Battenfeld Extrusionstechnik: “profile” with four lines

About 220 customers accepted the invitation from Battenfeld Extrusionstech-nik GmbH, Bad Oeynhausen, Germany to attend the Open House on profile extrusion, which was staged at its subsidiary SMS Extrusion, Kempen on May 23 and 24. Wolfgang Studener, Managing Director and CEO of Battenfeld Ex-trusion, was pleased with the success of this event: ‘Our decision to demon-strate our expertise in all respects by showing four profile extrusion lines in full production has met with an enthusiastic response from our customers.’
This Open House was part of a series of events, by which Battenfeld Extrusion-stechnik is celebrating its 25th anniversary jointly with its customers. After several highly successful presentations had already taken place last fall, the topics being ‘aluminium composite pipe production’, ‘high-solution line’ and ‘film extrusion’, the Open House about ‘profile extrusion’ was now the first European event in 2006. The last event in this series, planned for June 2006, will be a demonstration of the ‘drip irrigation pipe’. Two more customer events will be staged at the facilities of the com-pany’s subsidiary Battenfeld Extrusion Systems in Shunde, China and at American Maplan Corp. in McPherson, U.S.A.
‘With these four lines which we are demonstrating today, we want to prove two points: first, that we supply complete systems from a single source for virtually all applications, and second, that it is also possible to manufacture a wide range of spe-cial products with our very attractively-priced standard equipment. The best example is our winBEX, equipped with a parallel twin-screw extruder, on which we are manu-facturing PVC profiles with wood fiber content. Of course, we take special pride in our new model, the techBEX, which we are presenting here in Kempen for the first time. techBEX lines are manufactured and assembled in our very successful Chi-nese subsidiary Battenfeld Extrusion Systems and then sold by us to the European market. For our customers, this means that they receive equipment in well-known Battenfeld quality at an enormously favorable price’, Wolfgang Studener summa-rized the highlights.
WPC extrusion with a standardized system
‘In contrast to our competitors, who frequently recommend extrusion systems spe-cially designed for processing wood-plastic composites, we have set out to prove that these alternative materials can also be processed with standard equipment’, Manfred Jäcker, Product Manager profile extrusion, explained. For this purpose, Bat-tenfeld Extrusionstechnik presented a standard line from the winBEX series in Kem-pen, equipped with a BEX 2-92-28 V parallel twin-screw extruder and the well-known matching downstream package. The die used was a conventional coextrusion die with a dry caliber and vacuum tank supplied by the Swiss company Fentech, which also delivered the material to be processed. A co-extruded window main profile was manufactured with a core consisting of 50% PVC and 50% wood pellets, covered by two layers of PVC. ‘We are sure that the reluctance of many processors to make WPC products will be overcome, once they can also use standard equipment for this purpose. In this way, we can contribute to making such products more widely known and more interesting’, Jäcker commented.
techBEX - the highlight
The new techBEX line celebrated its premiere at the Open House. This low-cost standard line for the production of small profiles and technical profiles is entirely manufactured and assembled in China and on offer worldwide. ‘Compared to other known standard lines, techBEX is about 30% cheaper, but nevertheless on a high technological level’, the profile extrusion product group manager emphasized. techBEX lines can be equipped with either the BCE 1-45-25 D single-screw extruder with an output of 40 kg/h, or the BCE 1-60-25 D laid out for about 60 kg/h. The downstream equipment includes a calibrating table, a belt haul-off, a saw or, alterna-tively, a cut-off knife and an ejection table. Battenfeld demonstrated this profile line in Kempen with an output of 20 kg/h and a line speed of 3 m/min. The article manufac-tured was a transparent light slot cover made from Styrolux, an impact-resistant type of polystyrene supplied by BASF. The die came from TMVK, Gladbeck, Germany.
Jäcker was highly gratified by the customers’ response to this new line. ‘We sold four of these lines on the spot. However, the product is so new that we cannot re-spond to all enquiries as quickly as our customers would like.’
Twin-strand miniBEX
‘Also for the first time today, we are presenting our miniBEX, another standard line, with a twin-strand process in response to a request from our customers’, Jäcker said.
With the miniBEX, Battenfeld Extrusionstechnik launched a series of standard extru-sion lines for manufacturing small profiles in 2002, which has since been sold more than 100 times. This was the starting point for developing further standard models, such as the winBEX for window main profiles, soon to be followed up by the bigBEX for large profiles, as well as the low-cost models techBEX and the new baseBEX for the medium performance range; the latter is still in planning. At the Open House, the 220 visitors witnessed a miniBEX line with a conical twin-screw extruder manufactur-ing two PVC glass strips at 5m/min with an output of 90 kg/h. The materials used were a type of PVC-U supplied by Ineos and stabilizing agents from Baerlocher. The die came from one of France’s leading toolmakers, France Filière Plastiques. ‘For the twin-strand variant, we have also used standard components, including the cali-bration table. To ensure a high degree of flexibility, the twin caterpillar haul-off and the twin saw can be adjusted independently’, the profile extrusion product group manager explained.
Specialized line for PVC guttering
In contrast to the three lines described above, the fourth line presented was not standard equipment, but a highly specialized solution. Jäcker commented: ‘Here we are showing a process well-known in the production of cable conduits or siding articles, this time applied to a new task, i.e. cost-efficient production of guttering.’ On this line, coextruded roof gutters were manufactured by means of the postforming process, with a UV coating being applied to the top side. ‘The great advantage of this process is its speed. While the average speed in conventional extrusion is approximately 5 m/min, up to 30 m/min can be achieved with this process’, Jäcker pointed out the benefit. At the Open House, the line operated with a speed of 17 m/min and an out-put of roughly 600 kg/h.
The specialty of the process shown is that, after leaving the extruder, the melt first passes through a strip die and then through a small roller calender. Only thereafter, the smoothed and optionally embossed band is guided through the forming tool and cooled. Here too, the material used was a type of PVC-U from Ineos with Baerlocher stabilizers, plus a masterbatch from Holland Colors. ‘This complete line has already been sold to a Polish company. B-Tec, Italy has kindly agreed to let us use the tool and the calibration unit for this demonstration.’
A successful event
Finally, Wolfgang Studener expressed his thanks and appreciation to the many part-ner firms who contributed to the overall success of this event by their uncomplicated support. These were also present with small information booths in the large assem-bly hall in Kempen, where a ‘guest room’ and a presentation area had been set up especially for this Open House. ‘A special thank-you goes to Reisner, who has sup-plied us with a complete cooling water system to provide cooling water for four lines running simultaneously’, the Managing Director emphasized.

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