusionsanlagen

Rohr- und Profilextrusion

Ingenieurwissenschaften

Elektrotechnik

Energieeffizienz

Energy-Efficient Use of Drives

New polymer composites for the production of multi-layer small tubes are being developed to give products specific functions. With suitable co-extrusion dies and a thermal barrier option, even complex layer composites with melt temperature differences of more than 50 °C can be processed reliably and in high quality.

CV-T 5-layer co-extrusion die in pilot plant operation: tubes with small cross-sections that fulfill a multitude of demands can be produced by  co-extrusion

Combining Polymers with Very Different Processing Temperatures

Temperiergeräte

Gießanlagen

Temperiertechnik

Baugewerbe (Hoch- und Tiefbau)

Medizintechnik (KU)

Kunststoffverarbeitung

Bautechnik, Sanitär

Extrusionswerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Extruder-Folgeeinrichtungen

Extrusions-Zubehör

Automotive

Fahrzeugbau

Co-Extrusion with Thermal Control

In the area of pipe and profile extrusion, the focus remains on increasing efficiency. In addition to energy-saving systems, the focus on efficiency increasingly includes flexibilization of plants and processes, as well as reproducibility of quality in production.

Optimization of Components and Expansion of Plant Control Systems Offer Potential  for Improvement

Kreislaufwirtschaft

Efficiency Remains the Order of the Day

Before the direct extrusion of profiles made of polyvinyl chloride was developed, it was previously necessary to produce a dry blend. This process is expensive and energy-intensive and, in contrast to direct extrusion, discontinuous. The direct extrusion of PVC using planetary roller extruders promises an improvement. In addition to soft PVC, rigid PVC can also be processed in this way with a few adjustments.

The direct extrusion of PVC profiles on planetary roller extruders can save costs and energy and simplify the process

Extrusion of Rigid PVC without Dry Blend Production

Kunststoff-Profile

Granulat, PVC- (Compound)

Andere Werkstoffe

Werkstoffe für additive Verfahren

Polyvinylchlorid

Kunststoff Werkstoffe

Thermoplaste

Kunststoff

Bauwesen

Baustoffe

Direct Route to the PVC Profile

The Italian company Bausano offers a new service for the operational leasing of extrusion lines. This provides customers with an alternative financing option for increasing their production capacities.

For extrusion lines, Bausano now offers an operating leasing model for financing

16:9

Extrusionsanlagen für KU-Verarbeitung

Kunststoffverarbeitungsmaschinen

Bausano Offers Rental Model for Extrusion Lines

The pipe manufacturer used a new generation conEX extruder to replace an older model in an existing extrusion line and was then immediately able to meet all requirements in terms of quality standards and output.

Fränkische Rohrwerke Invests in conEX NG Extruders

Kunststoffe international asked manufacturers in the field of pipe and profile extrusion what developments are influencing their product portfolios – and what trends are determining their future. Due to the many different types of application – ranging from microcatheter tubes to gas pipes – these companies are faced with very different challenges. Even so, they have much in common where extrusion, the use of recyclates, or digitization  are involved.

KraussMaffei supplies systems for up to 7-laser pipes; here we see a modular designed multilayer pipe head

Impressions of the Current Status of Pipe and Profile Extrusion

Schröder, Susanne

Between New Material Mix and  Energy Efficiency

Carbon Truck & Trailer GmbH invested in a pultrusion system of KraussMaffei subsidiary Pultrex. The iPul pultrusion system for lightweight profiles made of carbon fiber-reinforced plastic (CFRP) produces profile parts for around 70,000 vehicle chassis annually.

The injection box is the core of the iPul technology. Endless fiber rovings are soaked with a matrix in the box and formed into composite profiles.

Pultrusion System for Lightweight Profiles

Leichtbau

Pultrusion

Vehicle Chassis Become  60 Percent Lighter

Biogasoline fuels such as E10 and improved fuel injection systems to reduce consumption have changed the specifications for gasoline fuel lines. As a result, extractables from conventional components of the fuel system can clog injection nozzles in individual cases and lead to critical situations. To eliminate this, new low-extractable multilayer tubes for fuel lines were developed. 

Development, Testing and Processing Low-Extractable Multilayer Tubes for Fuel Lines 

Polyamide

Beschichten von Kunststoffen

Purity Requirements for Fuel Lines 

Simultaneous extrusion of polyvinyl chloride profiles with a PS foam core is challenging due to the different processing conditions and has not been performed before. A trial plant for researching this process has now been set up at the SKZ.

Fig. 1. The foaming of PS was investigated in a test system developed for this purpose 

Method for the Simultaneous Extrusion of Window Profiles with a Foam Core

Schaumstoffe und Vorprodukte

Schaumstoffe

Polystyrol

Dichtungsschäumen

Schäumen / Reaktive Verarbeitung

Foamed and Still Extruded  in One Step

Profiles made of rigid PVC have many advantages: they are easily extrudable, inexpensive, and with suitable additives, they exhibit good UV resistance. However, regarding its mechanical and thermal properties, PVC occasionally reaches its limits. This shortcoming can be evaded by co-extrusion with a PBT blend.

If the properties of pure PVC profiles are inadequate, PBT co-extruded versions are an option. For example, their thermal expansion and post-shrinkage when heated are lower.

Co-Extrusion of PVC with Modified PBT Blend Improves Profile Mechanics

Polybutylenterephthalat

Technische Kunststoffe

Extending the Limits of PVC

Thus, new solutions for savings have to be found. In extrusion, costs can be specifically compensated by using sustainable measuring technology as an example calculation made by Sikora shows.

The prices for plastics are rising. Extruders are not powerless in the face of this, Sikora calculates.

How to Cope With Rising Plastic Prices

Inline-Messtechnik

Messtechnik

Measurement Technology for Significant Material Savings in Pipe Extrusion

At the K, battenfeld-cincinnati will visualize its complete line competence for the first time by unveiling the new, consistent design of its pipe extrusion lines, this year’s winner of the coveted IF Award.

The Multi-Touch  roll stack is ideally suited for the manufacture  of environmentally friendly PP flooring.

Messe K-Kunststoffmesse

kunststoffe-international.com

Granulate

Complete Systems for the Entire Extrusion Sector

K preview: Bausano to showcase in Düsseldorf its new lines for single and double output pipes offering enhanced performance.

The Smart Energy System heats the barrel by induction and significantly reduces the energy consumption for extrusion.

kunststoffe.de

Energy-Efficient Pipe Extrusion

Theysohn is expanding its portfolio of parallel twin-screw extruders upward with the new XTS138 and downward with the XTS78.

out its portfolio of counter-rotating twin-screw extruders for pipe extrusion.

Rounding out of the Twin-Screw Extruder Portfolio

At K, Greiner Extrusion is presenting the state-of-the-art technologies, particularly for technical profile extrusion, under the motto “Digital Extrusion Solutions.”

At K, Greiner Extrusion is presenting the state-of-the-art technologies, particularly for technical profile extrusion, under the motto “Digital Extrusion Solutions.” The company offers a one-stop solution for completely networked extrusion lines for technical profiles as well as window profiles.

The offer comprises matched overall solutions in the field of digital extrusion. With the <a href="http://Digi.Master" target="_blank">Digi.Master</a>, Greiner is going one step further toward the completely automated line – for more efficient and more sustainable production.

The Greiner Extrusion team, a globally active group of experts, has been offering tailored, high-quality complete solutions since 1977. With individual skills and leading technologies in extrusion, the supplier characterizes itself as a personal and solution-oriented partner. Customers are supported throughout the entire extrusion service process and at a performance level according to their needs.

At the beginning of the year, Greiner Extrusion became part of the Nimbus portfolio. United under the Nimbus umbrella, Greiner Extrusion and battenfeld-cincinnati can ideally combine their strengths in profile extrusion solutions while also remaining independent companies. On July 1, 2022, Christian Pum became CEO and will lead the company into the future.

At the booth, the visitors expect many exhibition items both virtual and live. The special highlights include extrusion-management software for profile extrusion.

Exelliq Austria GmbH  

https://www.exelliq.com

At K, Greiner is presenting a new extrusion management software.

2022-10-17 - Greiner

issue 02/2023

issue 01/2023

issue 09/2022

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