strong on performance, versatile and highly competitive …
TRANSCRIPT
STRONG ON PERFORMANCE, VERSATILE AND HIGHLY COMPETITIVE ON COST
36D twin-screw extruders – pipe extrusion series
IN PARTNERSHIP WITH INDUSTRY
KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide
Whatever you aim to achieve in plastics or rubber
processing, KraussMaffei is your partner. We are
the only company with intensive expertise across
the three main engineering fields. And we have a
strong track record in integrating this expertise to
develop new processes and systems.
Ready for any challenge
Our Injection Molding Machinery Division
supplies machinery and systems from 35 to 4,000
tonnes for standard applications and for all
processing variants, together with fully automated
solutions. We have a strong customer base in all the
relevant industries worldwide.
Our Reaction Process Machinery Division supplies
machines and complete systems for processing
polyurethanes and other reactive materials.
Completing our product portfolio, Automotive
Component Systems supplies foam molds, cutters
and routers. Our customer base is wide, with a
focus on the automotive, construction and white
appliances industries.
Our Extrusion Technology Division supplies
machinery and systems for compounding, for pipe,
profile and sheet extrusion, physical foaming, and
the production of technical rubbers and inter-
mediates for tire production. Machinery from the
company’s range – from single extruders to
complete extrusion lines – is used in many
industries, including chemicals, pharmaceuticals,
automotive, construction, furniture and packaging.
People for Plastics
We are the “people for plastics”. We are your
partners from the first exploratory discussion,
through development to commissioning, servicing
and operating your system, and final disposal. At all
times, you are assured of outstanding competence
in planning and engineering, as well as reliable and
fast spare parts, service and support.
Adding value for customers
We put our expertise to work for your success.
With machine ranges engineered for modular-
ity, we can deliver application-specific solutions
based on our wide range of standard modules and
specially engineered solutions. This strategy offers
customers technical and cost advantages.
Close to customers around the world
As an international company, KraussMaffei has
a presence in all the major markets for the plastics
and rubber processing industries and employs
around 3,000 people worldwide. Our sales and
service network keeps us close to all our
customers around the world.
Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive
Electrical / Electronics Packaging
High throughput and top quality with 36D twin-screw extruders
Our parallel 36D series twin-screw extruders have been specifically engineered for PVC processing. Our aim is to ensure you a good return on your investment through a combination of high throughput and top product quality. The platform for our wide product range is a modular machine concept that enables customized production solutions for cost-competitive, high-performance pipe extrusion.
Look at the striking advantages. The specially designed screw concept enables very gentle and homogenous plasticizing. Long processing units ensure stable processes and very reliable production in many different applications. You profit from high output, consistently excellent product quality and an outstanding price/performance ratio – over the whole performance range.
TRANSPARENT TECHNOLOGY
Meet the machine: take a tour of a 36D twin-screw extruder
Gear lubricating unit for filtering and heating/cooling the gear oil
Choice of AC or DC drive technology
High-torque gear system
Horizontal metering unit
Gravimetric weighing
Vacuum degassing with a sturdy waste pipe and quick connection for easy cleaning
Mixer
Feed throat
36D processing unit with molybdenum-plated screws and deep-nitrided, air-cooled barrel
Vacuum degassing unit with double solids separator
Diagram showing a 36D extruder equipped for foamcore pipe extrusion
Blowing agent metering
Material hopper
Suction conveyor
DESIGN bASICS
36D twin-screw extruders with an optimized screw concept for ultra-flexible processing of PVC pipe compounds
The 36D twin-screw extruders with their HPG
(High Performance Geometry) screw concept
are ideal in every way for producing U-PVC and
M-PVC pipe, foamcore PVC pipe and PVC-O pipe.
High Performance Geometry (HPG)
The HPG screw design incorporates an effective
preheating length with an extended output and
mixing zone. The whole length of 36 L/D can
be used for processing the PVC compound. This
results in significant benefits for processors.
The long effective preheating zone means a high
degree of flexibility to process a range of material
formulations – and to deliver maximum output.
The long metering zone makes it possible to build
up a higher pressure; this makes for a very stable
process and optimal control of the melt tempera-
ture in the whole output zone. The long mixing
zone, together with the optimized geometry of
the mixer element, ensures a perfectly homog-
enous melt. They have a positive impact on the
dispersal of additives and blowing agent through
the melt. The HPG screw concept reduces process
fluctuations – for all grades of PVC pipe compound –
to an absolute minimum.
Processing zones in a 36D twin-screw
extruder screw
Technical data and dimensions 36D twin-screw extruder – pipe extrusion series
KMD 75-36 E/R KMD 90-36 E/R KMD 114-36 E/R KMD 133-36 E/R
Output range [kg/h] 210-540 300-770 480-1200 600-1550
Power output [kW] 57 75 117 166
Screw torque, max. [Nm] 9400 15 000 30 000 48 000
Screw speed, max. [min -1] 54 45.5 35.5 31
Screw length [L/D] 36 36 36 36
Screw diameter [mm] 75 90 114 133
Screw temperature system Internal Internal Internal Internal
Extrusion height [mm] 1000 1150 1150 1150
Dimensions [mm]
Length including intake 4600 5420 6680 8030
Width incl. operator console 1300 1400 1420 1700
Height incl. hopper 2420 2520 2580 2660
1 = Feed zone2 = Precompression zone3 = High compression zone
4 = Venting zone5 = Metering zone6 = Mixing zone
4466 55 22 22 22 22 11
15D15D 21D21D
33
Raw material costs can account for up to 90%
of the manufacturing cost of plastic pipe.
Material costs can be slashed by producing PVC
foamcore pipe on 36D twin-screw extruders
combined with the foamcore pipeheads developed
by KraussMaffei Berstorff. The 36D twin-screw
extruders deliver premium product quality. They
can be used as main extruders or as coextruders.
Foaming the middle layer of the 3-layer pipe
reduces its density to as low as 0.6 kilograms per
cubic decimeter. This reduces the total density of
the composite pipe by up to 30% compared with
compact PVC pipe. The use of PVC foamcore pipe
in non-pressure applications is on the increase, for
example, for waste water pipe.
CUTTING MATERIAL COSTS
PVC foamcore pipe – produced on 36D twin-screw extruders
Extruder combination for the production of PVC foamcore pipe comprising a KMD 75-36 E/R for the outer
and inner layers and a KMD 90-36 E/R to produce the foamed middle layer
Page 12 36D twin-screw extruders for pipe extrusion
DETAILED PRODUCT INFORMATION
Our modular extruder concept – the recipe for success with cost-effective, customer- specific solutions
Like all the extruders built by KraussMaffei
Berstorff, the twin-screw extruders in the
36D series are engineered to an intelligent
modular design.
The extruder concept
Starting with a universal machine frame and
a standard barrel, KraussMaffei Berstorff can
supply customized extruders closely matched to
customer requirements. A closed-loop controlled
metering unit with a conveying spiral ensures
constant specific melt throughput, even with
different formulations. The metering unit is part
of the standard system. For a fully-automated
extrusion process, we also offer the option of
gravimetric weighing. This supports a highly
consistent process and lets processors make the
most of the potential for material savings. All
KraussMaffei Berstorff twin-screw extruders are
fitted with deep-nitrided barrels, manufactured
using a nitrided steel grade which produces an
extremely hard surface in the barrel bores. The
parallel screws are armored with a patented
molybdenum layer as standard. The molybdenum
armoring on the screw flights and the nitrided
barrel are an ideal friction couple, offering very
good surface slip characteristics and keeping
wear to a minimum.
Air-cooled barrels
The air cooling unit is part of our standard
system. The system uses aluminum half shells
with cast-in heating coils and integrated cooling
fins. The temperature sensors are fitted to the
sides of the barrel between each pair of cooling
blocks so as to keep control circuits as short as
possible. The system is completely maintenance
free. There is no risk of scaling, which can occur
with copper fins, so that constant high heat transfer
is always guaranteed.
Cooling fan
Aluminum cooling blocks with cast-in heating coils
Big savings in pipe manufacturing costs through
the use of fillers or by foaming the core layer
cannot be allowed to impact on pipe quality.
Special metering unit for high filler content
In the fiercely competitive PVC pipe market,
where producers are face constantly increasing
pressure on prices, there is a strong trend towards
taking filler content as high as possible. This is
especially the case for waste water pipe, but also
increasingly for pressure pipe. Producers not only
need to increase filler content, but also to obtain
very high output and meet market demands for
perfect product quality. Formulations with high
chalk content (up to 60%) demand significantly
higher energy input to process and this is
optimally satisfied by a longer effective
preheating zone. The 36D twin-screw
extruder range meets these technical
challenges with ease. The extruder is
fitted with a horizontal-vertical metering
unit to process compounds with a high
chalk content (over 30%). An optional
metering unit for regrind can also be
integrated. The 36D design guarantees
absolutely reliable degassing for normal
and highly-filled PVC compounds.
DETAILED PRODUCT INFORMATION
Lower material consumption and constant product quality – with twin-screw extruders from our 36D series
KMD 90-36 E/R equipped to process highly-filled PVC compounds
Horizontal metering unit with corotating twin metering screws
Gravimetric metering for regrind
Color metering
Vertical metering unit
Page 10 Detailed product information
Mobile operator panel
(option)
KraussMaffei Berstorff standard operator panel:
integrated in the control cabinet
Swivel-mounted operator panel (option)
DETAILED PRODUCT INFORMATION
The C5 control – one of the most advanced control and monitoring systems in the industry
Centralized control of the extrusion line
Meeting tough specifications for product quality and
output demands a stable, reliable production process.
This is where the C5 control system scores. As one of
the most advanced systems in the industry, it offers
dependable technology and intelligent functions for
centralized control and monitoring of extrusion lines.
For the operator, the C5 ensures optimal set-up and
start-up, and a clear, consistent overview of the pro-
duction process. Monitoring and control is facilitated
by efficient visualization of the status of different
extrusion line components on a series of screen pages.
Central synchronization of the whole line, including
multiple extruders, is fast and simple. The operator
panel allows direct intervention in the operation of
all key elements in the extrusion line. The current
operating status of the whole line is always displayed,
together with a customizable selection of seven actual
parameters. Prompts and alarm messages flash up
in your chosen language. The C5 offers extensive
documentation options and easy connection to a host
computer. The standard design features an integrated
operator panel; swivel-mounted or mobile panels are
offered as options. The swivel-mounted panel, for
example, enables the operator to run the whole line
from a position near the die.
Page 15
CUSTOMER bENEFITS AND APPLICATIONS
36D twin-screw extruders – pipe extrusion series
The parallel twin-screw extruders in our
36D pipe extrusion series are specially engineered
for processing PVC dryblend and highly-filled
PVC compounds, and for production of 3-layer
PVC foamcore pipe.
Your benefits at a glance:
· Low maintenance thanks to internal screw temperature control and air-cooled barrels
· Optimal control of the melt temperature over the whole output range
· Reliable degassing – also for highly filled compounds
· Higher pressure build-up thanks to longer metering zone
· High output and perfect product quality
· More flexibility with a wide processing window for different formulations
· Optimal plasticizing and mixing, eg, of masterbatch
· Outstanding melt homogeneity
· Optimized mixer geometry for excellent mixing
· Low compression ratio in the high-compression phase
· Cost savings from extended service life for the processing unit, higher output and less load on the gear system
· Outstanding price/performance ratio
Customer benefits and applications
PVC foamcore pipe
Highly filled PVC pipes
Socketed PVC pressure pipe
PVC pipes for pressure and non- pressure applications
Rely on us for a fast and competent response to
all your service needs anywhere in the world.
Whatever you need – from troubleshooting and
training to spares or repairs – we’re on the job.
We’re dedicated to supplying service quality on a
par with the outstanding quality of our machines
and systems. We offer far more than spare parts
and hotlines. We’ll work with you to choose the
best and most cost-effective solution for your
operation. We’ll help you test new applications
and we’ll plan customized service packages.
All-round service
Our service offering is broad. We’ll configure your
system, install and commission it, train your staff,
plan measures to minimize your downtime risk and
maximize productivity, and carry out maintenance,
repairs and upgrades. You’ll find us fast, reliable
and competent. Our hotline is manned by highly-
trained and experienced service technicians.
If necessary, we’ll get a technician to you quickly.
Remote diagnosis, interfacing directly with your
machine’s control system, can be a practical
alternative. Spares for all important wear parts are
available at short notice. We’re continuously
expanding our service network to speed up spare
parts shipment. Talk to us about the right service
solution for your business.
Customer trials and prototyping in our test lab
The Extrusion Division operates a test lab fitted
with the latest machinery and equipment. We can
run trials, produce prototype parts and fine-tune
processes on your behalf. We can work with you
to test and evaluate processes, machines and
equipment in order to identify the best approach
for a particular project. Our highly-qualified
application engineers are there to help you.
Training with high hands-on content
Courses are held in our lab and training centre,
or, optionally, on your premises. We offer
clearly-structured basic and advanced training in
operation, process control and maintenance for
KraussMaffei extrusion systems. On request, we’ll
plan and hold special courses on topics of your
choice. All participants spend a high proportion
of their training working hands-on with original
KraussMaffei machines. A well-structured
training program produces skilled operators
and technicians, which will positively impact
your up-time and productivity.
SERVICE WORLDWIDE
Service, support and spare parts – when you need them, where you need them
Worldwide hotlineWorldwide hotline numbersnumbers
Extrusion Technology ServiceExtrusion Technology Service
KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH
Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2
80997 Munich80997 Munich
GermanyGermany
Contacting us by postContacting us by postIf you need to contact any of our
international service or spare parts teams
by post, use this address:
KraussMaffei Technologies
India Pvt. Ltd.
Pune, India
Phone: +91 20 41404610
Fax: +91 20 414046 99
Email: [email protected]
Krauss-Maffei Extrusion
Technology (Zhejiang) Co., Ltd.
Jiaxing City, China
Phone: +86 573 86973888
Fax: +86 573 86967111
Email: [email protected]
KraussMaffei Technologies GmbH
Munich, Germany
Customer Service
Phone: +49 89 8899-2273 (electrical systems)
Phone: +49 89 8899-4380 (mechanical systems)
Email: [email protected]
Application Engineering
Phone: +49 89 8899-4094
Fax: +49 89 8899-2161
Email: [email protected]
Krauss-Maffei Italiana S.r.l.
Abbiategrasso, Italy
Phone: +39 02 94963181
Fax: +39 02 94699482
Email: [email protected]
Berstorff Krauss-Maffei OOO
Moscow, Russia
Phone: +7 495 9377554
Fax: +7 495 9701731
Email: [email protected] Krauss Maffei Corporation
Florence, USA
Phone: +1 859 2834307
Fax: +1 859 2830290
Email: [email protected]
Krauss Maffei de México
S. de R.L. de C.V.
Mexico City, México
Phone: +52 55 53082383
Fax: +52 55 53081727
Email: [email protected]
Krauss Maffei do Brasil Ltda
São Paulo, Brazil
Phone: +55 11 46129171
Fax: +55 11 46128366
Email: [email protected]
Krauss-Maffei (U.K.) Ltd.
Warrington, UK
Phone: +44 1925 644100
Fax: +44 1925 234284
Email: [email protected]
KraussMaffei Technologies GmbH
Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2546 ··· Fax +49 89 8899 - 4043www.kraussmaffei.com
KraussMaffei is a premium partner for the plastics and rubber processing
industries worldwide. KraussMaffei machines and systems are used wherever
plastics and rubber are converted into products. As a knowledge-driven
technology company, we build on many decades of experience and a strong
commitment to research and development.
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Our 36D twin-screw extruders have been engineered specifically for optimal processing of PVC formulations and for an outstanding cost-benefit ratio. With a wide product portfolio, based on our modular machine concept, we can offer application-specific production solutions which are high-performance and extremely cost-effective. Your decisive benefits include the specially engineered screw concept for very gentle, homogenous material processing. Long processing units increase the stability of the process and ensure a highly reliable production system across a wide range of applications. You profit from high output, constant product quality over the whole output range and an outstanding price/performance ratio.