Strictly-Extrusion

A new die system for extruded polystyrene (XPS) foam board dramatically reduces downtime for product changeovers, enabling manufacturers to offset much of the loss in productivity caused by switching to a non-ozone depleting blowing agent, it was announced today by Extrusion Dies Industries, LLC (EDI).  In addition, EDI’s technology incorporates innovations that enhance control over product dimensions, reduce scrap, and eliminate shutdowns for die maintenance.

XPS foam board is widely used as insulation and plays an important role in weatherizing homes and buildings to reduce consumption of fossil fuels and combat climate change. Because the hydrochlorofluorocarbon (HCFC) blowing agents used to produce the foam had raised concerns about ozone depletion, signatories to the Montreal Protocol mandated a switch to chlorine-free HFC blowing agents by January 1, 2010. The process changes needed to accommodate the new blowing agent reduce board production by 30%. The new EDI die system helps address this problem by eliminating hours of downtime incurred with conventional die systems whenever a change in product dimensions must be made.

“The EDI XPS foam board die technology makes it possible to accomplish a product changeover on the fly in only 15 minutes,” said Dennis S. Paradise, vice president of sales and marketing. “By comparison, a change in width or thickness with a conventional die system requires shutting down the production line for at least eight hours, followed by a two-hour startup phase in which no saleable board is produced—only scrap. The added uptime generated by our new system is sufficient to offset the lion’s share of the output loss imposed by the switch to HFCs.”

XPS foam board producer DiversiFoam Products reports that by using the new EDI system at its Rockford, MN, plant, the company has virtually eliminated downtime for scheduled thickness setups, making it possible to produce 11% more saleable product. Operations manager Steve Slavik reports other benefits: “Our new die can operate at a much higher pressure than the old one, which is very important when using HFC blowing agents. In addition, it provides better temperature control, enhanced adjustability, and simpler maintenance.”

Faster Product Changeovers and More Extruder Uptime

While EDI has successfully supplied dies to the XPS foam board industry for years, its new die system represents a totally different design.

One of the central innovations is a new type of forming box. When polystyrene passes through any XPS foam board die, it is charged with blowing agent. As it exits the die lips, it undergoes a thirty-fold increase in volume almost instantaneously. This expansion takes place just beyond the lips in the forming box, which has four-way adjustability. The forming box gives the board its initial shape in terms of thickness and width.

In most conventional die systems, the forming box and die lip constitute a single component. Changing the dimensions of the board requires stopping the production line, disassembling the lip/forming box, adjusting for new product dimensions, and reassembling the unit. The forming box in the new EDI system, on the other hand, is a separate, independently adjusted component that makes possible on-the-fly product changeovers without stopping the production line.

A second new component that reduces downtime is an adjustable full-manifold internal deckle inside the flow channel of the die. The deckle blades at either end of the manifold can be used to change flow-channel width by being moved farther into the channel or farther out.

Deckles are conventionally used for changing product width, but in the XPS process, where the material ultimately expands in all directions, deckles can be used to adjust thickness as well. By coordinating the settings of the deckle blades and the forming box, for example, it is possible to produce thicker board without changing width. This on-the-fly capability makes it possible to do so with little adjustment in comparison with conventional die systems.

Still another new component for ensuring dimensional consistency is external edge restrictors that create the final side dimensions of the board as it emerges from the forming box and passes between the two top and bottom sizing plates that are typically used in foam board production. Mounted on rails that extend from the front of the forming box, the edge restrictors ensure board edges that are more flush and flat. Here too, the omni-directional nature of foam expansion comes into play. While edge trim losses in conventional XPS board production typically are around 10%, restricting expansion at the edges results in more lineal feet of board.

A fourth innovative component in the EDI XPS board die system is a purge block located between the extruder and the die. This makes it possible to carry out die maintenance while the extruder is temporarily shut down but still full of polymer. The purge block acts as a valve, blocking flow from the extruder while purging material from the die.

Film manufactures are increasingly seeing themselves exposed to rising production costs. Huge increases in raw material prices, higher demands on quality from the end user, shorter delivery times and the compulsion of material saving has left little elbow room.
Leading edge companies have already invested in extrusion automation with some 3rd or 4th generation systems with high levels of automation being specified as a standard for new equipment. However there is a need for many older machines to be upgraded with modern automation systems to bring them up to date. Very efficient measures can be carried out at only a fraction of the cost of a new machine in order
to increase productivity and quality.

Utilization of high performance air rings with integrated profile control not only increases the output of the line by up to 50% but also the film tolerance is improved significantly plus a measurable reduction in scrap. In total the effectiveness of production is improved through, additional production capacity, improved film tolerances, order change times are minimized and raw material savings due to reduced gauge tolerances and shorter setup times…

-click here- for further information (incl. detailed information,examples and case study)

BinMaster: Collaborate on Development of BinLink Remote Wireless Monitoring Solution

BinMaster Level Controls and Digi International (www.binmaster.com) have collaborated on the development of BinMaster’s BinLink Web-based bin, tank and silo monitoring solution.  The solution enables remote wireless inventory management of stored material from any PC with Internet access. This saves customers time and money by eliminating the need for on-site remote bin level measurements. The solution includes BinMaster SmartBob2 and SmartBob-TS1 sensors mounted on the bins and a Digi Connectport™ X gateway running the SmartBob application to provide bin level measurement data that can be accessed easily via the Internet.

“BinMaster’s customers have been seeking an integrated, turnkey solution that allows them to access bin material levels via the Internet whether they are on site, off site or in the corporate office. The Digi gateway provides the critical interface between the SmartBob sensors and the BinLink Internet-based software,” stated Todd Peterson, vice president of sales for BinMaster. With BinLink, users can view inventory data on demand or receive automated alerts to their cell phone, PDA or computer when bin conditions meet user-defined thresholds.

BinMaster is an iDigi Tank Monitoring Solution Partner. Digi ConnectPort X gateways enable centralized data collection and when integrated into the BinLink solution can be used by any type of business that desires remote bin management for one to hundreds of bins for one or many sites. BinMaster’s customers span cement, aggregates, mining, plastics, chemical and pharmaceutical manufacturing, food processing, ethanol and biofuels processing.

The Italian company Colines presents the latest innovations on their HANDrollEX® stretch film line at their factory in Azzate (Varese) from February 15 to 26, 2010. More information -click here-

At SPE’s FlexPackCon in Houston, Feb. 22-24, 2010, Hank Schirmer of BBS Corp. will discuss research on barrier films produced with up to 75 layers of various resins, including EVOH and COC.Utilizing a modular die system, the researchers used both downward and upward extrusion to produce variants of traditional barrier films. They substituted up to 75 nano-layers such as PP/EVOH and COC/EVOH for the barrier core.

While the COC/EVOH films suffered from lack of adhesion between the components, they exhibited excellent optical qualities. The PP/EVOH structures were hazier, presumably because of the inherently higher haze of the PP and rheological issues.  The researchers report no enhancement of oxygen barrier, either wet or dry, resulting from the nano-layer structure. They hypothesize the nano-layer technique may have modified the crystallinity and inherent barrier of the component resins, or brittleness may have degraded layer continuity and barrier. The researchers suggest how modifying the resins might improve adhesion.

Among other related papers at FlexPackCon will be “High Barrier, Non-Foil Packaging Materials” by Tom Dunn, Printpack, and “Value Films from Sub-Micron Layers” by Gary Oliver, EDI.  The three-day FlexPackCon program will also include sessions on sustainability and source reduction, recent advances in materials and converting technologies, and the impact of recent regulatory changes on flexible packaging manufacturers.

More information on SPE’s FlexPackCon 2010 and International Polyolefins 2010 Conference is available at http://www.spe-stx.org/PolyolefinsConference.htm, at www.4spe.org, or by calling Lesley Kyle at +1 203-740-5452.

The latest edition of the “EDI Advances” newsletter (Number 19) from Extrusion Dies Industries, LLC (EDI) is released. Chief topics include:

● Hot melt adhesive coating. A full-length technical article reports on two innovations, including a coating die for clear, streak-free pressure sensitive adhesives and a turnkey hot melt coating station. The article starts on the back page (8) and continues inside.

● Polystyrene foam board insulation.  A special die for this application helps manufacturers offset productivity losses incurred as they switch to non-ozone depleting blowing agents. (The deadline for making the switch was three weeks ago—January 1!)

● Super-hard, super-sharp die lip edges. Such edges are critical for achieving the highest levels of quality and precision in film, sheet, and coating.

● Rheology—a lot more than melt index. A look at EDI’s rheological analysis capabilities, including information on why the science of polymer flow is important for extrusion processors.The latest edition of the “EDI Advances” newsletter (Number 19) from Extrusion Dies Industries, LLC (EDI) is released. Chief topics include:

● Hot melt adhesive coating. A full-length technical article reports on two innovations, including a coating die for clear, streak-free pressure sensitive adhesives and a turnkey hot melt coating station. The article starts on the back page (8) and continues inside.

● Polystyrene foam board insulation.  A special die for this application helps manufacturers offset productivity losses incurred as they switch to non-ozone depleting blowing agents. (The deadline for making the switch was three weeks ago—January 1!)

● Super-hard, super-sharp die lip edges. Such edges are critical for achieving the highest levels of quality and precision in film, sheet, and coating.

● Rheology—a lot more than melt index. A look at EDI’s rheological analysis capabilities, including information on why the science of polymer flow is important for extrusion processors.

● EDI news—lots of it. In the six months since the last issue of “EDI Advances,” EDI has added personnel (including a new sales director for the Americas), appointed new agents in Korea and Turkey, brought a modular slot die coating system to China, and begun reworking blown film dies.

Please -cklick here- to download your copy.

● EDI news—lots of it. In the six months since the last issue of “EDI Advances,” EDI has added personnel (including a new sales director for the Americas), appointed new agents in Korea and Turkey, brought a modular slot die coating system to China, and begun reworking blown film dies.

Please -cklick here- to download your copy.

Reportlinker has announced that a new market research report “US extruded plastics industry” is available. This industry study covers historical demand data (1998, 2003 and 2008) plus forecasts for 2013 and 2018 by resin type and market. The study also considers market environment factors, evaluates company market share and profiles industry competitors. Click here for more information.

KraussMaffei Berstorff (www.kraussmaffei.com) is now offering complete systems for continuous production of PU-insulated pipes. The extruded plastic pipe is given an insulating polyurethane layer, followed immediately by the addition of a protective polyethylene sheath. KraussMaffei Berstorff can call on many decades of technology competence and experience in pipe extrusion and in PU processing. This unique know-how enables the company to develop complete production solutions which successfully integrate different plastics processes.

The pipe – made of PE-HD, PE-X, PE-RT or PB according to the application – is produced on a conventional pipe extrusion line. A barrier layer can be

Photo: KraussMaffei

applied. The pipe coming off the line is wound onto large steel drums ready for transfer to the second production system unit for application of the insulation layer. Alternatively, the insulation layer can be added to bought-in pipe. In this second unit, the pipe is unwound from the steel drums, heated if necessary, and fed under tension into a shaping conveyor. A PU mixing head dispenses the polyurethane mix at the inlet throat. The aluminium shaping jaws define the outer diameter of the insulation layer by limiting the foam volume. A film prevents the polyurethane from adhering to the aluminium shaping jaws. Once the PU insulation layer has cured, the pipe leaves the shaping conveyor and a PE outer sheath is applied, using a single-screw extruder with a sheathing die. This outer sheath is cooled, the whole composite pipe is hauled off and wound on a drum. The system allows the integration of anti-diffusion barrier layers and/or wires to monitor leakage.

Insulating properties

The standard version of this production system can be used to produce pipe with an outer diameter between 20 and 110 mm. For pipe diameters from 20 to 63 mm, a complete pipe element usually contains two pipes (outflow and return pipes). The exterior diameter of the pipe element will then be between 75 and 180 mm, depending on the diameter of the pipes and the thickness of the insulating layer.

The mixing performance of the PU mixing head produces an insulation layer with a very low thermal conductivity – between 0.02 and 0.03 W/m*K, depending on the type of foam. This highly efficient insulation makes these pipes the ideal solution whenever a significant temperature differential must be maintained between the medium flowing through the pipes and the ambient temperature. In some cases, the medium being transported is hotter – such as supply lines for combined heat and power or geothermal plants, or hot water pipelines in general. Insulated pipes are also sometimes required for potable water transport if there is a risk of the pipes freezing. In other cases, the medium must be kept cold or cool, for example, in air conditioning or refrigeration systems, or in pipes for transporting liquefied gas. With the current focus on energy savings, strong growth in demand can be expected in all these application areas.

New production system concept from a single-vendor partner

KraussMaffei Berstorff can now quote on complete, precision-planned systems for the production of media pipes and for applying the insulating layer and protective sheathing. By contrast with some other systems on the market, KraussMaffei Berstorff technology is characterized by sharply reduced wear on all system components, high system reliability and a high-quality end-product.

No limits on pipe length

Producing insulated pipe in a continuous process has several advantages compared with discontinuous production. One major advantage is the relatively high level of automation that results in lower labour costs. Furthermore, there are virtually no limits on the length of the pipe being produced. Contributing to this wide freedom is the design of the PU mixing head, which eliminates stoppages for cleaning and changing the mixing head. Longer pipe sections reduce the number of production system restarts and also the number of connections needing to be made when the pipe is laid. This in turn eliminates the risk of thermal bridges and leaks, and makes pipe laying easier and quicker.

A new film extrusion grade of cyclic olefin copolymer (COC) from TOPAS Advanced Polymers, Inc. (www.topas.com) extends the commercial glass transition temperature range down to 33° C. TOPAS 9903D-10 is the company’s latest film extrusion resin which delivers a unique combination of low-temperature shrinkage, sealing, and high stiffness for a range of shrink films and sealant films for the consumer packaging industry.

The new material is used to enhance polyolefin formulations for a range of monolayer and multilayer packaging film applications including shrink film, shrink sleeves and shrink labels for bottles and other consumer packaging, and in improved sealant films for stand-up pouches. In polyolefin blends containing 5% to 50% of the new COC, low-temperature shrinkage and stiffness were improved significantly, resulting in better downstream processing. In multilayer sealant films, the new material provides excellent low-temperature sealing and high stiffness for stand-up pouches.

TOPAS 9903D-10 boosts the performance of ultra linear-low-density PE which is typically used in applications that require low-temperature shrinkage. Higher stiffness is a key benefit, resulting in improved web handling and printing operations. Shrinkage is also enhanced, but unlike most stiff polymers, shrink force is actually reduced by the COC resin so packages are less likely to distort or crush when wrapped.

TOPAS 9903D-10 COC resin has a melt flow index of 0.9 which is similar to that of LLDPE grades that are used for shrink films. The material’s tensile modulus of 100,000 psi increases when the film is oriented. TOPAS COCs are amorphous polymers that offer high transparency, outstanding moisture barrier, high rigidity and strength, excellent biocompatibility, and good electrical insulation properties. This unique combination of properties has led to TOPAS COC applications in such areas as medical devices, food and pharmaceutical packaging, optics, and electronics.

Sabic Innovative Plastics (www.sabic-ip.com) has added two new extrusion lines for the production of PC sheets at its film and sheet facility in Gujarat (India).The booming building and construction industry in India generates a strong demand for PC sheets. The LEXAN products are mainly used for industrial roofing and metro rail seating.