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

Extrusion

Rohr- und Profilextrusion

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

Kunststoffverarbeitung: Verfahren

Schaumstoffe und Vorprodukte

Kunststoff Werkstoffe

PVC-Profile

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Schaumstoffe

Polystyrol

Thermoplaste

Polyvinylchlorid

Dichtungsschäumen

Schäumen / Reaktive Verarbeitung

Foamed and Still Extruded  in One Step

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

Elektrische Antriebe

Antriebe

Flachfolien- und Plattenextrusion

Extruder

Kunststoffverarbeitung: Maschinen und Komponenten

Extrusionsanlagen

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

Kunststoff

Bauwesen

Baustoffe

Direct Route to the PVC Profile

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.

16:9

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

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.

kunststoffe.de

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 is presenting a new extrusion management software.

Completely Networked Lines

The I-Box replaces the resin bath: Practical design criteria for the new process were developed at the IKV.

How fibers become profiles: The IKV in Aachen has developed design criteria that can be used to design injection boxes for new applications.

Faser- und Filamentextrusion

Pultrusion

How It Works: Injection Box Design  for Pultrusion

A multi-channel ultrasonic measuring system was used to study the homogenisation of polymer blends. It was demonstrated that this method is suitable for analysing the condition of the melt along the extruder screw. 

Quality Assurance: Residence-time Measurements and Detection of Melt Heterogeneities 

Simulation programs are widely established as aids for designing flow channels. However, the programs lack the option of allowing the flow-channel geometry to improve itself autonomously. This deficit is now to be made good by an automatic optimization tool in the XNS software. 

Die Design: Automatically Optimizing Profile Dies 

Plant constructors are currently concentrating on two topical areas, energy efficiency and raw materials economy. That does not mean that the pursuit of higher throughput, lower cost plants and higher productivity is a thing of the past. These aspects are apparently now taken for granted. 

Pipe and Profile Extrusion: Sustainability of Continuous Production 

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

The Smart Energy System can significantly reduce the energy consumption during extrusion. It consists of forced-cooled induction coils with special openings for air circulation and the installation of a temperature sensor. The coil is enclosed in highly thermally insulating materials to minimize the heat transmission from the barrel to the environment. In addition, the special internal structure can transfer the cold air directly to the extrusion barrel, which results in faster cooling than in resistive systems. A Nextmover extruder with the Smart Energy System and in combination with an extrusion head with two outputs for the manufacture of PVC pipes will be exhibited at the trade show. It will be demonstrated how the technology from Bausano achieves a total production rate of 2000 kg/h at diameters from 63 mm to 160 mm while also saving 35 % energy.

Finally, K also offers the opportunity to present the E-GO R technology developed by Bausano, which allows heavily contaminated plastics to be completely reintegrated into the production processes. One example is HDPE residues originating from containers for milk, motor oil, detergents, etc. In addition, PP wastes, for example from yogurt tubs, as well as LDPE consumer wastes can be processed.

Bausano & Figli S.p.A.  

https://www.bausano.com

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

2022-10-10 - Bausano

issue 02/2023

issue 01/2023

issue 09/2022

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