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

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

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 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

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

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.

Messe K-Kunststoffmesse

kunststoffe-international.com

kunststoffe.de

Completely Networked Lines

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 

Production of PVC pipe in Bitterfeld, Germany, in 1935 ushered in the use of plastics for pipe production. This required exact knowledge of material properties, life expectancy and permissible loads. This was recognized from the very beginning and pursued systematically. 

Qualitätsnachweise

Looking Back: Materials for Pipes – Meeting Changing Requirements 

Circular distributor technology makes it possible to achieve a modular building-block system for coextruded pipes and hoses. Rapid material color change and the possibility to fulfill product specific requirements open up a broad range of applications. 

Blasformen

Extrusion Dies: Melt Flow in a Circular Distributor 

“Turn the crisis into an opportunity” is an oftenheard statement in times of economical upheaval. In fact, such times are almost ideal for repositioning the company in the market or increasing a company’s market share. A prerequisite, of course, is to have products that meet the demands of the market. 

Spritzgießwerkzeuge

Pipe and Profile Extrusion: Output Assured 

Again this year, the offering in line designs and retrofit solutions was enormous. Suppliers awaited the fair with foreboding. But following the fair, they all wore a look of satisfaction. Full order books and a high level of interest confirm that recovery is on its way after a time of economic turbulence. 

Aufbereitungsmaschinen

Films: Multi-Layer, Efficient and Sustainable 

Between New Material Mix and  Energy Efficiency

Impressions of the Current Status of Pipe and Profile Extrusion

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.

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.

Rarely has planning or prognosis been as difficult as in the last two years. In the meantime, many machine manufacturers in the plastics industry are smiling again over well filled order books. Based on interviews with manufacturers, Kunststoffe international presents their impressions of the mood vis-à-vis the status quo in the field of pipe and profile extrusion.

The manufacturers are in a consistently positive mood. Following the challenges presented by last year’s pandemic, many have been reporting very positive developments in incoming orders in the previous year. “The increase in orders is largely due to growing demand for compounding extruders in the fields of food and medicinal packaging, emphasizes Clemente Bausano, Vice President of Bausano & Figli.

Mood and Economic Situation: Consistently Positive

Christoph Scabell, Managing Director at Extrudex Kunststoffmaschinen describes the situation thus: “In the wake of a very difficult two-year period, postponed investments are being caught up with. We expect a very satisfying annual statement for 2021 with further recovery in 2022.”

Dr. Friedrich Kastner, CEO and Managing Partner at Collin Lab & Pilot Solutions recently made this statement: “The year 2020 was challenging. Of course, we reckoned with setbacks that in fact took place. However, we used free capacities to proceed with our program of improvements and development even more intensively and continued to realize the resulting new opportunities in the very important medicinal/pharmaceutical area.” Collin also reckons with a positive annual financial statement for 2021.

What Trends Are Influencing Technology and Product Portfolios?

In recent years, various tendencies have shown up in product portfolios or in developments in system technology that differ from one application and/or segment to another. Clemente Bausano: “The developments in recent years have mainly affected applications of plastic pipe. From water and gas distribution networks to rainwater drainage and the transport of various fluids all the way to energy supply systems and sprinkler systems, worldwide demand has grown exponentially and will continue to strengthen. For this reason, Bausano has completely revamped its product portfolio for the extrusion of PVC, PP, and PE pipes in order to keep up with increasing demands from manufacturers for melt homogeneity, process flexibility, maximized throughput, and reduced energy consumption. After all, demand is growing for profiles made from materials that can be manufactured from recovered polymers and up to 80 % natural fibers: products that have proven to be better than wood in terms of reliability, performance, and production costs.”

KraussMaffei also offers a wide range of products in the field of pipe extrusion. Among other items they include systems for drinking and heating water, or gas pipes. Coextruded pipe can be produced from various combinations of materials in as many as seven layers. Some examples are PVC foam core pipes, PU foamed pipes, or a material mix of PP-R, glass fibers, adhesion promoters, and an EVOH oxygen barrier. “The classic product program for building construction is stable and has been expanded to include multilayer technologies. We are pleased that we will be able to introduce fair visitors personally to these multilayer technologies in particular at the Fakuma,” says Dr. Volker Nilles, Executive Vice President New Machines at KraussMaffei.

ETA Kunststofftechnologie is active in the field of (co)extrusion dies and manufactures mainly spiral distributor dies for the production of round products such as pipes, hoses, hollow body blow molded products, or blown films. With these dies, products can be manufactured with low single-layer thickness and tight wall thickness tolerances by mono and coextrusion in up to nine layers. The sizes of them range from dies for medicinal technology in weights ranging from a few kilos up to large pipe or hose heads weighing up to several tons. In the area of automation and digitization, ETA has developed the electromagnetic centering of extrusion dies in recent years. “This enables extrusion dies to be “set at the push of a button” in such a way that products can be extruded with uniform wall thickness. Defined setpoints are entered on a touch panel. We are planning to couple this system to existing wall thickness measurement systems with feedback and optimization of the real measured values next year,” explains Dr. Patrick Weiss, Managing Director of Development and Design at ETA. The thermal separation of individual plastics layers in coextrusion dies represents a further development. With it, high-quality coextruded products consisting of different plastics can be manufactured despite considerable differences in the melting temperatures. It will enable the manufacture of new types of functionalized composite products.

Extrudex’s product portfolio includes systems for media-carrying lines in the fields of medicine, vehicles, sanitary pipes, and lines for cable sheathing, as well as for the production of microfilaments. The manufacturer sees a trend toward energy optimized extruders and systems. For this area, the company has developed their patented Helibar line of single-screw extruders, touting its energy efficiency as a unique selling point. The Helibar principle is suitable for many different types of applications such as blow molding and films, as well as for processing PE, PC, PP, PMMA, PET and many other thermoplastics. With Helibar, a special application was developed to produce 3D filaments from PC in which up to four monofilaments can be produced simultaneously on one system. With only minimal retooling, the system can alternate between water and air cooling and thus be used for a wide range of materials.

Collin supplies systems for manufacturing pipes and hoses. They range from microcatheter tube with less than 0.5 mm overall diameter – even by multilayer coextrusion – to multilayer pipe systems in diameter up to approx. 60 mm. Their own modular die concept permits a number of materials combinations or even from one to several strips in various layers. Collin sees a strong demand for high-speed lines for various markets. Medicinal applications and 3D printing are pushing demand; the material mix is becoming more and more varied and presents new challenges. In the Collin Medical Line of products – these include hoses and strand systems – the requirements for precision are ever stiffer. That means ever tighter tolerances together with increased throughput. Among pharmaceutical strand systems the number of layers is increasing, all of which are laden with several different active ingredients. Here, too: more throughput and tighter tolerances.

Volker Nilles brings the role played by recyclates at KraussMaffei down to the point: “The recycling issue is playing an increasing role, of course. In the field of pipes and profiles, many solutions have been in place for years. KraussMaffei provides solutions for the production of multilayer pipes with recycled layers. Of course, where composite pipes are involved, recyclability is difficult to impossible – that has to be taken into consideration.”

“The use of recycled material is playing a main role in our sector,” says Clemente Bausano. “For instance, the recycling of post-industrial PVC residues by granulation offers a double benefit: environmental protection, since energy consumption by the production of the equivalent amount of new PVC is reduced, as is the emission of hot-house gasses from it. Moreover, company costs for the disposal of PVC wastes are minimized, creating a closed cycle that turns the administrative effort into an advantage. A closed cycle represents a real alternative, especially in times like this that are characterized by difficulties in the disposal of new raw materials. One of the greatest challenges in PVC recycling, however, is the transformation of regenerated materials into a high-quality product. To this end, machine manufacturers will be concentrating increasingly on researching and developing high-performance systems that can process such wastes.”

At ETA, as well, the recyclate issue is gaining in importance: “Among our customers, we have been observing the development toward a constantly increasing use of recyclates for a long time. The homogeneity of recyclate melts has a high priority here. To achieve it, ETA manufactures special mixing screws as well as plasticizing units,” says Patrick Weiss. At Collin, too, more and more recyclates are being used, whereby the processibility of shredded material is a major issue.

… Prof. Daniel Schwendemann, since 2010 Head of the Department of Materials Development, Compounding, and Extrusion at the Institute of Materials Engineering and Plastics Processing (IWK) at the Ostschweizer Fachhochschule (OST) in Rapperswil-Jona, Switzerland.

Many manufacturers see a trend toward multilayer composite products. Doesn’t that stand in the way of the greater goal of recyclability?

The path will be narrow between maximally feasible technology, on the one hand, and recyclability on the other. The decision to use a multilayer composite design or a monomaterial construction has to be made specifically for each component. My personal opinion is that the use of multilayer composites is justified by the properties gained. In the packaging field, however, the trend will be toward monopackaging. Pipes are very durable products whose service life is longer than 20 years in many infrastructure areas. Ultimately, the question will be to what extent are the polymers damaged, and whether materials recycling is still possible.

What trends do you see in the field of pipe and profile extrusion?

As is the case for injection molding, extrusion will be increasingly simulated. “Digital twins” will be created to enable faster and better targeted developments. This is failing now for two reasons: the lack of materials data and simulation tools, for example, for cooling, crystallizing, and calibrating extrusion profiles. Aside from that, the digitization of entire processes and the use of new production technologies such as additive manufacturing will find their way.

What role will the energy efficiency of systems play?

Everyone is talking about sustainability, and the CO2 footprint of products is playing an important role. In addition to the energy expense of plastics production, processing is an essential factor. The manufacturers of extrusion lines have already done a lot to optimize their extruders, but peripheral systems and devices have not been sufficiently included in the overall assessment.

Where do the challenges lie? Which “nut still has to be cracked?”

Pipe and profile extrusion is divided up into several different areas, and complete systems are made up of modules from various components. For digitization, there exist no or insufficient exchange protocols. The linkage is thus system specific and not fed with enough data from the periphery. Energy consideration and digitization must join hands here. At the moment, many processers do not know how much energy is being consumed by which parts of the system. In the future, processers will be faced with the challenge of having to supply such data to their customers. Solutions must be provided to do this.

Digitization is playing a main role in all fields. Collin is betting on an SPS platform capable of connecting all different types of bus systems. Components can be connected via ethernet-based field bus systems, such as EtherCAT, ProfiNEt, Ethernet/IP, or classically via CANopen, Profibus, or Modbus. Unless proprietary protocols are used, OPC UA is used as an interface.

Bausano recently introduced its Orquestra software that uses modern 4.0 technologies to control all components of an extrusion line. These include, among other items, intelligent diagnosis and predictive maintenance. The central control system is also suitable for revamping and ensures continuous monitoring of the entire line in real time. Moreover, it enables immediate reporting with intuitive graphs of performance indicators including machine status, waste production, and man hours. The analysis of the raw data collected and made available by Orquestra makes it possible for the end user to independently optimize the entire extrusion process, refine the final product, and avoid damage to the line.

With smartAssist, KraussMaffei allows, at the touch of a button, worldwide service contact via professional and secure audio/video communication, e. g. between technicians at the machine and experts wherever they may be. Virtual texts and symbols can be superimposed on actual objects via augmented reality, increasing the quality and speed, e. g. for troubleshooting.

In the year of pandemic, system monitoring gained ever greater significance. “Remote maintenance has become a must, as all have established during the time of Corona,” emphasizes Volker Nilles. “With its multiple interfaces, KraussMaffei’s C6 control is well equipped for the data world of tomorrow. In addition to proven, conventional paths (USB, PDF Export), various network-based data interfaces (e. g., OPC UA, Euromag 84) are available to access to machine and operational data. Internal and external data recorders support the analysis and optimization of processes. The availability of remote diagnosis via internet and secure access to machine operation through contactless identification by RFID reader round off our digital portfolio.”

At Bausano, as well, remote maintenance is meanwhile standard: “Thanks to Orquestra software, we can remotely access operational machine data if our customer has granted us permission to transfer data to the cloud and report possible anomalies in advance,” says the company chief. “This simplifies the remote assistance performed via our Acty augmented reality app, which happens to be an interactive app. Our technicians have the option to make contact through 3D glasses in order to provide customers with qualified assistance and undertake remote start-up of the complex system.

At Collin, the option used most last year was remote machine observation. With it, their own Scada system can control machines remotely. Via remote access, the system can be monitored in home office. In addition to remote maintenance, the user has the opportunity to monitor production or laboratory procedures in home office.

What issues will be important for the field of pipe and profile extrusion in the future? Volker Nilles of KraussMaffei sums them up: “Energy savings, materials savings, digitization and recyclability”.

ETA is focusing on coextrusion and throughput maximization: “In pipe extrusion, besides ever higher system speeds, we are mainly observing further developments with new coextruded composite products to fulfill all sorts of requirements with a functionalization of single or multiple layers. In addition, a rising level of automation will become more and more important for extrusion processes in order to produce as efficiently as possible and prevent quality variations,” Patrick Weiss reports. In addition to introducing their product for electromechanical centering for extrusion dies and the further development of technology for thermal separation of individual plastics layers in coextrusion dies, ETA is working at the moment on the configuration of new melt distributor concepts to obtain additional process and production technical advantages.

“Environmental sustainability and recycling are the two most important topics that will influence the future of pipe and profile extrusion. We at Bausano are of the opinion that our current understanding of the production and consumption of plastics has to undergo a paradigmatic shift, so that the entire life cycle is truly sustainable and repeatable over the course of time. The real challenge consists in developing technologies that improve the environmental footprint of materials such as PVC in order to accelerate the transition to a circular economy and contribute to mitigating the climate change,“ according to Clement Bausano.

Christoph Scabell of Extrudex thinks that energy savings, good service lives, and low maintenance requirements together with high production quality will be decisive in the future. He spots a trend toward turnkey systems and away from individual components. Innovations at Extrudex include variable die heads with exchangeable sheets for various pipe superstructures, as well as energy optimized extruders with special insulating heat bands. Since the pandemic the company is also feeling increased use of the remote maintenance modules offered for several years.

Collin sees the future challenges mainly in high speed and smaller space requirements. Beyond that, the company perceives increased demand in the area of 3D printing. “A nut that still has to be cracked is the automated start-up,” Kastner adds.

To summarize the opinions of the manufacturers we interviewed, a difficult task is growing for the developers of extrusion systems. On one hand is the call for maximizing throughput and multi-material composites. On the other, energy and materials savings, as well as recyclability are being demanded. Kunststoffe international will continue to serve you with reports of the latest developments.

COLLIN Lab & Pilot Solutions  

https://www.collin-solutions.com/

EXTRUDEX GmbH  

https://www.extrudex.de

ETA Kunststofftechnologie GmbH  

Bausano & Figli S.p.A.  

https://www.bausano.com

OST Ostschweizer Fachhochschule Inst. f. Werkstofftechnik u. Kunststoffverarbeitung (IWK)

https://www.iwk.hsr.ch

Ausgabenartikel

Dr. Patrick Weiss, Managing Director of Development and Design at ETA: “We are observing constant further developments in coextruded composite products with the functionalization of single or multiple layers.“

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

Prof. Daniel Schwendemann: “The energy of the entire system can be optimized only with the aid of digitization.“

Clemente Bausano, Vice President of Bausano & Figli: “Environmental sustainability and recycling will be the two most important issues influencing pipe and profile extrusion in the future. Production hast to undergo a paradigm shift.“

Dr. Friedrich Kastner, CEO and Managing Partner at Collin Lab & Pilot Solutions: “We are seeing stronger demand for high-speed lines and 3D printing. A nut that still has to be cracked is the automated start-up.“

Dr. Volker Nilles, Executive Vice President for New Machines at KraussMaffei: “We are also offering solutions for multilayer pipes with recyclate layers. However, we must keep in mind that composite pipes are difficult to impossible to recycle.”

In Collin’s pharmaceutical strand systems the number of layers is increasing, all of which are laden with several different active ingredients. The challenges: more throughput and tight tolerances

Trendartikel Rohr und Profil_su

This article was written with the assistance of Prof. Daniel Schwendemann, since 2010 Head of the Department of Materials Development, Compounding, and Extrusion at the Institute of Materials Engineering and Plastics Processing (IWK) at the Ostschweizer Fachhochschule (OST) in Rapperswil-Jona, Switzerland.