Archive for January, 2006


Wednesday, January 4th, 2006

Extrusioneering International’s ‘Twin-Screw University’ seminar and workshop series is now in it’s third successful year. These training programs focus on the application of intermeshing co-rotating extruders in compounding applications. Training is directed towards machine operators, process engineers and supervisors as well as product development scientists in both research and manufacturing environments. Participants are reminded that the goal of compounding is to produce properties, not pellets. The goal of this workshop is to explain how twin-screw extruders create properties.

Interactions between screw design, raw materials and process parameters are presented in such a way that both experienced users and novices will benefit. Common unit operations are explained in practical terms with no prior knowledge or experience required. Upon completion of the training, participants will return to the workplace armed with techniques to improve quality, production rate and yield.

The 2006 TSU schedule starts on March 14-16, 2006 at the Polymers Center of Excellence in Charlotte, North Carolina ( and continues on April 18-19, 2006 at the Akron Polymer Training Center in Akron, Ohio ( more seminar and workshop locations throughout 2006, visit the website of Extrusioneering International, Inc. at

Brampton: Installation of new multi-layer film lines

Wednesday, January 4th, 2006

Canadian blown film specialist Brampton Engineering is installing two new multi-layer lines in its North American technical centre to support worldwide sales of seven and nine-layer systems. The two lines – a nine-layer conventional blown system and a seven-layer Aquafrost system – will be available for production development trials and technician training from the spring of 2006. “We have more than a dozen nine-layer lines operating around the world,” said Brampton president and chief executive Bud Smith. “We recognise that some processors consider producing seven to ten layer film a complex and sometimes difficult task. These new lab lines will give us the ability to train processors to use these sophisticated lines.” The decision to install a seven-layer Aquafrost system, which uses a water-quenched bubble, underlines the company’s confidence in the technology and positive customer feedback from the first commercial systems. Brampton claims the Aquafrost system produces high clarity thermoformable films at cast film output rates but without the associated trim scrap. Applications for Aquafrost films include barrier packaging of fresh and frozen meats, cheeses and prepared foods such as pasta.

VBE: Profile and Pipe firm adds further extrusion lines

Tuesday, January 3rd, 2006

UK profile, pipe and tube manufacturer VPE has installed two new extrusion lines as it experiences growth along with sister company Verplas, which supplies the ventilation market. The EURO 728,000 investment, which also includes factory services and a new power supply, increases the Dorset company’s number of extrusion lines to eight. The larger line is a 90mm twin Kraus Maffei extruder with integrated downstream controls and feedstock provided by a twin station gravimetric feeder from Colormax to handle blends of materials and recycled product. The line has capacity for profiles up to 320mm wide by 130mm deep but the principle products will be ventilation ducting VPE manufactures for Verplas. VPE managing director Ken Armstrong said that Verplas products had achieved significant growth in recent years and further growth was planned. Baston supplied downstream equipment for this line and also the 60mm Boston Matthews extruder VPE has installed. The smaller line includes a swarfless guillotine and saw combination purchased specifically for the medium-sized profiles used extensively in the leisure home and general industrial markets which VPE supplies.

Davis-Standard: Integrator™ PRO Maximizes Line Control and Data Acquisition

Tuesday, January 3rd, 2006

The newly introduced Integrator™ PRO control system from the Davis-Standard, LLC Converting Systems Group combines total line control and data monitoring into one highly-functional information center. Equipped with the best elements of Black Clawson’s Integrator technology and Davis-Standard’s EPIC control system, the Integrator PRO is specifically designed for high-level converting processes encompassing cast film, blown film, extrusion coating, solvent and aqueous coating and drying. Using a Windows® point-and-click interface, operators are able to monitor system operations, track quality standards, collect and trend historical data and store product recipes from a standard PC computer.
“When Davis-Standard and Black Clawson merged, we combined the best of our supervisory control technology so that converters have a multi-faceted control set that is simple to use,” explained Tarek Adly, product manager of drives and controls for Davis-Standard’s Converting Systems Group. “The ability to manage all critical system functions and data from a single point of control will improve internal efficiencies and ultimately, profitability.”
One of the primary advantages of the Integrator PRO is its user-friendly design. Converting machine components are tightly integrated into the system so that all process and control data can be accessed through a single operator interface powered by Microsoft® Windows® XP. Individual systems can be networked together using standard Ethernet TCP/IP connections for remote monitoring and future system expansion. The Integrator PRO is also supplied with multiple levels of security access, as well as a complete system back-up to minimize downtime and keep lines operational.
The new system can be installed on all new and existing machines, including the Black Clawson, Davis-Standard, Egan and ER-WE-PA equipment brands. For more information about the Integrator PRO, contact Tarek Adly at [email protected] or Mike Dickter, systems engineer, at [email protected]

Coperion Werner & Pfleiderer: The ZSK 18 MEGAlab Laboratory Extruder for Perfect Scale-up

Monday, January 2nd, 2006

To expand its series of twin-screw compounders (ZSK), Coperion Werner & Pfleiderer GmbH & Co. KG, Stuttgart, has developed a new laboratory extruder with a screw diameter of only 18 mm. The ZSK 18 MEGAlab is designed for developing formulations of plastics compounds, masterbatches, and powder coatings in the test laboratories of production facilities, and for carrying out basic tests and research in universities and research facilities. The ZSK 18 MEGAlab offers two particular advantages for these fields of application:

With a diameter ratio Doutside/Dinside = 1.55, a specific torque of Md/a³ = 11.3, and a maximum
speed of 1,200 min –1, it features the same process engineering characteristics as the rest of
the ZSK MEGAcompounder series. Thus the scale-up of an optimized current process or a process developed for new products to production-machine scale presents no problems.
Reliable basic tests can be carried out due to its extensive performance range, from batches of 200 g up to a throughput of 40 kg/h. This is a deciding point in its favour, particularly with expensive starting products or those available only in small quantities.

Because the design and process engineering of the ZSK 18 MEGAlab matches the larger Coperion Werner & Pfleiderer compounding extruders, its use in basic and advanced training is a
very promising application for the newest and smallest member of the ZSK MEGAcompounder family.
The processing section of the ZSK 18 MEGAlab laboratory extruder can be supplied in two standard models. The version with 10 barrels, i.e. with a screw length of 40 D (D = screw
diameter), is designed for developments in the handling and compounding of engineering plastics as well as of masterbatches of all types. Formulation constituents can be added directly to the melt downstream via the ZS-B twin-screw side feeder, whose flange connection has a quickaction coupling. A shorter processing section with 6 barrels, i.e. with a screw length of 24 D, is ideal for powder coating product- and process development. Various models of the peripheral equipment required upstream and downstream such as feeders, pelletizers, or chill rolls, are available for both versions. For simple, flexible use in product development and research, the ZSK 18 MEGAlab offers numerous other advantages:
The processing section has a modular construction. The 4 D barrels and the wide variety of screw elements can be exchanged as desired. Their 3.2 mm flight depth ensures that pellets
can also be reliably fed and melted.
The very high torque of 2 38 Nm is available via the hammered screw shafts and the optimized involute gear teeth in the screw elements.
The laboratory extruder, which is equipped with a powerful SPS control unit, can be operated easily via a touch screen and is largely self-explanatory; in case of problems, help can be obtained quickly via a modem.
The plug-and-play design ensures a quick, problem-free initial start-up; the only requirements are power and water connections. The integrated construction on a mobile base frame makes it easy to use the extruder in various locations.
Peripheral pieces of equipment such as e.g. a cooling unit and vacuum pump are installed in the base frame.
The quick-action couplings and small size of the extruder enable simple, fast cleaning or change-over of the processing section and thus a quick product change.
Finally, the ZSK 18 MEGAlab, like all the ZSK MEGAcompounders, fulfills all the features of European Patent EP 0 852 533 B1 and thus falls under its protection. The two versions of the
laboratory extruder with the standard lengths of 24 D or 40 D will be available at an extremely attractive price for immediate delivery beginning in April 2006.