More information: pcarry@tsm-controls.com or at the K 2010 on booth no 10J54

An MVL system consists of two model MVL 3DLevelScanners, a controller that aggregates the data, 3D Vision software to be loaded onto a PC, and a 3DLinkPro modem for remote access to the scanners. The BinMaster MVL system works by integrating the measurement data from two scanners mounted on the top of the vessel in locations optimized to most effectively cover the entire surface area of the material. Generally, one scanner is mounted near the center and the other eight to ten feet from the outer perimeter. The scanners take multiple measurements of the material surface using dust-penetrating, acoustic-based technology. A controller then combines the data from the two scanners and generates a single merged visual representation of the topography of the material and displays the image on a PC loaded with the 3D Vision software that can be viewed as real-time 3D images or historic 3D image movies.

This process relies on Bandera’s patented High Vacuum Twin Screw Extruder (HVTSE) technology,which allows PET to be processed without the need for raw material drying and crystallizing. The HVTSE extruder de-volatilizes and de-moisturizes the material as part of the extrusion process. The twin-screw extruder will be teamed with downstream systems furnished by PTi, a global supplier of single-screw sheet extrusion systems, as part of a turnkey package. PTi will also provide its TITANTM supervisory control system and UL approved electrical components for delivery throughout North America.

Dana Hanson, PTi President says “our total investment in facilities infrastructure and equipment is projected to exceed $ 3 million USD. Furthermore, this will be the only full scale ‘dryer-less’ twin screw sheet extrusion demonstration system available throughout North America. We want to provide our customers with the ability to run production scale trials using the HVTSE ‘dryer-less’ twin screw technology as oppose to having to scale up from a small lab scale pilot line that can often provide inaccurate estimations and unfavorable results. This completely eliminates the uncertainties associated with a scale-up from a small laboratory line. It will truly provide customers with a proof-of-production result.”

Since announcing a strategic business alliance with Luigi Bandera of Italy to market the industry proven HVTSE technology in North America, the companies have been hard at work in the planning stages for this production scale demonstration line which will be up and running by the beginning of the New Year.

Short-term interest in the technology has surpassed even out most optimistic estimates. While we anticipated interest from companies looking to run post-consumer PET, the interest from companies’ currently running PET production with mostly virgin or partial recycle content has been a pleasant surprise.

Energy savings are a tangible benefit. Compared to conventional and infrared drying processes, the total energy consumption using the HVTSE twin screw process reduces power requirements by as much as 35%. This figure plays most favorably in the pay-back calculations our customers have shared with us. The demonstration line will enhance our abilities to market the technology in North America, but we anticipate having several orders consummated by the time the demo-line is installed. We could also envision companies buying blocks of machine production time, thus allowing them to have samples in the volume range sufficient for test marketing programs not normally associated with lab or pilot-scale equipment.

In the three years since its introduction, the MRS extruder has become a key technology for the processing of PET post consumer flakes without pre-drying. Ever more processors have become convinced by the extremely high devolatilizing and decontamination performance of this completely new type of extruder together with its attractive investment and running costs. Thanks to its patented combination of single screw extruder together with a multiple screw section is the extruder also particularly robust, as well as easy to operate and maintain.

At this year´s „K“, Gneuss will for the first time be showing a complete line for the direct recycling of light fibre or film scrap, consisting of an MRS 110 extruder, equipped with a Cutter / Feeder Combination together with an RSFgenius 150 and an Online Viscometer VIS. This new combination of equipment permits the processing of the most diverse fibre and film waste to a product which is comparable with virgin material, at a throughput rate of 500 to 700 kg/h.

The Gneuss Filtration Technology product group will present its Rotary Melt Filtration Systems at the „K“, with further design enhancements. With the latest generation of RSFgenius Melt Filtration Systems, Gneuss has once again extended its technological lead and with regard to back flushing material waste levels and energy consumption, sets new unparalleled standards.

With the optimisation of the back flushing (which is now completely electronically controlled) and further improvement of heating and insulation, filtration with the RSFgenius models is now even more efficient.

All models for extrusion lines of medium capacity from 500 to 4.000 kg/h. now have an active filtration area increased by up to 40 %. In many cases, this permits the use of one model size smaller at the same throughput rate and filtration performance, considerably reducing the investment cost.

An SFXmagnus melt filtration system will be exhibited, which thanks to a strengthened drive system is suitable for high pressure applications.

Last but not least, Gneuss rounds of the package of new developments with products from its Measurement Technology product group. The complete range of Melt Pressure Transducers has been changed to the non mercury NTXTM- medium as standard, and which permits even more reliable and accurate measurements than with mercury. With this step, Gneuss has set new standards with regard to environmental friendliness and safety. The second new development is the Extrusion Pressure Monitoring System (EPM). Gneuss is the first manufacturer of Melt Pressure Transducers to offer a package to match the increased European requirements on the over pressure safeguarding of extruders.

XOL Automation is an Engineering, Sales and Service organization that specializes in the paper, film, and foil converting industry. They will provide sales and service support for Enercon throughout the Middle East and North Africa (MENA) region.

Headquartered in Beirut Lebanon, XOL is servicing the entire MENA region for a variety of web handling products and services including guiding, slitting, winding, gauging, and tension control equipment.

Enercon Industries Corporation, headquartered in Menomonee Falls, WI, is a major manufacturer of equipment for the plastics, converting and packaging industries. The company supplies custom built corona and atmospheric plasma treating systems, as well as induction cap sealing systems.

“We have been a Davis-Standard customer since we started the business 10 years ago. The Super Blue extruders have addressed our needs as customer demands have dictated,” said Greg Mitsch, President of GaMra. “There is a short lead time and the extruders were up and running quickly. We feel like the return on our investment has been almost immediate. These machines are quiet, reliable and a very good value. They are such a good value that it makes sense to pay a few thousand more to purchase a new Super Blue over a used machine.”

A short lead-time is significant for extruders like GaMra because of unique customer requirements. According to Mitsch, the first Super Blue ordered in February of 2009 was shipped within seven days and operating in four days after it was received. This enabled GaMra to respond almost instantly to new business. In addition to the quick turnaround, the extruders have been ideal for the company’s profile and crosshead extrusion processes, which involve PVC, Nylon 6 and Nylon 12 among other resins. The company is capable of producing a range of parts with tolerances as low as plus or minus .003-inch (.08mm). The majority of GaMra’s business is in the U.S., but they also ship to China, Mexico, India and Brazil.

The Super Blue is available in 2-inch (50mm), 2 ½-inch (65mm), 75mm, 3 ½-inch (90mm), 100mm, and 4 ½-inch (114mm) sizes, each with a 24:1 L/D ratio. Extruders in 30:1 ratios are available in 75mm, 3 ½-inch (90mm) and 4-1/2 inch (114mm) sizes. It is equipped with preferred features including a low noise, high torque double-reduction gearbox; cast aluminum finned heaters bolted to the barrel to ensure barrel-to-heater contact; a brushless AC drive and motor; and a high capacity, highly efficient air cooling system. The Super Blue is engineered for custom profile and tubing applications as well as basic wire and cable and film applications.

For more information about the Super Blue, contact Wendell Whipple at wwhipple@davis-standard.com.

At its Technology Center in Chippewa Falls, EDI (www.extrusiondies.com) is carrying out the first scientifically rigorous study of the benefits and limitations of layer multiplication, according to Gary D. Oliver, vice president of technology. “One result thus far is the development of a technique for selective multiplication of the barrier-resin layer of a multilayer film or sheet structure,” Oliver said. “By transforming a single layer of a resin such as EVOH into several microlayers, it is possible to reduce oxygen transmission rate (OTR) by 60 to 80%. And while EVOH is a crystalline, relatively brittle material, replacing a single thick layer with multiple microlayers increases formability for thermoforming and flexibility for vacuum skin packaging.”

The resulting benefits for food packaging include:

● Prolonged shelf life. Besides reducing OTR, layer multiplication substantially reduces total oxygen ingress over an extended period.

● Enhanced quality and lower material consumption.  In the case of deep-draw containers where corner-thinning has been a problem with less formable materials, for example, multiplication of the EVOH layer may eliminate the need to offset thinning by increasing sheet thickness.

An Advanced Layer Multiplier and Its Benefits for Food Packaging

The layer multiplier is a special tool that can be engineered to multiply some or all of the layers within a coextrusion “sandwich” provided by a feedblock. The resulting microlayer structure then passes into the manifold of an extrusion die, where it is transformed into film or sheet of target width and thickness profile. No matter how many microlayers there are in the structure, the overall thickness is no greater than that of a conventional coextrusion, and the structure contains the same amount of raw material.

In 2009, EDI introduced an advanced system that is easier to deploy, more compact, more accurate, and more versatile than any other layer multiplier, including one previously offered by EDI. It is available to purchasers without licensing or royalties.

In the research at its Technology Center, EDI used its new system to multiply the EVOH core layer in sheet used for thermoforming single-portion retort cups, such as those for packaging fruit cocktail and diced peaches. EDI extruded the sheet and used a commercial cup mold to solid-phase pressure form sheet with one, four, eight, and sixteen EVOH layers.

All sheet structures were 50 mils in thickness, with thick (41 to 43%) skin layers of polypropylene and tie layers between the skins and the EVOH core. Barrier resins included a standard general-purpose EVOH and a “retort” grade of EVOH.

Thirty days after retort, cups with a single layer of the “retort” grade of EVOH exhibited three to six times higher oxygen transmission rates (OTRs) than cups where a layer of similar material had been multiplied. In that same period, total oxygen ingress was also three to six times greater.