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Infiana Group adds extruder in Malvern, Pa

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Infiana Group GmbH is expanding its UNITED STATES capacity by adding a new extruder at its Malvern, Pa. facility.

The company, formerly known as Huhtam?ki Films, in January changed its brand to Infiana. Private equity organization Deutsche Beteiligungs AG led a operations buyout in November 2014, acquiring the film organization from Huhtam?ki Oyj of Finland.

This will add to our portfolio, noted Robert Shumoski, general manager of Infiana North America.

He said the company s current building had room for the extra line.

Shumoski said the Malvern facility has already established a strong presence in the setting up and construction market. The new series strengthens its functions and also permits new chances in pressure sensitive movies markets and will help increase its composites and personal care markets. The expansion also gives it more flexibility and the ability to handle seasonal demand.

He said he cannot elaborate on the specifics of the expansion. Infiana has been around Malvern since 1964 and delivering blown film since 2003.

The company said that it has about 100 employees in Malvern supplying silicone-coated release films in addition to non-siliconized smooth and embossed film.

We have been well on our approach to developing THE UNITED STATES into a high-caliber business with a broad technology base, efficient gear, and more than anything setting up on a human capital base which will make our strategies in the U.S. a mixer extruder success, explained Peter Wahsner, CEO of Infiana Group, in a affirmation.

This marks Infiana s first growth since it became independent. The brand new name is derived from three words - innovation, infinity and film.

Infiana Group GmbH is headquartered found in Forchheim, Germany. Overall it has about 1,000 employees with development services in Forchheim; Malvern; Camacari, Brazil; and Samutsakorn, Thailand. Infiana reported 2014 product sales of about 200 million euros ($219 million).

Improved Dry Vacuum Calibration Tables

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Dry vacuum calibration tables were formulated in response to the necessity to hold complex plastic material profiles to very restricted tolerances while they were being cooled on the extrusion process. Tables were developed to carry the calibration tooling needed to produce tight tolerances at high result rates and to allow for the easy changeover from one component to another. Even though calibration tooling is required to obtain this, it is extremely expensive and alternate strategies have been developed to improve rates without building longer and much longer calibration tooling. Tables needed to be modified to be able to handle the alternate cooling methods.

CALIBRATION TOOLING

The calibration tooling could be made from aluminum for better heat transfer nonetheless it is normally created from stainless for better life because of the abrasive nature of filled plastics rubbing on the polished surfaces. The inner surface area is trim in the shape of the required profile and extremely polished for low drag level of resistance. Cooling channels are cut in to the tooling for flow of the critically important cooling water. In addition, channels are cut in to the program for vacuum to draw the plastic part out against the calibrator wall structure to create good contact to make sure cooling and acquiring the proper dimensions. Generally the tool is built to be dry and therefore no normal water touches the extruded account in the calibrator. Some calibration is built to actually introduce a small amount of normal water or let leakage of cooling water to act as a lubricant between the part and the metallic surface. This can also enhance the cooling efficiency.

The original calibration tooling shall smooth the top of hot plastic material since it first enters the tooling. The primary job of the calibration tooling is to cool the component as it is managing the decoration of the plastic. The length of the calibration tooling will change with the relative line quickness of the extruded component, the complexity of the account, and the dimensional tolerances essential of the profile. Increasing any of the factors shall increase the required amount of the tooling. Calibrators are typically built-in sections of 4 to 15 inches long for ease of manufacture and handling. They are then found in sets to attain the needed amount of calibration necessary for the profile either with or without gaps between each calibration block. Calibration of 4 legs or more is not uncommon in complex windowpane profile lines.

Since the primary reason for the calibration tooling would be to cool the plastic since it is being held in form, it is advisable to have water channels through the tooling in the correct location for uniform cooling and have adequate water flow to keep up the desired processing temperature. Typically chilled water that is maintained at 50 - 55 F is used to circulate through the tooling. Sometimes it is desirable for the initial calibrator to be slightly warmer compared to the rest to raised impart a smooth surface to the plastic and to reduce drag caused by shocking the plastic material with the initial cooling. This warmer heat in the 1st calibrator is generally attained by adjusting the flow of water entering that first calibrator, on the other hand a temperature controlled device can be used to assure consistent temperature.

CALIBRATION TABLES

Dry out vacuum calibration tables have been developed and are offered by many companies offering a convenient base which the calibration tooling can be mounted. They generally provide a heavy duty framework with the vacuum and drinking water pumps along with all of the necessary plumbing, including filters, temperature exchangers, etc., alongside necessary controls. They allow for simple link with modular calibration tooling so that it could be changed out conveniently. The tooling is going to be mounted on some type of rail program for dependable alignment with itself. The table usually incorporates a tray system under the mounting rails to catch any leaking or stray normal water.

Alignment of the calibration tooling to the extrusion tooling is crucial so movements of the desk is controlled by allowing adjustment of the positioning laterally and up and down. These linear activities are typically achieved by a hand steering wheel traveling a gear program although a powered drive system can be used. Motion of the table toward and from the extruder is usually driven due to magnitude of the switch that is needed.

AUXILIARY TANKS

An auxiliary container is usually installed on the calibration table after the first calibration tooling so that you can offer more cooling for the profile. These tanks are typically 6 to 12 foot long. They are designed to keep forming plates that continue steadily to hold the part straight while the applied vacuum retains the part out against the forming plates to hold the size and dimensions. They are designed to immerse the component in normal water with turbulent mixing to split up the insulating coating of water around the skin of the component. The container itself is designed for drinking water to be presented at the front end of the container and the vacuum is undoubtedly utilized at the downstream end of the container drawing the drinking water through the tank. Turbulence is created by the placement of holes found in the forming plates usually. Holes all around the part create some turbulence but alternating plates with holes above the part and below the portion increase turbulence and water flow across the part, raising cooling efficiency.

These types of tanks require a complete large amount of water movement to attain the turbulence required for very good cooling efficiency. That water is being drawn out of the container by the vacuum applied at the downstream end of the tank. This requires the application of liquid ring vacuum pumps that may handle both air needed to pull a vacuum along with the water that is being released for cooling and has to be screw extruder machine sucked out of the tank. Nevertheless, the more water that the pumps need to maneuver reduces their effectiveness to pull vacuum pressure that is their primary purpose. Therefore, larger hp pumps and more of these are needed to make this system work. Typically a 10-hp pump would be needed for each six to eight 8 foot of auxiliary tank as well as the vacuum requirements of the calibration tooling. In lots of high output applications 10, 20 as well as 30 toes of auxiliary tanks will be needed to achieve the desired cooling. All of these liquid ring vacuum pumps operating at low effectiveness because they need to pull so many water create a bigger capital expenditure in advance along with higher on-going functioning and maintenance costs.

BETTER SOLUTION

A better solution would be to separate the normal water from the air in order that each can do it s intended job. The new air is needed to draw a vacuum as the water is necessary for cooling. The use of a higher intensity spray from nozzles that surround the part all the way down the tank supply the necessary quantity of cool water for cooling with no need of substantial volumes just to set up turbulence. The intensity of the spray of cold water onto the surface of the portion breaks up the coating of heated water that can slow down cooling. This volume of normal water drops to the bottom of the tank where it can easily be taken away separately from the vacuum port. With this construction, the vacuum pump must handle a substantially lower level of water and may therefore be more efficient. In fact a liquid band pump may not be required permitting the use of a far more efficient and lower horsepower Regenerative pump.

Early tables that utilized this technology had the drawback of experiencing a fixed length of rail section for the dried up calibration to permit for the particular auxiliary tank. A new generation of hybrid dried out calibration tables are becoming made that separate normal water pumping and vacuum systems and provide variable lengths to install calibration tooling. This offers the versatility that most processors require. This versatility can include adjusting spray intensity in different sections to optimize cooling as expected, or allowing for different degrees of vacuum as well as different water temperatures in various sections of the tank.

In conclusion, these new dried out vacuum calibration systems can offer the control of dimensions and size that end users have come to anticipate at higher rates and lower energy costs that processors are seeking. Innovative calibration table designs get this to both convenient and possible.

How To Stop Profile Warpage

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Faster! Every company wants to run quicker to get more product out on the same production collection and from the same sum of labor. Plastic profile extrusion corporations are no exception. It is easy to speed up the extruder to drive more pounds or to buy a larger extruder to obtain additional output. On the other hand, when extruding plastic material profiles, the productivity is usually controlled by the cooling of the profile and the ability to hold the part in the correct shape while it is being cooled. It is hard more than enough to cool simple shapes like circular pipe and tubing more rapidly but the difficulty increases when the complexity of the account raises. Window profiles and various other complex parts have become difficult to interesting uniformly, and if the parts do not cool uniformly warpage and bow is the result.

Like the majority of materials, plastics shrink because the temperature of the plastic decreases, but they shrink greater than other materials usually. Plastics shrink at one charge when they will be in the solid (frozen) state, but they shrink much more if they are still very soft or in the molten state. The issue for the profile extruder is controlling this shrinkage when cooling the scorching plastic, appearing out of the extruder, all of the real way right down to room temperature. Let s take the simplest exemplory case of a flat sheet where one part cools faster than the other. When still delicate both sides happen to be shrinking at the same amount. Even if one area is cooling quicker and shrinking more rapidly the other side is still pliable plenty of to come along with the various other shrinking side. Even so, once one area cools at night crystalline heat range or its glass changeover temperature, a couple of things happen. Initial, that material stiffens and is not any longer pliable more than enough to follow the other part and the amount of shrinkage falls significantly. It is as if the stiffened side is not any shrinking as the other pliable area continues to shrink longer. Therefore, because plastic recycle machine the pliable part goes on to shrink it is pulling on the stiffened area and causing a bow in direction of the medial side that cooled last. In this case in point, and in other straightforward profiles, the right part will bow in the direction of the material that cooled last. In more complex profiles the right parts may twist, distort, or warp in all types of fashions depending on which parts of the component cooled last. We ll cover more upon this later.

In addition to this problem is the point that plastics are very good thermal insulators, meaning that they don t transfer temperature very fast. Which makes it difficult to pull all of the heat out from the part in the first place, let alone carrying it out uniformly. Thermal conductivity is undoubtedly a way of measuring how fast supplies transfer heat. Steel has a thermal conductivity of 43 while Aluminum s higher heating transfer is 250 and most plastics are approach down at values between 0.1 and 0.3.

TYPES OF COOLING Surroundings COOLING

Considering these problems with cooling profiles it should not be surprising that historically account extruders often used weather to cool parts.

Air racks are simple tables or frames with plates / tutorials and fixtures that contain the part in form as it is being pulled slowly over the table. Fans are generally used to improve overall cooling while compressed oxygen jets are added where particular additional cooling is required. Metal fingers, cables, and jigs attached to the table with clamps or vise grips are used to push the portion into shape as it cools very slowly.

Air is quite inefficient, meaning SLOW, which in this case is great because slow provides operator time to make changes and get the part just right without warping or other distortion. Complex profiles or parts with several wall thicknesses on numerous sections of the right part might need customized cooling. The operator can direct more cooling to where he desires it with compressed oxygen nozzles or retard cooling in other areas by insulating a section to continue to keep it from cooling too fast. Since thicker sections cool more gradually than thin sections, specific actions must be employed to avoid warp. The operator will have to direct a lot more cooling on thicker sections to encourage them to nice to the same heat concurrently as slimmer sections on the same profile. Likewise, inside a U-channel or merely an internal corner will great slower than another corner and will require extra directed cooling. Output rates are limited by between 100 - 250 lb./hr. using air since it is so slow.

Even today, some may even now use weather cooling when:

Profiles have become complex

Using materials with completely different thermal conductivities

Size of production runs do not justify more expensive tooling

SUBMERSION WATER COOLING

When more significant output rates are required, then cooling with normal water is used. There are many ways to run a part through water based on many variables.

Submersion Tanks

For very easy shapes the part can be extruded over the top of an extended water tank and become pushed right here the drinking water by rollers or sizing plates. This may only be utilized for parts where it doesn t matter that the bottom of the part hits the water first (and is cooled initial) while the leading comes down into the water an instant later.

Vacuum Tanks

Extruding larger or more complex shapes directly into the water tank is an excellent idea that runs into the simple problem of gravity pulling water out of the container through the hole that the portion needs to go through in to the tank. Even tiny gaps between the sides of the part and the sides of the entry plate will allow water to leak out. This problem is usually solved by applying vacuum to the complete within the tank to carry the water in. Of course, this requires a particular tank that's strong enough never to collapse from the differential power of vacuum inside and air pressure on the outside of the tank.

Other Options

Another option is to make a little vacuum sleeve around the entry to suck off any normal water trying to move through the gap between part and entrance plate. More recently, profile extruders will place a dried out vacuum calibrator in front of the water tank to perform a similar thing. This vacuum calibrator is often as short as 3 for less vital profiles or given that 10 feet for parts that have to come to be hardened to extremely precise dimensions prior to going into the water container for more cooling. Dry vacuum calibration isn't as efficient as water cooling nonetheless it is the price that must be paid out when tighter control of the sizes is required.

Water Temperature Choices

It s really obvious that vacuum tanks are actually closed totally. With an open normal water tank it is extremely difficult even, if not impossible, to find yourself in the tank to place fingertips and jigs to force the part into shape as is performed on an oxygen rack. Additionally it is difficult to direct cooling normal water or even to insulate sections of the proper part from cooling. However, it is possible to reduce the productivity of cooling (i.e. slow it down) to mimic the more uniform cooling likely with an air rack by heating the water. This is done with parts which have a strong inclination to warp and specifically with higher heat engineering substances. In cases like this a temperature control unit must control the temperature of the normal water at a placed value. The bigger the water temperature is the slower the cooling and therefore the better it is to attain uniform cooling. Controlled heat range normal water between 80 F and 130 F is typically used in the original tank until colder drinking water may be used to entire the cooling. Of course, with the desire for quickness, the colder the drinking water the more quickly the cooling, hence most account extruders shall use chilled water at temperatures between 50 F and 55 F every time they can.

Water Flow Characteristics

Even even though immersing the entire profile in water offers faster and more efficient cooling it may not be the very best cooling method. Unless the water has been agitated to give turbulent stream around the part, then your layer of water up coming to the part will warmth up and that warm water following to the part will decelerate the cooling. The same phenomena might occur on simple designs like round pipes or tubing to trigger uneven cooling and bowing. We all know that warmth rises and heated water is usually no exception. This is great for the water up coming to the vertical floors of a part going right through the water. The water is going to be heated by the component and this heated water will rise along the part drawing cold water behind it to further cool the spend the a continuous renewing of cool water against the portion. However, heated water on the bottom surface area cannot rise as as the part is in the manner easily. It does slowly move up and draw cool water behind it but less efficiently than what's going on on the sides. The top is even more of a problem because despite the fact that the heated water is not obstructed from moving up and from the portion, the only real water that is drawn in to replace it's the heated water moving up the sides of the portion. The top isn't cooled as fast and pipes or other areas will generally bow up (bend upwards). Sizing plates in the tank help break up this movement but only allow cold water onto the most notable of the part immediately after the sizing plate. Turbulent circulation of drinking water in the tank considerably supports this problem.

SPRAY COOLING

Spray cooling can be an improvement over immersion cooling and another method to response the cooling challenge. Spray nozzles are evenly distributed around the portion and down the container to ensure a continual replenishment of heat range controlled drinking water to the surface of the part. This spray as well ensures considerably more uniform cooling by spraying drinking water equally into U-channels and inside corners in comparison to outside corners and straight surfaces. Parts with a simple cross section can be sprayed with chilled water and work at substantial rates of production. The task of uneven wall thicknesses should be addressed separately still. If spraying cold water alone is not sufficient to attain the uniform cooling that's needed to avoid warping, the normal water can be temperatures controlled to slow down the cooling and lessen or eliminate warping. Drinking water is required in a sufficient volume to create the turbulent move in the tank that is needed to break up the insulating coating of warm water.

Some people declare that spray cooling is significantly much better than immersion cooling as a result of evaporative cooling effect. That's where the drinking water sprayed onto the warm part is quickly turned to steam and evaporates holding off a lot more heat than the drinking water can hold off when immersed. While this result is real, it really is only true when the surface area of the plastic material is above about 250 F. This just happens in the very first seconds or even tenths of seconds of the portion entering the cooling tank. With the high performance of cooling of the normal water and more importantly the very low conduction of high temperature from the plastic to the surface, the surface temperatures quickly drops below 250 F. and stays there in order that no more evaporative cooling occurs. Still, the constant replenishment of cool water to the area is an improvement in the effectiveness of the drinking water cooling, with the added benefit of certainly not requiring vacuum to carry the water inside the tank. Spray cooling does offer extra uniform distribution of cooling water over the surface and continuous replenishment of cold water on the surface with the added advantage of using much lower flow rates of water.

CONCLUSION

So, the plastic component shall tell you when it is not getting cooled uniformly simply by bowing, warping, or distorting. With simple shapes the portion will bow in direction of the wall or section that cooled previous. In more complex shapes the contortions is probably not as convenient to figure out with as much as 6 to 10 different wall sections cooling at several rates. Directing even more cooling to sections that certainly would awesome slower because they're: thicker, inside corners, in any other case shielded from circulating or spray water shall result in control of warpage. Now the trick is to velocity it up and resolve the issue all over again.

How To Maximize Potential With Effective Plastic Extrusion Business Marketing

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Entrepreneurs face challenges and handle risks, however they discover that earning an excellent living even while doing something they love is worth it. Before starting your own plastic material extrusion company, take time to conduct thorough study on what you'll need to perform and who your rivals will probably be. Creating a great plastic material extrusion company requires mindful planning and adequate focus. Here's some recommendations to look at when starting and developing your plastic material extrusion consulting business.

Success in the wonderful world of plastic extrusion consulting business isn't measured by only assembly the standards you set at the beginning. Businesses shall fade away if they stop moving forward, so a great plastic material fabrication consulting business owner will always have to update their goals. Focus on new trends in your discipline and stay established if you would like your plastic plastic pellet extruder extrusion consulting business to expand. Once you're in a position to do most of these steps, you need to find success as a growing plastic extrusion provider easily.

If you're looking to excel in plastic material extrusion consulting business, you will often need skills that can only be acquired through practical work. According to the experts, useful learning is key in understanding how a plastic material fabrication consulting business is run. Learning out of every job you're assigned will help you start your own plastic extrusion consulting business. True skills can only just be developed by real effort face to face, even though reading a great plastic fabrication consulting organization book could be a great method to invest time off work.

A sensible way to assist in making plastic extrusion consulting organization decisions is through a brainstorming session with workers and key personnel. Simplify the look process through a summary of pros and cons. Keep your entire recommendations and thoughts organized so that you could easily refer to them as you move forward with your plans. Meet up with a plastic fabrication consulting business development planner to plot the next move when you are still sense unsure about your decision.

Protecting your plastic-type material extrusion consulting business out of a fiscal implosion is simpler when you prepare a full risk assessment prior to making crucial decisions that have an impact on the continuing future of your plastic-type fabrication consulting organization. The greater the chance, the even more devastating the harm could be, and recovery could consider years. Diminish the hazards, so that any possible damage could have a low effect on your income. Keeping your plastic extrusion consulting organization out from the red is task one, so ensure that you conduct an evaluation of potential dangers when making important decisions.

Effective businesses know the trick to growth is getting crucial feedback from clients after every transaction. When you determine that most your clients are pleased with their shopping encounter, you understand you have the natural material in place that can enable you to develop a successful plastic material extrusion consulting business. Little or nothing pleases a customer a lot more than getting asked for their opinion; when you demand feedback, shoppers tend to be more willing to put further orders. Provide coupons and discounts as a genuine way to entice consumers to review your program or products.

Hot Melt Granulation in a Twin Screw Extruder Effects of Processing on Formulations with Caffeine and Ibuprofen

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Hot-melt granulation (HMG) by twin screw extrusion is undoubtedly a good novel technology for the continuous processing of pharmaceuticals but confidence must still be gained regarding whether the environment affects drug real estate. In this preliminary research, granulation was studied for a unit product including lactose monohydrate and active ingredients of differing drinking water solubility, namely ibuprofen versus caffeine. The formulations screw extruders were granulated at 220 rpm and 100 C with polyethylene glycol binders of differing molecular weights and at concentrations between 6.5% and 20%. In terms of granule properties, the low melting stage of ibuprofen had a dominant impact by producing larger, better granules, whereas the caffeine goods were more comparable to a blank including no active ingredient. Drug degradation was research by differential scanning calorimetry, X-ray diffraction, and high-pressure liquid chromatography. The only detected transformation was the dehydration of lactose monohydrate for the caffeine and blank products, whereas the lubricating influence of the ibuprofen safeguarded its granules. The brief residence time ( 60 s) was consider to become influential in minimizing destruction of the drug despite the temperature and shear related to HMG in the twin screw extruder.

Extrusion Troubleshooter

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Extrusion is a good "black-box" process. We can not see what goes on inside an extruder, so we rely on instruments. We must make sure that all sensors are working and readouts are calibrated correctly.

Single-screw extruders are the most common machines found in plastics processing. Though quite simply simple in function, they are subject to many destabilizing factors that can bring about out-of-spec item or a shutdown. When trouble strikes, you shall need a strategy for identifying the complexities quickly. An essential element of that strategy may be the troubleshooting timeline. Right here we'll describe what it is and how it can be used to solve one prevalent extrusion problem-melt fracture in tube and account extrusion.

Start with sensors

Prerequisites to effective troubleshooting include good machinery instrumentation, current and historical process data, detailed feedstock data, complete maintenance data, and operators with an excellent knowledge of the extrusion process.

Extrusion is a "black-box" process. We can't see how are you affected inside an extruder, consequently we rely on instruments. We have to be sure that all sensors are working and readouts will be calibrated correctly.

They are the important method variables to monitor:

Melt pressure, typically about 100 times/sec.

Melt temperature every 1-10 sec with an immersion probe or every 1-10 millisec with an infrared sensor.

Temperatures of the feed casing (if it's water-cooled).

Barrel temperatures (a couple of sensors per zone).

Die temperatures (one to 30 or even more sensors, depending on die type).

Heater power found in kw.

Cooling power, measured as fan rpm in the event that air-cooled or water-temperature flow and increase rate in the event water-cooled.

Screw speed.

Motor load found in amps.

Line speed.

Finished-product dimensions.

Other process variables may be monitored about upstream devices such as for example dryers, blenders, conveyors, and feeders-and in downstream devices like gear pumps, display screen changers, calibrators, water troughs, laser gauges, pullers, and winders.

To be able to solve extrusion problems, you will need to understand the procedure. So operators not used to extrusion should consider classes covering material features and machinery features such as for example instrumentation, handles, and screw and die design. Many extrusion operations, even so, primarily on on-the-job training rely, though this is often the least effective and, in some respects, the most expensive method. Improper procedure of an extruder by untrained staff can result in costly damage or even injuries.

Troubleshooting timeline

To understand why an activity isn't behaving properly, you will need to compare current approach conditions to previous conditions once the problem didn't exist. Constructing a process timeline helps discover what changes in circumstances upset the process.

The timeline requires records from periods of process stability through the point once the process upset was noticed. You'll need records of all process data-temps, pressures, and dimensions. Make sure to list all events which could have affected the procedure (see Fig. 1), such as a power outage, modification of screw, or a new resin lot. Some important events are less apparent potentially, such as construction for the reason that certain area of the plant, changes in resources handling, maintenance actions on the plant's drinking water system, or the beginning of a new operator.

Note that not all events have an immediate effect. There may be a considerable incubation time before the effects of a noticeable switch are noticeable, so it's important never to jump to conclusions. You'll want to start a timeline far more than enough back, several months before the problem appeared even.

Stopping melt fracture

A good troubleshooting timeline helped a tubing processor to isolate the source of a processing problem. One extrusion line started building tubing with surface roughness due to melt fracture suddenly. Melt fracture may take various appearances-slip-stick (or "bamboo"), palm-tree, spiral, or random roughness (Fig. 2).

The timeline showed that the tube brand ran well for pretty much six months before processor switched to a new resin. The timeline as well showed a thermocouple have been changed-another suspect. The thermocouple was checked for accuracy, and it turned out to be calibrated and was reading temperatures accurately properly. That remaining the resin as the utmost likely culprit. It was a metallocene-type polyolefin, which is commonly more vunerable to melt fracture since it maintains larger viscosities at larger shear rates-i.e., it is less shear-thinning.

In basic, melt fracture involves stresses in the die and is often resin-related. It can be healed by either material or mechanical means. In this full case, the processor cannot change the material.

Melt fracture could be eliminated or reduced by streamlining the die flow channel, reducing shear tension in the land region, using a processing help, adding die-property heaters, operating above the critical shear strain for melt fracture (referred to as "super extrusion"), or adding ultrasonic vibration-a minor known but successful approach highly.

Streamlining the die's stream channel is always a good idea to quit melt fracture, nonetheless it adds price. For a high-volume product it makes sense to pay for a completely streamlined die, but which could not be worthwhile for a small-volume item.

Reducing shear stress in the land region can be carried out by increasing the die gap, reducing the extrusion rate, increasing die-land temp, increasing melt temperatures, or reducing melt viscosity. Viscosity can be reduced with a process help or lubricant. When 500 to 1000 ppm of fluoroelastomer is undoubtedly put into a polyolefin, a covering is formed double screw extruder by it on the die. This coating takes from five minutes to over an hour to form anywhere.

Other common answers to melt fracture are to install a heater to raise die-land temperature to the point where the shear stress drops below the essential shear stress for melt fracture.

Residence period of melt in the die-land area is indeed short that temperature ranges there can be set relatively high. HDPE, for example, which operations at about 400 can go through a die l, at and F575 F without degrading. Die-land heaters could be retrofitted on the outside of the land area of a tubing die.

A die-land heater may also reduce die-brain pressure and present up to 20% higher extrusion throughputs while retaining good merchandise appearance and dimensional tolerances.

Super-extrusion is a method in which shear stress in the die-land place is well over the critical shear rate for melt fracture. That is possible with HDPE and certain fluoropolymers (FEP and PFA types), which exhibit another region of stable extrusion at higher shear than in the zone where melt fracture appears (Fig. 3).

Ultrasonic vibration of the die with attached transducers also causes shear thinning of plastics externally. Limited information is on this technique, but it can lessen melt viscosity by orders of magnitude when the pace of deformation is great enough. The plastic melt layer at the die wall structure is most exposed to high-frequency deformation, producing a huge drop in melt viscosity at the die wall. This reduces die-mind pressure, die swell, melt fracture, and die-lip drool.

-Edited by Jan H. Schut

Chris Rauwendaal spent some time working in extrusion for 30 years nearly. He heads his private consulting organization in Los Altos Hills, Calif., which gives screw and die patterns and process troubleshooting offerings.

Extrusion blow moulding of plastic tubular objects

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Usual end products: packaging articles, i. e. bottles, barrels or canisters, technical articles, we. e. ventilation ducts, gaiters (e. g. steering gear gaiters and axle boot styles), suitcase hulls, luggage racks or gasoline tanks, huge children s toys (e. g. push-powered cars or Bobby-Car?)

Normal materials: PE, PP, PMMA, PC, PA, ABS, PLA, TPU, colour masterbatch

Typical throughputs: 300-1000 kg/h

Process description

In the extrusion blow moulding plan, thermoplastic resins and colour masterbatch granules are mixed at the intake of a single screw extruder. The thermoplastic resins generally emerge from silos while the colour masterbatch granules emerge from containers on the machine pedestal. Flash from blow moulding development is ground immediately at the device and the regrind can be directed from the grinder over a cyclone and blown into a buffer container. All three ingredients (thermoplast, colour masterbatch and and regrind) will be dosed respectively through a dosing axle of the GRAVICOLOR (gain-in-weight). Scrap is generally reground centrally, sometimes it afterwards is regranulated. This materials is fed back to the buffer container through a hopper loader and then reintroduced into the process.

Due to the high throughputs in the blow moulding procedure it makes sense to get a central vacuum program when several machines are involved. In a vaccum line system, the air level of the conveying blower and also the vacuum tubing are calculated so that only 1 hopper loader can convey at the same time. Therefore the proportion of blowers to the amount of conveying systems in the line must be chosen in order that every point of consumption comes with sufficient material at all times. In a central vacuum system several hopper loaders are capable of feeding simultaneously per collection or within the complete system. Through the variable allocation, output should not be reserved which effects in considerable energy savings. The parallel-operated pumps will shut down automatically (pressure controlled) based on surroundings requirements. Since full vacuum is present at all time and does not have to be built up after a run-on time as in lines, bigger throughput rates could be attained.

In the extrusion blow moulding task, a hose is generated through a mould by the end of the extruder. The hose is cut to fed and length to the ultimate blow moulded product for further processing.

Customer benefits

Versatile operation through modular designReduction of downtimes at materials changes through intuitive handling (spring catches, etc.)High-quality (digital) load cell technology secures better recipe integrity due to a very short reaction time in recipe and/or throughput adjustments. In addition, the time-consuming procedure for sampling and calibrating the co extruder machine system is definitely omittedAcquisition of the intake data precise bank account of fees and stockkeeping possibleVery precise control of the entire process (start-up stage, recipe change, quickly and continuous adjustment of production capacities), automatic start-up process through integration of upstream controlExpertise in method engineering and process-oriented total know-how would make motan-colortronic the ideal partner for you

Extruder Polymera closes

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HEBRON, OHIO - Polymera Inc., a profile compounder and extruder of wood-plastic composite material, closed July 14, laying off about 30 people.

The ongoing company was founded in 2010 2010 and began operations the next year in Hebron, about 25 miles east of Columbus, Ohio. Polymera management included several industry veterans with decades of knowledge from Crane Plastics Production Inc. of Columbus.

Polymera owner and President Maan Said did not return phone calls seeking comment.

After a tip that the ongoing company could possibly be closed, july 28 a Plastics News reporter stopped simply by the factory in a Hebron industrial park on. Leading door was locked. No autos had been in the parking whole lot. Then Jason Staffan, a laid-off plant worker, drove in his pickup up, trying to find a supervisor to signal his form to receive unemployment compensation.

July 14 staffan said the factory closed. Said called an emotional meeting between the third and second shifts to announce the news, Staffan said.

Staffan had worked at Polymera for about one-and-a-half years, running pelletizers plastic extruder and extruders.

I loved working here, he said. We had a great crew. Staffan said, I d arrive back, if Polymera can reopen.

Maan Said was a hands-on executive who pitched in to help you in the factory often, Staffan said. Maan was an excellent guy. He was out there sweeping the flooring around, he said.

Staffan said that of management was great and supportive to utilize. Asked if there have been any criminals in the closing, he explained: Money was the theif. You stop making money and you can t stay static in business.

Management personnel drove in to the parking lot then, and signed his unemployment form. The plant was confirmed by them had closed but referred questions to Said.

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alluringcatcall1
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