COMPOUNDING & REPROCESSING EXTRUSION SYSTEMS

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Rosamund Heath
6 years ago
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1 COMPOUNDING & REPROCESSING EXTRUSION SYSTEMS

2 6-inch Scrap Reclaim Extruder Application Film Scrap APPLICATION GUIDE Design Standard Ram Stuffer Dual Diameter Scrap Reclaimer Hot Melt Foam Scrap Davis-Standard s single screw compounding and reprocessing systems are engineered to satisfy specific applications and requirements. Extruders feature heavy-duty gear reducers, specially designed feed throats, single or multi-venting capabilities, and advanced process controls. Compounding and reprocessing systems extruder sizes from 1 1/2 inches (40mm) to 10 inches (250mm). Specific feed systems include Ram Stuffer, Dual Diameter Scrapper, Scrap Reclaim, Melt Fed, and standard designs. All systems incorporate proven process engineered feedscrew designs with optional venting. We also supply complete process feed systems for volumetric, gravimetric, weigh blending, or starve feeding as required. Injection Molding Scrap Blow Molding Scrap Fiber Scrap Sheet- Thermoforming Scrap Continuous Mixer Feed Twin Scew Feed Virgin Pellet w/ Additives Selecting the Right System We custom engineer our compounding and reprocessing systems to meet exact specifications. To determine the right system for the process, we work collaboratively with customers to analyze and consider several parameters. These include: Solids feeding and conveying Compression and melting Development of a homogeneous melt Addition of non-melting materials or low melt viscosity components Devolatization Decompression, additional homogenizing and increase of suitable head pressure Melt filtration Pelletizing Shredder Extruder Pelletizer

Single Screw Extruder Options THERMATIC SERIES EXTRUDERS The Davis-Standard Thermatic is known as an industry workhorse.

multiple processing requirements and applications.

and abrasion-resistant liner materials available Optional vent stack for removal of volatiles from extrudates through the barrel vent opening

capacity blower systems available Water-cooled extruders include a stainless steel tank, pump, manifolds and valving, flex hoses, and water-cooled

cooling tubes with cast-in NPT fittings on the heater bottoms for water connections Motor Available in AC or DC variable speed, externally

Reducer Specifically designed by Davis-Standard for extruder applications Heavy wall, two-piece iron housing Input shaft driven forced lubrication

cylindrical roller thrust bearing mounted in integral thrust housing Note: On 8-inch (200mm) extruders or larger, the thrust bearings are tapered.

3 Single Screw Extruder Options THERMATIC SERIES EXTRUDERS The Davis-Standard Thermatic is known as an industry workhorse. This premium extruder is engineered for durability, high processing rates, increased mechanical and thermal capacity, and quiet operation for multiple processing requirements and applications. Barrel Designed for 10,000 psi operating pressure One-piece bimetallic cast-in liner Rupture disc behind front flange Optional corrosion-resistant and abrasion-resistant liner materials available Optional vent stack for removal of volatiles from extrudates through the barrel vent opening Cooling System Heater/Coolers For air-cooled extruders, air blowers are mounted on individual heater shrouds Standard blowers or optional high capacity blower systems available Water-cooled extruders include a stainless steel tank, pump, manifolds and valving, flex hoses, and water-cooled heat exchangers Cast aluminum heaters are precision bored and securely bolted to the barrel Water-cooled heaters supplied with cast-in serpentine cooling tubes with cast-in NPT fittings on the heater bottoms for water connections Motor Available in AC or DC variable speed, externally ventilated or fan cooled Mounting plate is movable to adjust belt tension when belt driven; motor mounting is rigid when direct coupled Gear Reducer Specifically designed by Davis-Standard for extruder applications Heavy wall, two-piece iron housing Input shaft driven forced lubrication system All gearing is single helical AGMA quality class 11 or better All shafts supported on single row, tapered roller bearings High capacity cylindrical roller thrust bearing mounted in integral thrust housing Note: On 8-inch (200mm) extruders or larger, the thrust bearings are tapered. Roller and thrust housings are not integral. Oil Circulation System Input shaft mounted positive displacement of oil pump 25 micron oil filter with differential pressure indication Water-cooled heat exchanger Cooling System Barrel Vent Motor Gear Reducer Heater/Cooler Motor Coupling Oil Circulation System

COLD FEED EXTRUDERS Davis-Standard s cold feed extruders are able to handle a wide range of polymer requirements.

10-inch (255mm) Single Screw Compounder 10-inch (255mm) 10:1 Melt Feed Extruder Ram Stuffer Extruder Ram Stuffer Scrapper Extruder MELT FED EXTRUDERS Melt fed extruders from Davis-Standard are

This melted compound is then pumped through a strand die or die-faced pelletizer to form pellets.

4 COLD FEED EXTRUDERS Davis-Standard s cold feed extruders are able to handle a wide range of polymer requirements. They are available in air or water-cooled models with integral or free-standing control panels. These extruders have been designed to provide processors with a rugged, low maintenance system. 10-inch (255mm) Single Screw Compounder 10-inch (255mm) 10:1 Melt Feed Extruder Ram Stuffer Extruder Ram Stuffer Scrapper Extruder MELT FED EXTRUDERS Melt fed extruders from Davis-Standard are engineered to accept plastics that have already been melted and compounded in a batch mixer or continuous compounder. This melted compound is then pumped through a strand die or die-faced pelletizer to form pellets. Our melt fed extruders minimize the addition of mechanical or thermal energy often associated with unwanted temperature increases. Melt temperature stability is easily achieved when combined with Davis-Standard s feedscrew designs and patented melt temperature control system. MERRITT MX EXTRUDERS Merritt MX Extruders are available from 2- to 12-inch to match any reclaim operation. Whether running small amounts of scrap several times a month or running day in and day out, the MX extruders are engineered to perform and are built to last. Specialty Extruders for Reprocessing Davis-Standard supplies a complete line of reclaim extruders and systems for post-industrial and post-consumer processing. This includes reprocessing capabilities for low and high bulk density scrap, lightweight feedstocks, printed scrap, foam scrap, fiber scrap, rolled scrap, and loose film scrap. The Ram Stuffer, Scrapper, and Scrap Reclaim extruder models are widely used for these types of applications. RAM STUFFER EXTRUDER This extruder design is engineered primarily for processing light feed stocks. It features a feed throat equipped with a pneumatic ram to stuff material into the screw. A grooved feed throat improves performance through positive material conveyance and interaction with specifically designed barrier screws. Other advantages include: A large feed opening approximately 3 diameters long by 3 diameters wide eliminates choking with light materials in the throat entrance. The ram system is housed separate from the throat and hopper, minimizing transfer of fluff into the plunger enclosure. A filtered air vent and cleanout port above the ram eliminates air buildup, or vacuum, and allows for easy clean-out. A seal in the rear of the feed section prevents leakage of fluff or powder around the screw shank. Standard L/D ratios are 34:1 and 38:1, which provide better process ability. SCRAPPER EXTRUDER The Davis-Standard Scrapper is a dual-diameter single screw extruder engineered for processing extremely light bulk density feed stocks. The Scrapper incorporates a large diameter feed area with a smaller diameter processing section. The feed section has an extra large opening and is water-cooled. This allows the light material to reach the deep flighted screw where it is captured and forwarded through the transition into the melting/devolatization/pumping zones. Other advantages: The gear reducer, feed section, and drive motor are mounted to a rugged, fixed base.

SCRAP RECLAIM EXTRUDER For light to medium bulk density feed stock, Davis-Standard has the Scrap Reclaim Extruder (S.R.E.). This extruder utilizes an extra wide tangential feed throat.

5 The transition and barrel are mounted on a rugged moveable base with casters and tracks to allow access to the screw for cleaning/removal. Barrel sections are bimetallic lined and the transition to the smaller diameter section is nitrided for long wear. SCRAP RECLAIM EXTRUDER For light to medium bulk density feed stock, Davis-Standard has the Scrap Reclaim Extruder (S.R.E.). This extruder utilizes an extra wide tangential feed throat. A grooved horizontal liner creates a positive material conveyance through the use of specifically designed feedscrews. Heavier materials can be processed by using a starve-feed device. WIDE MOUTH EXTRUDERS The Merritt wide mouth feed throats are designed to allow feeding of chip, flake or irregular sized materials including hot melt into an oversized throat that has an aggressive feed design. Scrap Reclaim Extruder Merritt Cascade Reclaim System Panel Metal Detector Shredder Transfer System Cascade System Pelletizer Extruder 2 Extruder 1 The Merritt Cascade Reclaim System is designed to process polymer scrap materials with higher contamination levels. The two extruder system is excellent for changing bulk densities and removing gasses. Shredded or ground material is fed into the ram extruder, then through a screen changer to remove solid contaminants. A melt pump pushes the polymer to the feed hopper of the second extruder where it is exposed to the atmosphere and volatile gasses are vented off. Additives can be metered into the process at this point. As it exits the hot-melt extruder, the processed polymer can be filtered a second time or sent directly to the pelletizer for final processing. Davis-Standard Systems Our reprocessing and compounding systems typically incorporate temperature controls, extruder drives, melt filtration, and pelletizing systems. Temperature controls can be as simple as a stand-alone discrete panel, to a sophisticated and integrated PLC-based line control system. Extruder drives are either AC or DC variable speed. Melt filtration systems include single breaker plate to manual screen changers, to hydraulic slide plate screen changers, to PLC controlled continuous process backflushing designs. Pelletizing systems include strand, water-ring, and underwater units. Systems can be combined with other Davis-Standard extrusion equipment to accommodate in-line processing of sheet and profiles. Pelletizer

The Davis-Standard, LLC Difference There is a reason why our equipment is recognized as being among the best in the world our service and expertise are focused on supporting our customer s investment.

Production scale and laboratory equipment are available to analyze various processes.

specific applications. FEEDSCREWS Our feedscrews are superior in design, construction, and versatility.

Each feedscrew is manufactured on the basis of individual customer parameters encompassing output rate, melt temperature, pressure requirements, extruder output consistency and stability, melt

6 The Davis-Standard, LLC Difference There is a reason why our equipment is recognized as being among the best in the world our service and expertise are focused on supporting our customer s investment. Technology Center TECHNICAL CENTERS We have fully staffed Technology Centers in the United States and Europe, making our screw design and technical capabilities among the best in the world. Production scale and laboratory equipment are available to analyze various processes. A team of experienced and knowledgeable process engineers and screw design specialists collaborate with customers to evaluate process parameters and implement feedscrew technology best suited for specific applications. FEEDSCREWS Our feedscrews are superior in design, construction, and versatility. Output is maximized and melt temperature is controlled, while thoroughly homogenizing the polymer melt. Each feedscrew is manufactured on the basis of individual customer parameters encompassing output rate, melt temperature, pressure requirements, extruder output consistency and stability, melt homogeneity, and melt quality. Feedscrews CONTROLS Davis-Standard is one of the leaders in advanced process control systems (CIM) for the plastics and rubber industries. The EPIC III color touch-screen operator interface and supervisory control system features patented dual-thermocouple control, responsive closed loop line control with an operator friendly graphical interface featuring pictorial control screens, trending, SPC/SQC networking and other data acquisition capabilities. All systems are custom engineered in-house for system reliability. 24/7 CUSTOMER SERVICE/AFTERMARKET SERVICES We have service technicians available 24 hours a day, seven days a week, to handle parts inquiries and emergency service needs. Parts, if in stock, can be shipped within one day. We maintain complete mechanical and spare parts inventories ranging from feedscrews and barrels to thermocouples and motors. On-site service by a technician is also available. We provide aftermarket services for all Davis-Standard heritage brands including Black Clawson Converting Machinery, Sterling, Egan, Hartig, Killion, NRM Extrusion, ER-WE-PA, Betol, Merritt, and Repiquet. For parts and service call EPIC III Controls Spare Parts

650/1000mm Scrapper Extruder 6-inch Scrap Reclaim Extruder

Get to Know Us Davis-Standard has set the standard in

We hope you will take the time to get to know us.

They extend to our professional training experts, laboratory

7 650/1000mm Scrapper Extruder 6-inch Scrap Reclaim Extruder 6-inch Polycycle Reclaim System 8-inch Ram Stuffer Extruder Get to Know Us Davis-Standard has set the standard in compounding and reprocessing equipment and systems. We hope you will take the time to get to know us. Our capabilities go far beyond our equipment. They extend to our professional training experts, laboratory personnel, design engineers, and hands-on field engineers who will work with you every step of the way.

8 Davis-Standard Business Areas Aftermarket Services Blow Molding Systems Blown Film Systems Cast Film Systems Compounding Systems Elastomer Systems Extrusion Coating and Laminating Systems Fiber Systems Foam Systems Laboratory Equipment and Specialty Systems Liquid Coating and Laminating Systems Pelletizing Systems Pipe, Profile and Tubing Systems Process Control Systems Recycle/Reclaim Systems Sheet Systems Twin Screw Systems Unwinding and Winding Systems Wire and Cable Systems #1 Extrusion Drive Pawcatuck, CT USA Tel: Fax: Room 1007, Jing An China Tower 1701 Beijing (W) Road Shanghai P.R. CHINA Tel: Fax: Unit 33 Hainge Road Tividale, Oldbury, West Midlands B69 2NY UNITED KINGDOM Tel: Fax: North First Street Fulton, NY USA Tel: Fax: South Adamsville Road Somerville, NJ USA Tel: Fax: Mettmanner Strasse 51 D Erkrath/Düsseldorf GERMANY Tel: Fax: Davis-Standard, LLC. All Rights Reserved. JWRP5K1007

RANDCASTLE S Taskmaster

RANDCASTLE S Taskmaster Taskmaster The 36:1 L/D Taskmaster can do more than any other single screw extruder mixing and devolatilizing like a twin with triple vents. The patent pending mixing technology, previously available only