Tailored ZE-UT-R twin-screw extruder for highly-filled masterbatch compounds
(Hannover, 20thSeptember 2012) KraussMaffei Berstorff has optimized its ZE-UT-R twin-screw extruder series by adding innovative features for compound filling. This technical improvement is the result of systematic research work performed in close co-operation with renowned compound producers. On the occasion of Fakuma 2012 inFriedrichshafen (hall A7, stand 7303/7304), KraussMaffei Berstorff will present the newcustomized extrusion line concept.
Compounds with 80 percent filler contents
“In the course of the last two years, KraussMaffei Berstorff has already sold 15 lines for the 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 in the production of blown film for carry bags, sacks or construction film, for instance. “Thanks to their excellent mixing properties and the high concentration of functional additives that offer unparalleled logistic and economic benefits, highly filled compounds are used to an ever increasing extent as masterbatches for film and sheet production”, explains Dr. Winkelmann.
Optimized processing section
The deep-flighted ZE-UT-R series exhibiting a D/d ratio of 1.74 and a correspondingly large free volume is particularly suited for the production of highly filled compounds. The available free volume is especially beneficial as high filler quantities or fillers of low bulk density must be mixed in. In addition, the high filler shares of up to 80 percent require long processing sections to ensure that the filler particles are perfectly incorporated into the plastics matrix. This is why the ZE extruders tailored for this task feature processing section lengths ranging between 50 and 56 D.Further highlights of these lines arethe 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.
Effective degassing
The type and number of degassing units is of particular importance for these applications. The introduction of fillers automatically involves the inclusion of air between the particles, which is eliminated from the 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 feed, degassing and mixing zones. The melt pressure required for pelletizing the well homogenized but highly viscous melt is built up by a gear pump of appropriate rating that is arranged at the discharge end of the extruder. The downstream underwater pelletizing system subsequently produces the final masterbatch pellets.
Photos:
Photo_1_120918_PM_EXTHAN_Zweischneckenextruder_ZE_UT: Thanks to the long residence time and the low shear load, theZE 90 UT x 56 D twin-screw extruder with its large free volume is particularly suited for the production of highly-filled compounds.
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Press contact:
Andreas Weseler
KraussMaffei Berstorff
Hannover site
Phone:+49 (0) 511 5702 586
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About KraussMaffei Berstorff
Around the world, the KraussMaffei Berstorff product brand stands for advanced, future proof extrusion solutions. The company’s product spectrum ranges from single extruders with application-specific tooling, to up- and downstream components and fully automated extrusion lines. This product range, plus a customer-specific choice of service modules, guarantees that KraussMaffei Berstorff is a robust system partner for customers such as the bulk chemicals, automotive, construction, packaging and pharmaceuticals industries. KraussMaffei Berstorff, part of the KraussMaffei Group since 2007, was created through a merger of KraussMaffei and Berstorff, an engineering specialist with a long tradition.
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About KraussMaffei Group
The KraussMaffei Group is among the world’s leading suppliers of machinery and systems for producing and processing plastics and rubber. Its products and services cover the whole spectrum of injection and reaction molding and extrusion technology, giving the company a unique position in the industry. The KraussMaffei Group is innovation-powered, supplying its products, processes and services as standard or custom solutions which deliver sustained added value along the customer’s value-adding chain. The company markets it’s offering under the KraussMaffei, KraussMaffei Berstorff and Netstal brands to customers in the automotive, packaging, medical, construction, electrical, electronics and home appliance industries. Continuing a long tradition of engineering excellence, the international KraussMaffei Group currently employs around 4,000 people. With a global network of more than 30 subsidiaries and more than 10 production plants, supported by around 570 sales and service partners, the company is close to customers around the world. KraussMaffei has been headquartered in Munich since 1838.
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