Pelletizing process and equipment selection - K-Tron

Pelletizing process and
equipment selection
Increase your profitability
for high filled thermoplastics
Klaus Arlandt| Sales Manager Asia | May 2014
Pelletizing process and equipment
selection for high filled thermoplastics
About Maag-Automatik
The group is a merger of the two companies
Maag Pump Systems AG and Automatik Plastics Machinery GmbH.
 Ownership: PSG , a Dover Company , USA, $8 billion revenue, 34,000 employees
 Sales turnover 2011 - 2013 of Maag-Automatik: 130  145 mEUR
 Homepage: www.maag.com
Maag Pump Systems AG
 Headquarters: Oberglatt, Switzerland
 270 employees
 Leading company for pumps/filters
Automatik Plastics Machinery GmbH
 Headquarters: Grossostheim, Germany
 240 employees
 Leading company for pelletizers
Pelletizing process and equipment
selection for high filled thermoplastics
About Maag-Automatik: Comprehensive solutions from a single source!
As an integrated group, the company
offers complete systems as well as
top-quality components spanning the
entire production chain from the reactor
or the extruder tip to finished pellets.
For customers this means:
Underwater
pelletizer
SPHERO®
Screen
changer
Melt
pump

One stop supplier

Perfectly adapted interfaces

Less manpower required
for engineering
Pelletizing process and equipment selection
for high filled thermoplastics
Table of Contents
1. Process and equipment selection
 Market expectations and market offers
2. Material properties, pellet shapes, processes
 Influences to equipment selection
3. How to increase your pelletizing system performance…
 Customized solutions
4. A better profitability?
 Investment as per life-cycle-costs
April 2014 | Page 4
1. Process and equipment selection
Offers and expectations
What do compounders request?
 High product quality
As better the quality as higher the selling price can be!
 Low production costs
In order to maximize profit
And what can you expect?

State-of-the-art pelletizing and melt handling systems from
one single source, tailored to your needs

The most comprehensive range of products and services

Impartial technical advice at any stage of your project

Worldwide service network

Skilled staff all around your solution
April 2014 | Page 5
1. Process and equipment selection
The pelletizing system selection process
Some questions to be clarify first
Type and amount of the product you want to
pelletize, actual and in a 3 - 5 year planning?
Does your customer (the end-user) specify
some detail properties of your product?
Any special environmental issue or legal
requirement to be considered?
Brand-new production, or revamping old
equipment, or planned capacity increase?
Do the products have special properties, are
they abrasive or are they moisture sensitive?
How large is the space in the factory?
Expected investment and production cost?
sufficient spare
 Plan
capacity for future time!
 Would he prefer round or
cylindrical pellets?

Consider while planning;
later is more expensive!
Different pellet shapes
 cannot be blended!
Plan appropriate solution
 details!
 Don’t forget infrastructure!
determines
 Investment
< 15 % of production cost!
Continued 1
April 2014 | Page 6
Pelletizing process and equipment selection
for high filled thermoplastics
Table of Contents
1. Process and equipment selection
 Market expectations and market offers
2. Material properties, pellet shapes, processes
 Some background information
3. Customized solutions
 How to increase your pelletizing system performance…
4. A better profitability ?
 Investment as per life-cycle-costs
April 2014 | Page 7
2. Material properties, pellet shapes, processes
Some material specific background
We must consider specific material properties during system selection

Some materials are brittle
 dust formation and irregular shape

Some materials are abrasive
 avoid damage of machine parts

Some ingredients are sensitive to moisture
 secure accurate recipe and processing

Compound application requires uniform particle size;
similar to the other recipe components of finished product

Recipe components are expensive
 only little material waste acceptable

For small production lots, almost no stocks
 frequent product change required
April 2014 | Page 8
2. Material properties, pellet shapes, processes
Basic equipment background info
Pelletizing options for compounding applications
Dry cut with PRIMO /
M-ASG / BAOLI or JSG
Underwater cut with
SPHERO®
The correct choice
offers easy processing
and smooth operation
In the end it
increases your profits
April 2014 | Page 9
2. Material properties, pellet shapes, processes
Select the suitable system – background info
Pellet size:
- normal (~ 3 mm)
- micro pellets
 both strand and underwater
 preferably underwater
Pellet shape: - spherical
- cylindrical
 underwater
 strand
Brittle or fragile products
 preferably underwater
(strand possible with special processing
features)
Moisture sensitive products or
ingredients
 both strand and underwater, but with
special processing features
Alternative: EBG belt conveyor pelletizer
Shear sensitive melt
 preferably strand
Abrasive products
 both strand and underwater
with features
Production lot size
 strand
 underwater
(determines frequency of product
changes/system productivity)
April 2014 | Page 10
2. Material properties, pellet shapes, processes
Background info strand pelletizing
Conventional strand pelletizing
 Polymer strands are
extruded into a water bath
and cooled there
 Upon start-up, the strands
are manually threaded
through the system to the
pelletizer
 In the pelletizer a draw-in
section transports the
strands to the cutting
section, where they are
cut into pellets
 Process automation
possible  JSG
April 2014 | Page 11
2. Material properties, pellet shapes, processes
Background info underwater pelletizing
Underwater pelletizing systems SPHERO®
TIC
Legend:
1 Diverter valve
2 Die plate
3 Cutting chamber
4 Drive with knife support
5 Process water distribution
6 Centrifugal dryer
7 Process water system
April 2014 | Page 12
2. Material properties, pellet shapes, processes
Underwater versus strand pelletizing
Comparison
of pellet shape
Process
Underwater pelletizing
Strand pelletizing
Pellet shape
Spherical
Cylindrical
Bulk density
~ 10 % higher
−
Fines / dust
~ 10 % less
−
Behavior during heating up
or cooling down
Point contact thus less
sticking tendency
Surface contact thus higher
sticking tendency
Pellet size distribution
± 15 %
±5%
(± 10 % possible by using the
liquid-heated die plate)
Influence to polymer
respectively to the process
Pressure loss p > 60 bar
Pressure loss p < 30 bar
due to smaller bore diameters at
the die plate
Thus higher temperatures inside
the melt, thus higher shear rate
April 2014 | Page 13
Pelletizing process and equipment selection
for high filled thermoplastics
Table of Contents
1. Process and equipment selection
 Compounder’s expectations and market offers
2. Material properties, pellet shapes, processes
 Some background information
3. Customized solutions
 How to increase your pelletizing system performance…
4. A better profitability?
 Investment as per life-cycle-costs
April 2014 | Page 14
3. How to increase your pelletizing system
performance…
… by using the proven solutions for compounding applications
PRIMO E
PRIMO S / BAOLI
PRIMO Plus
The cantilevered
pelletizer for small
production lots and
lab applications
 800 kg/h.
PRIMO S/BAOLI
for small to medium
throughputs and for
the most standard
applications
 3,000 kg/h.
PRIMO Plus for
small to medium
throughputs and
more »challenging«
products
 5,000 kg/h.
M-ASG
The pelletizer for
automatic systems
(JSG) and for the
highest throuputs
 12,000 kg/h.
April 2014 | Page 15
3. How to increase your pelletizing system
performance…
PRIMO E: Quick access without tools to all cutting chamber
components

Very fast cleaning –
e.g. for product changes

Easy access to all components of
the cutting head – without tools
After a few seconds the cutting head is ready
for inspection, service and maintenance!
Time is money
April 2014 | Page 16
3. How to increase your pelletizing system
performance…
Benefits with Primo 200 E
Primo 200 E :
Easy cleaning, fast access to the cutting chamber better than competitor
Customers comment :
Compared to the competitor, the cleaning is faster by 10 minutes
What does that mean to you ?
Masterbatch application:
Cleaning frequency per day :
Time saving:
Time saving / week / month
500 kg /h, Color masterbatch
approx. 3 to 6 times a day ( 1 to 2 times/ shift ) + for product changes ?
30 to 60 minutes a day or more !
2,5 to 5 hours / week = 10 hours / month = 120 hours / year
Additional production possible: 120 x 500kg/h = 60.000kg/h / year.
Price of Masterbatch:
Average 5,-- € / kg (from 2 to 12 Euro/kg depending on grade)
Possible additional Turmover:
Profit:
This means:
60.000kg x 5,-- € / kg = 300.000,-- €
5 % = 15.000,-- €
additional profits,
02.05.2014 | Page 17
3. How to increase your pelletizing system
performance…
… by using the tailored solution for reinforced and other special compounds
 High
efficiency
 The JSG performs selfthreading; no manual
operation, just supervision
 Less
waste during start-up
 Increased output
JSG 900
View into cutting head of
PRIMO Plus pelletizer
 High
flexibility
 Cooling length and
cooling time are variable
to suit process
requirements
Transition zone from strand
guide to conveyor belt
April 2014 | Page 18
3. How to increase your pelletizing system
performance…
… by comprehensive selection of cutting tools and wear protection
Cutting rotors
Bed knives
Feed rolls

Stainless steel (WS)

 Elastic

Powder metallurgic (PM)  Ceramics (CE)

Tungsten carbide (HM)

Ceramics (CE)

Tungsten carbide (HM)
Diamond (PCD)
coating for high
temperature with high
wear resistance
 Stainless
steel,
serrated or knurled
April 2014 | Page 19
3. How to increase your pelletizing system
performance…
… by comprehensive selection of cutting tools and wear protection
Different numbers of teeth (6 to
120) for variations in pellet size
Eight different tooth profiles for
different plastics materials
Carbide cutting rotor (HM02F)
with exchangeable blades e.g.
for abrasive products
Optimum solution for every application results in
 Less
wear and thus more up-time
 Lower
production cost
 Better
product quality
April 2014 | Page 20
3. How to increase your pelletizing system
performance…
… by using EBG – the sophisticated system for challenging products like

Water sensitive polymers
(e.g. EVA, WPC)

Biologically degradable materials
(e.g. corn starch)

Highly filled compounds (e.g.
amount of fillers and
reinforcements like minerals,
metals, ceramics > 60 %)

High temperature thermoplastics
(e.g. FEP, PEEK, PPS, PPA)
April 2014 | Page 21
3. How to increase your pelletizing system
performance…
… by using EBG – the sophisticated belt conveyor pelletizing system for
challenging products

Various belt materials possible: Plastic belt for low temperature (< 120 °C),
steel belt for high temperature products

Cooling either
 With compressed air under a closed cover (e.g. for flexible products like TPU, TPE,
EVA) – also axial ventilators (instead of compressed air) possible
 Or with water – from top directly or indirectly from below via a closed steel belt,
sprayed with water from underneath

Large spectrum of suitable strand pelletizers and peripherics
Strand die head
Belt cooling
Air knife
Strand pelletizer
Classifier
April 2014 | Page 22
3. How to increase your pelletizing system
performance…
… by using an innovatice and ergonomic assembly concept

Free access to all
SPHERO®
components from all
sides, even with lifting
tools

No laying of rails
necessary

Quick assembly and
start-up, e.g. by
»container design«

Easy and safe
operation and
maintenance
SPHERO® 50
SPHERO® 140
SPHERO® 100
April 2014 | Page 23
3. How to increase your pelletizing system
performance…
… by using the unique cutter head design and flow conditions

Less down-time due to
special knife design,
making turning of
knives unnecessary

Special treated knife
and die plate material
for an increased life
time

Uniform, short dwell-time, consistent pellet quality

Reduced cavitation in the cutting chamber and in
the connection ducts

Less energy requirement
April 2014 | Page 24
3. How to increase your pelletizing system
performance…
… by using specialized equipment for special applications, e.g. micro pellets

Micro pellets with dimensions below 1.0 mm

The smaller the pellet shape, the more complex and sophisticated the equipment

Processing conditions differ considerably from same of standard size pellets
Cylindrical micro pellets
Spherical micro pellets
Die plate with nests of
small holes for producing
spherical micro pellets
April 2014 | Page 25
3. How to increase your pelletizing system
performance…
… by using energy-efficient centrifugal dryers for normal applications
View into CENTRO 300

Closed, contamination
free rotor

Housing optimized for
easy access to screen
and rotor

Screen easily
exchangeable

Residual moisture
< 0.1%

Rotor lifter blades in the bottom sector
interchangeable

All parts in contact with product or process water
made of stainless steel
CENTRO 150 centrifugal dryer
April 2014 | Page 26
3. How to increase your pelletizing system
performance…
… by using the new dryer designed for abrasive and sensitive materials
Belt dryer DURO
DURO 500 in production

Lower production
costs due to long
lifetime of all parts
coming into contact
with pellets

Gentle pellet handling
ensures high product
quality and less dust
generation

Reduced energy consumption because no additional
energy supply necessary

Suitable for retrofitting into existing pelletizing lines

Low residual moisture < 0.1 %
Belt dryer unit DURO 500
April 2014 | Page 27
Pelletizing process and equipment selection
for high filled thermoplastics
Table of Contents
1. Process and equipment selection
 Compounder’s expectations and market offers
2. Material properties, pellet shapes, processes
 Some background information
3. How to increase your pelletizing system performance…
 Customized solutions
4. A better profitability? How to achieve it ?
Investment as per Life Cycle Costing
April 2014 | Page 28
4. A better profitability?
Definition of LCC
What is Life Cycle Costing?
Life Cycle Costing (LCC) , also called Whole Life Costing
is a technique to establish the total cost of ownership.
It is a structured approach that addresses all the elements of this cost and can
be used to produce a spend profile of the product or service over its
anticipated life-span.
The results of an LCC analysis can be used to assist management in the
decision-making process where there is a choice of options.
Source:
http://webarchive.nationalarchives.gov.uk/20100503135839/http://www.ogc.gov
.uk/index.asp
April 2014 | Page 29
4. A better profitability?
Life Cycle Costing or the »Iceberg Principle«
Machine life time
Maximizing your long-term return on investment
10 - 30 %
= part of the life cycle
costs for a
machine/pelletizer
70 - 90 %
= Follow-up
costs
Customer‘s first impression:
The pellet quality!
 Planning
 Invest
 Down time
 Product loss
 Quality costs
 Energy
 Maintenance
 Spare parts
 Operators
 Upgrades
…
End of life time
April 2014 | Page 30
4. A better profitability?
Total Cost of Ownership
Maximizing your long-term return on investment
 The question is : “Can I afford to pay
less for an inferior product?”
 For the right answer one have to calculate
the total cost of ownership (TCO), including:
 Expected operating life
 Downtime and product changeover time
 Product wastage
 Operational reliability and repair costs
 Personnel time (not to mention the
troubles with the »cheap« product)
 A higher investment mostly
delivers the best long-term returns!
April 2014 | Page 31
4. A better profitability?
Example: Drying of GF-compound
Option 1:
Use centrifugal dryer  excessive wear of paddles and screens
Option 2:
Use belt-type dryer DURO  higher investment, less wear
Question:
Which option leads to a more favorable Life Cycle Costing ?
Rely on the supplier‘s advise and offer, or perform own evaluation?
 We have an open mind and offer impartial advise!
April 2014 | Page 32
4. A better profitability ?
Search for an independent source of advise
April 2014 | Page 33
4. A better profitability?
Evaluation of the dryer options (sample calc.)
Option 1 Centrifugal dryer
150 h/a
300 t/a
0.00 €/a
Option 2: DURO belt dryer
Downtime for exchange of wear parts
Related production loss (at 2,000 kg/h)
Additional turnover (at 1.75 €/kg)
25 h/a
50 t/a
87,500 €/a
April 2014 | Page 34
Pelletizing process and equipment
selection for high filled thermoplastics
Table of Contents
1. Process and equipment selection
 Compounder’s expectations and market offers
2. Material properties, pellet shapes, processes
 Some background information
3. How to increase your pelletizing system performance…
 Customized solutions
4. Investment following Life Cycle Costing
will lead to a better profitability
April 2014 | Page 35
Pelletizing process and equipment selection
for high filled thermoplastics
Conclusions

Selecting the adequate pelletizing process and equipment is predominantly a
question of close cooperation between the machinery supplier, the equipment
user and an engineering provider

Two major options for pelletizing of compounds :
dry cut strand pelletizing and underwater die-face pelletizing

Automatik has the most comprehensive product range – equipment + services

Automatik has an open mind and offer impartial advise

Lower production cost can easily compensate higher investment costs and
produce long-term profit

Automatik is continuously innovating processes and machinery
 For the advantage of our partners – our customers – for YOU!
April 2014 | Page 36
Pelletizing process and
equipment selection
Thank you!
Klaus Arlandt | Regional Sales Manager | May 2014