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KraussMaffei Berstorff  #12(118), 2012

The company KraussMaffei Berstorff has made an upgrade of twin screw extruder of the ZE-UT-R series, having introduced several innovative solutions for production of highly filled masterbatch compounds. These technical improvements became the result of persistent research work carried out in close cooperation with renowned compound producers. At Interplastica-2013 in Moscow the experts of KraussMaffei Berstorff will present the concept of the new tailored extrusion line.

“Over the past few years KraussMaffei Berstorff has sold 15 lines for production of highly filled PE or PP compounds with a talc or chalk share of up to 80 percent”, - reports Dr. Thomas Winkelmann, head of twin-screw extruder process technology at KraussMaffei Berstorff in Hannover. These compounds are used, for instance, in production of blown films for carry bags, sacks or construction films. “Due to their excellent mixing properties and the high concentration of functional additives that in turn offer unparalleled logistic and economic benefits, highly filled compounds are used to an ever increasing extent as masterbatches for film and sheet production” - concludes Dr. Winkelmann.

The deep-flighted screws of ZE-UT-R series provide a D/d ratio of 1.74 and, correspondingly -large free volume, which is particularly suited for production of highly filled compounds. The available free volume is especially beneficial when high filler quantities or fillers of low bulk density must be mixed in. High filler content (share of up to 80 percent) requires long processing sections to ensure that the filler particles are perfectly incorporated into the plastics matrix. Therefore the optimal length of ZE processing section ranges (depending on specific task) between 50 and 56 D. Further crucial points of these lines are the type of product addition and the number of metering systems used. In addition to the polymer in granular form and various additives, the filler material is partly introduced in the feed zone as well. The residual filler quantity is subsequently added in different portions via two side feeders arranged along the processing section.

The type and number of degassing units is of particular importance for these applications. “Feeding by fillers” automatically involves inclusion of air between the particles, which is eliminated from processing chamber by means of three atmospheric degassing systems and one vacuum degassing unit. It goes without saying that the screw geometry is tailored to the specific design of the feeding, degassing and mixing zones. The melt pressure required for pelletizing of well homogenized but highly viscous melt, is built up by a gear pump of appropriate characteristics that is arranged at the discharge end of extruder. The downstream underwater pelletizing system subsequently produces the final masterbatch pellets.

The product brand KraussMaffei Berstorff stands for advanced, high-end, future proof extrusion solutions worldwide. The company’s product spectrum ranges from single extruders with application-specific tooling, to up- and downstream components and fully automated extrusion lines. This broadest product range together with customer-specific service modules makes KraussMaffei Berstorff a robust and welcome system partner for lots of customers in chemical, automotive, construction, packaging and pharmaceutical industries. Since 2007 the trademark KraussMaffei Berstorff, that appeared via merger of KraussMaffei and Berstorff, became a brand of KraussMaffei Group.
KraussMaffei Berstorff

The company KraussMaffei Berstorff has made an upgrade of twin screw extruder of the ZE-UT-R series, having introduced several innovative solutions for production of highly filled masterbatch compounds. These technical improvements became the result of persistent research work carried out in close cooperation with renowned compound producers. At Interplastica-2013 in Moscow the experts of KraussMaffei Berstorff will present the concept of the new tailored extrusion line.

“Over the past few years KraussMaffei Berstorff has sold 15 lines for production of highly filled PE or PP compounds with a talc or chalk share of up to 80 percent”, - reports Dr. Thomas Winkelmann, head of twin-screw extruder process technology at KraussMaffei Berstorff in Hannover. These compounds are used, for instance, in production of blown films for carry bags, sacks or construction films. “Due to their excellent mixing properties and the high concentration of functional additives that in turn offer unparalleled logistic and economic benefits, highly filled compounds are used to an ever increasing extent as masterbatches for film and sheet production” - concludes Dr. Winkelmann.

The deep-flighted screws of ZE-UT-R series provide a D/d ratio of 1.74 and, correspondingly -large free volume, which is particularly suited for production of highly filled compounds. The available free volume is especially beneficial when high filler quantities or fillers of low bulk density must be mixed in. High filler content (share of up to 80 percent) requires long processing sections to ensure that the filler particles are perfectly incorporated into the plastics matrix. Therefore the optimal length of ZE processing section ranges (depending on specific task) between 50 and 56 D. Further crucial points of these lines are the type of product addition and the number of metering systems used. In addition to the polymer in granular form and various additives, the filler material is partly introduced in the feed zone as well. The residual filler quantity is subsequently added in different portions via two side feeders arranged along the processing section.

The type and number of degassing units is of particular importance for these applications. “Feeding by fillers” automatically involves inclusion of air between the particles, which is eliminated from processing chamber by means of three atmospheric degassing systems and one vacuum degassing unit. It goes without saying that the screw geometry is tailored to the specific design of the feeding, degassing and mixing zones. The melt pressure required for pelletizing of well homogenized but highly viscous melt, is built up by a gear pump of appropriate characteristics that is arranged at the discharge end of extruder. The downstream underwater pelletizing system subsequently produces the final masterbatch pellets.

The product brand KraussMaffei Berstorff stands for advanced, high-end, future proof extrusion solutions worldwide. The company’s product spectrum ranges from single extruders with application-specific tooling, to up- and downstream components and fully automated extrusion lines. This broadest product range together with customer-specific service modules makes KraussMaffei Berstorff a robust and welcome system partner for lots of customers in chemical, automotive, construction, packaging and pharmaceutical industries. Since 2007 the trademark KraussMaffei Berstorff, that appeared via merger of KraussMaffei and Berstorff, became a brand of KraussMaffei Group.


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