Strictly-Extrusion

A blown film turning bar which protects the surface of the film with a cushion of air has been introduced by Reifenhäuser. The REIcofly bar has a microporous coating through which compressed air is pumped to keep the surface of the film from contacting the bar. This air is supplied by a standard factory air system and does not need a dedicated compressed air blower.
Tests have been done at the company’s Troisdorf R & D centre and the bar has been shown to be effective with high VA content EVA protective film, coextruded LLDPE stretch film and film with high optical properties. Benefits claimed for the new turner bar include reduced noise and cost from using factory compressed air, no frictional heat generation, and no bending of the turner required so no wrinkling of the film. The REIcofly bar can be retrofitted.

Multibase, Inc. announces a major conduit-tubing manufacturer has selected Multi-Flam 0803 NH LDPE for the fiber portion of their business.

Multi-Flam 0803 NH LDPE, a non-halogen based flame retardant chemistry, has replaced halogen systems for this application. Compared to halogen systems, Multi-Flam 0803 NH LDPE was selected above all other flame-retardant systems as well because of its excellent dexterity and low swelling when extruded to many diameters.

Multi-Flam 0803 NH LDPE belongs to the Multi-Flam (flame retardant) product range. This product range is ideal for injection ad extrusion; since they exhibit melt flows from 0.8 to 22 grams per 10 minutes.

Processing Multi-Flam grades present ease of transformation at an excellent cost ratio; providing a significantly wider processing window than typical halogen systems. Because Multi-Flam grades allow flexibility in part utility since they contain no halogen products, thereby opening potential markets. Additional economic attributes result from the fact that more flexible materials enable increased mobility in assembly.

Multi-Flam NH grades feature melt flows from 0.8 to 22.0. They provide 800-2500 psi tensile strength and flexural modulus of 20,000 – 55,000 psi.

HT Troplast has improved its polyvinylbutyrate (PVB) film introduced 20 years ago for composite security glass glazing, so that it no longer needs cooling or an intermediate PE film to prevent the film sticking to itself. The company says more product versions will follow this one for architectural glazing. Processors using the film will save cooling energy costs in storage and production areas, as well as creating an improved working environment, the company claims. Those processors that have been taking the film with an intermediate PE film will no longer be confronted by static charges as the PE film is rolled off, eliminating the risk of contamination by dust particles.

As a result of the elimination of the intermediate PE film, HT says that 66% more PVB film can be supplied on each roll, with consequent transport and storage benefits. It stresses that the new version does not cost any more than its predecessor.

VERBRUGGEN has presented its new multi-layer adapters MA-CARR and MA-CAFR. The Belgian manufacturer of flat dies and multi-layer adapters has developed a new concept of extremely flexible coextrusion adapters. The principle of the configuration cassettes and the rotating restrictor bars has been kept. The improvement is to be found in the heart of the adapter. Due to an ingenious system of sliding elements, one and the same adapter can perfectly be used for a wide range of coextrusion configuration. The system allows much bigger variations in thickness and viscosity than it ever did before, according to the company. Due to the modular concept, a total flexibility for future products is guaranteed. The more than thirty MA-CARR and MA-CAFR adapters with up to seven layers, delivered up to now, have proven their reliability and extreme flexibility.

For polyethylene pipes, Amut (Novara, Italy) has changed the design of the grooved feed zone and the screw geometry on its EA 60 HP single-screw extruders so that material is more quickly conveyed and lower melt temperatures can be used. Temperature controls have also been improved to allow processors to more closely regulate melt temperature. Five models are available, all with L/D ratios of 33:1; output ranges from 350 to more than 1200 kg/hr. The manufacturer has also designed a multiple coextrusion die head with spiral distributors targeted at processing five-layer PE pipe.

Periplast Equipamentos Industrials, a maker of extrusion machinery and tooling, offers a wide range of equipment used for the production of pipes, profiles, sheets, and compounding. This includes, among others, single- and twin-screw extruders, coextruders, pipeheads, vacuum tanks and tables, cooling baths, takeoffs, saws, and coilers. The company recently acquired the intellectual property of Speedex and the Speedex range of takeoffs, planetary saws, swarfless planetary cutters, and startup winches. All are now included in the Periplast range of machines. Periplast, 7 Brookside, Leeds, LS17-8TD, England, marshall.co@virgin.net

It is well-known among profile manufacturers that the start-up of the extrusion line requires much more vacuum than the later run under production conditions. This fact causes a waste of energy as during production more vacuum pumps are running than actually required. In order to eliminate this waste of energy Battenfeld Extrusionstechnik in Germany has launched its new ZV-series of profile calibrating tables with Automatic Vacuum Control. With this new system the operator is in a position to enter different vacuum levels at the operator panel. Each vacuum level entered will be maintained exactly during production and the control makes sure that no more vacuum pumps are running than really necessary. Even if one of the vacuum pumps fails and must be replaced during operation the control still ensures a steady vacuum. Tests have shown that it is possible to run a window main profile with only 1 x 3 kW vacuum pump instead of 4 x 5,5 kW as previously used. Even more impressive are the results if the Automatic Vacuum Control is used for dual strand extrusion as usually eight or more vacuum pumps are employed. This high potential of energy saving has already convinced several customers worldwide who have received their calibrating tables with the new Automatic Vacuum Control. The Automatic Vacuum Control also has a very positive side effect: There is no unpleasant noise which is usually caused by leaking air.

Polyco, which makes plastic window boards and architectural profiles, has extended its 2,000 sq metre site by 1,600sq metres. The extension will house a second production line that will produce window board. The firm also plans to take on 10 more staff to its 20-strong workforce. Managing director Ian Law said the firm was considering further expansion as it extends its range of products over the next two years. Polyco set up the Powys site four years ago. It has a factory in Reading.

In step with providing customers value-added packaging solutions, C&M Fine Pack, Inc., recently moved its compounding operation in-house with the installation of two Davis-Standard twin screw compounding extruders. The two extruders, commissioned in the fall of 2002 at the company’s plant in Fort Wayne, Indiana, have allowed C&M to custom compound its own polypropylene-based compounds, improve quality and inventory control, and custom compound blends to meet specific customer requirements. For C&M, a diverse and rapidly growing supplier of flexible packaging products, customization and quality control are essential to supply its vast customer base ranging from the airline industry to large national retail outlets.
“In the past, we purchased our custom compounds from outside sources,” said Russ Stephens, plant manager of C&M Fine Pack’s manufacturing and distribution facility in Fort Wayne, Indiana. “However, as our volume grew it became more cost-effective for us to manufacture these items internally. Bringing compounding in-house has also enabled us to readily match the product, which can vary from extreme low temperature resistance to extreme high temperature resistance, with individual client needs.”
In addition to the compounding extruders, C&M also installed two
Davis-Standard sheet systems at its Fort Wayne plant last year. Both systems are set up in a coextrusion arrangement and include EPIC III™ control systems and Davis-Standard winders. These systems process sheet that is then thermoformed to make products such as fresh meat and retail food packaging as well as case ready packaging. Additionally, C&M operates a Davis-Standard
re-pelletizing line, a coextrusion sheet system at its Fort Wayne facility, as well as a modified sheet line at its headquarters in San Bernardino, California. C&M has also replaced many of the barrels and feedscrews on its other equipment with Davis-Standard barrels and screws.
“We made the switch to Davis-Standard a few years ago based on their exceptional service and superior technology and have been pleased with the results,” said Stephens. “We’ve also spent a lot of time at Davis-Standard’s Technical Center conducting trials and doing research and development. We appreciate that we can take advantage of a quality facility and lab time.”
C&M expanded its Fort Wayne location in 2002 to more than 300,000 square feet (27,870 square meters) to meet increased demand and better serve customers. For more information about C&M Fine Pack, visit www.cmfinepack.com. For more information about Davis-Standard’s compounding and sheet solutions, contact Al Chrisbacher at achrisbacher@davis-standard.com.

Recycler Petco Plastics Inc. is adding a third extrusion line that substantially will boost its capacity to make sheet from recycled PET. Petco’s US$3 million expansion will add 12 million pounds of capacity, giving Montreal-based Petco a total annual capacity of 36 million pounds.