“blown film extrusion, it starts here” · 2010-05-25 · “blown film extrusion, it starts...

“Blown Film Extrusion, It Starts Here”

Presented by:Name: Steve GammellTitle: Sales Manager – North AmericaCompany: Macchi North America Plastic Machinery, Inc.

Resin Blending SystemsIn-Line Scrap Reclaim MethodsExtruders & Filtration SystemsBlown Film DiesAuto Profile Control MethodsAir Ring TechnologyIBC Systems

The Original Method

Volumetric Blenders

Gravimetric Batch Blenders

Continuous Gravimetric Blenders

Batch gravimetric blenders weigh individual resin components in a single common weigh vessel The weighed resins are then combined in a mixing chamberWhen used with a gravimetric extrusion control system a second load cell measures the loss in weight of the mixed batch as the extruder consumes the resin

Load cellGravimetric

extrusion control(continuous Loss-in-

weight)

Weight bin on 2 load cells(Gain-in-weight

Gravimetric blending)

MIXER with mixing paddle

Containing 3 batches on continuous mixing

Slide gate

Capacitive level sensor(min level)

Capacitive level sensor(max level)

Gravimetric Batch Blender

Each resin component has a dedicated loadcell to track individual resin consumptionThe component resin is continuously weighed and feed into the cascade mixing chamberThe combined component resin consumption data is used to gravimetrically control the extruder speed

312

Trim & film scrap grinding

Ground fluff extruder mounted refeed units

In-Line trim repelletizing system

Top View Side View

Film Trim Delivery Trim Feed Via Twin Screw

Extruder baseExtruder drive motor & gearbox arrangementsFeed-throat types & barrelsBarrel heating & coolingExtruder feed-screwsFiltration systems

The extruder base must be built with sufficient strength to support the extruder itself in it’s initial transportation

The base must provide the rigid strength to support its components and handle the axial stresses associated with the feed screw as well as the thermal expansion of the barrel and keep all the components in alignment

AC Belt Drive AC Direct Drive

Gearless Direct Drive

Typically manufactured from alloy steel to withstand 10,000 + PSIBarrels are lined with more wear resistant centrifugally cast long wearing boron alloyMore abrasive polymers require tougher alloy liner materials to extend the useful service life of the barrelWorn barrels/feedscrews contribute to numerous processing issues, check them for wear frequently

Typically manufactured from flame hardened 4141 steel, with Chrome rootsFlight surfaces, require more wear resistant materials such as Colmonoy 56/83full width or X830Flight materials are either full width or in-laidMixing sections for improved polymer homogenization & melt temperature control

Manual lever style screen changer

Manual hydraulic screen changer

Hydraulic screen changer

Continuous screen changer

Manual Lever Type Hydraulic Manual Type

Hydraulic Semi-Continuous Hydraulic Continuous

Normal Operating Position Screen Change Position

Bottom feed spiral mandrel die, mono layer or CoEx in either a oscillating & stationary configuration

Side feed spiral mandrel die, mono layer or CoEx configurations

Stack or pancake style die, CoEx die

Typically machined from ANSI 4140 & 4340 machinery steel.Dies are typically plated with either electroless nickel or chrome plating for improved polymer release properties, lower COF as well as to protect the die from corrosion. Factors in die design: material types, material properties & anticipated production rate by layer

Ten Layer Die

Principle Method

Principle Method

3 – secondary flow-Venturi control

2 – primary flow-

1 – downward flow-

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PRESENTED BYName: Steve GammellTitle: Sales Manager North AmericaCompany: Macchi North America Plastic Machinery Inc.