Profile Extrusion beyond of PVC

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Martin Bates
5 years ago
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1 Engineering Value Page 1 Profile Extrusion beyond of PVC Extrusion of technical profiles with new materials

2 Page 2 Agenda A new changing market, the lighting industry Challenge for different material properties KraussMaffei solutions Live in our technikum Integration of new requirements

3 Page 3 A new changing market, the lighting industry Krauss Maffei offer a large variety of equipment to process many different Material, using in a wide range of application. The finished profile are used in the automotive, furniture, electrical and constructions industries. In the last couple of years a new sector become to be important the lighting sector.

Page 4 A new changing market, the lighting industry The LED

Coextruded lamp housing appeared, they simplified enormously

4 Page 4 A new changing market, the lighting industry The LED technology brings a revolution, now the light can be adapted and placed almost everywhere. New design, new profile shapes are needed. Coextruded lamp housing appeared, they simplified enormously the lamp composition, LED, electronic, everything is integrated. But the extrusion process becomes more and more complex

5 Page 5 Challenges for different material properties To reach in this field the endproduct requirements; - Geometrie ( difficult shapes, tolerances) - Optical and surface (Tranparency, glass clear, translucent or opaque, gloss ) - Form Stability (mechanical properties, impact, against scratched, weathering exposure) two Materials dominate the market; Polycarbonate (PC) and Polymethylmethacrylat (PMMA) One important part the processing and the tool; In the tool and calibration you will find all the experience to reach the requirements. It give us the direction which machine and configuration we have to propose.

Page 6 KraussMaffei solutions Depending on customer requirements KraussMaffei Berstorff can propose different machine solutions with grooved or smooth bush and with integration of melt pump.

6 Page 6 KraussMaffei solutions Depending on customer requirements KraussMaffei Berstorff can propose different machine solutions with grooved or smooth bush and with integration of melt pump. KME D/C KME D/C KME B/R KME B/R KME D/P KME B/R KME D/P Output max. (kg/h) PP/HDPE 3,5-4, Output max. (kg/h) PC 3, Screw Length L/D Grooved / Smooth Bush S S G G S G S Screw diameter (mm) Extrusion heigth (mm)

7 Page 7 KraussMaffei solutions Two or more layers implement to have Coextruder solutions KME 20-25D and KME 30-25D KME 38-30D and KME 45-30D

Page 8 KraussMaffei solutions Dependant on

KraussMaffei Berstorff can offer different

Special adapted calibration table, water

Water bath, spray tank with conveying belt

8 Page 8 KraussMaffei solutions Dependant on customer processing characteristics KraussMaffei Berstorff can offer different downstream equipments. Special adapted calibration table, water flow, tempering unit. Water bath, spray tank with conveying belt Haul-off with band or caterpillar, Special cutting, saw or chipless, Ionisation air system Reception table

Page 9 Live in our technikum Efficient production of lighting tubes from Polycarbonate Main Extruder KME 60-30D/P Nominal drive power 37 kw Smooth bush, with tempering unit C6 Control system with

9 Page 9 Live in our technikum Efficient production of lighting tubes from Polycarbonate Main Extruder KME 60-30D/P Nominal drive power 37 kw Smooth bush, with tempering unit C6 Control system with possibility of complete line integration Standard suction unit (need pre-dryed material) Coextruder KME D/P 60 angle mounting on traversing system nominal drive power 23 kw Smooth bush, with tempering unit with own C6 control system, but synchronised with main extruder (master, slave) Display used for video camera system Standard suction unit (need pre-dryed material with Farbbatch premixed)

10 Page 10 Live in our technikum Efficient production of lighting tubes made in Polycarbonate Coextrusion tool for polycarbonate transparent profile coextrusion die, two dry calibrator 250 mm. 1,5 m/min Calibration table 6 meter length design for multi purpose application ECO Version energy efficient with one tempering unit and flow meter for calibrator, controlled via C6 from main extruder Electrical height and length adjustment 3 vacuum pumps with frequency controlled drive system. 45 vacuum outlets 30 water outlets

11 Page 11 Live in our technikum Efficient production of lighting tubes made in Polycarbonate Haul-off Cutting combination Belt haul-off width 135 mm contact length 1100 mm fix stop on upper belt adjustable per handwheel (avoid profil crushing) Chipless cutting Heated knife Servomotor drive for cutting and table integration of ionisation air curtain (to avoid chips in profile after cutting) Monitoring camera observation of deposit table,

12 Page 12 Live in our technikum Efficient production of lighting tubes made in Polycarbonate Deposit table total length 3 meter with conveying belt for profile extraction and 1 meter cross conveyor for 500 mm Profile as cache area Cache for possibility of Robotics integration. Profile escape trap incase of full cache Video Display film about automatic packaging unit with double linear roboter.

13 Page 13 Integration of new requirements Efficient production of lighting tubes made in Polycarbonate In this field customer expect more and more to propose solutions or to joint developments to meet their specifications. We currently are facing three major challenges. The automatic data acquisition with central control and supervision system, according to reach industrie 4.0. In line integration of Quality Control, Profile measurement. Handling system, Profile identification, packaging including protection film,

Page 14 Integration of new requirements Efficient production of lighting tubes made in Polycarbonate KraussMaffei Berstorff holds a unique position in the plastics and rubber processing industries.

14 Page 14 Integration of new requirements Efficient production of lighting tubes made in Polycarbonate KraussMaffei Berstorff holds a unique position in the plastics and rubber processing industries. We can offer complete extrusion package solutions that are reliable and stable in value. Using innovative technologies, we strive at enhanced cost-effectiveness and even higher efficiency in tomorrow s production. This is what our unique Engineering Value performance slogan is based on. A promise that reflects our outstanding commitment and our pursuit of actively contributing to our customer s value chain.

15 Page 15 Thank you for your attention! Eric Sanson Product Management Profile KraussMaffei Technologies GmbH

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