thermoplastic extrusion

Transcription

THERMOPLASTIC EXTRUSION
Automated pump and screen changer systems
Maag Group is the world’s leading
manufacturer of gear pumps, pelletizing systems and filtration systems for
demanding applications in the plastics,
chemical, petrochemical and food processing industries. Maag develops,
produces and distributes highly innovative, customer-specific solutions as complete pump/pelletizing systems, with
corporate and engineering traditions
dating back to the year 1910. At its
headquarters in Switzerland and operating locations in Germany, France,
Italy, Singapore, Taiwan, Malaysia,
China, Brazil and the USA, the group
employs a staff of more than 500. Maag
Group serves the global market under
the product brands Maag Pump Systems, Automatik Pelletizing Systems
and Maag Filtration Systems. The Maag
Group will become part of the Pump
Solutions Group, a business unit operating within the Fluid Solutions platform of Dover's Engineered Systems, a
segment of the Dover Corporation
(NYSE: DOV).
2
Maag Pump Systems is known around the globe as a pioneer and
technology leader in the development and manufacture of gear
pumps and complete system solutions tailored to customer needs.
Its pumps are used to convey high-viscosity products such as polymers, chemicals and lubricants, meeting the most demanding requirements of industrial users in terms of both reliability and performance. Maag Pump Systems is the world’s market leader in the
areas of polymer pumps and compounding pumps.
Automatik Pelletizing Systems has for decades been renowned
for the quality and innovative technology of its pelletizing solutions
and is the world’s number-one provider of underwater strand pelletizing systems. Its leading market position is built upon its state-ofthe-art technologies, along with its comprehensive and balanced
expertise across all pelletizing processes and pellet forms. As a complement to its long tradition of excellence in the development and
manufacture of sophisticated pelletizing equipment, the company
offers a comprehensive range of advisory and support services.
Maag Filtration Systems develops and manufactures advanced,
application-specific filtration solutions which ensure maximum performance and operational reliability. Its highly innovative large-area
filtration systems and screen changers are widely used in polymer
processing applications around the world, where they guarantee
superior filtration results with the shortest possible dwell times.
EXTRUSION PROCESSES
For high-quality finished products
Gear pumps optimize the extrusion process of thermoplasts as they supply the
required melt very precisely and efficiently build up the tool pressure thus relieving the extruder itself from building up
the pressure. This enhances the performance of the production line, improves
the quality of the finished product due to
reduced melt temperatures, and increases
the lifetime of the extruder. In addition,
pressure pulsations and pressure peaks of
the extruder are eliminated or at least
smoothened as the gear pump dampens
such pulsations and peaks.
Further benefits of the gear pump are that the chips produced during
the cutting process can be recycled and that the pump supplies the
melt very uniformly through the die, which in return ensures a constantly high quality level on the final product’s side.
In terms of processing quality and optical characteristics, products are
subject to high standards. Another important aspect in manufacturing
and processing of plastic material therefore is filtration, with the filter
discharging impurities from the liquid plastic melt. Maag Pump Systems supplies the devices necessary for filtration in numerous fields of
plastic production and processing. Permanent development processes
improve these filtration devices and thus contribute to our customers’
and end users’ satisfaction concerning quality.
Without gear pump
With gear pump
∆T
∆T
Pressure Homoge- Plasticizing Pumping
genera- nizing
and comtion
pressing
Pressure
generation
Pressure
Pressure
Temperature
Temperature
Homogenizing
Plasticizing Pumping
and compressing
Modular downstream equipment for customized extrusion processes
3
4
INTEGRATED THINKING
Optimal performance can only be expected from
systems which are truly designed to work together
Thermoplast producers and processors
need to compete in the global marketplace. With our worldwide network of
service and parts centers located close to
where you are, Maag Group helps you to
do this better. Together with our local
representatives and OEM partners, we
are always ready to provide rapid and
competent support to our customers,
wherever they are. In planning and optimizing your production system, the experienced sales engineers from Maag
Group provide comprehensive advice
which is balanced and takes an integrated view across your entire production
chain. Our entire staff understands that
your success in the marketplace depends
upon your product quality and operating
productivity. Our approach is therefore
to analyze your requirements in precise
detail so that we can offer you complete,
optimized solutions.
Our systems and components are designed for optimal rheological
performance and tailored to your material and operating requirements
to ensure unsurpassed process reliability and production economics.
Maag helps you to get the most out of your investment by recommending the processes and solutions which are best suited to your
specific application.
The Maag technical development and testing center provides you with
expertise and equipment to perform trials on your material and to put
your most innovative ideas to the test under real operating conditions.
Our development and testing facility is also ready to perform test runs
on your behalf or to devise solutions tailored to your exact filtration
and pelletizing needs. With more than 2.000 m² of floor space, this
state-of-the-art laboratory facility is fully equipped with multiple complete extrusion lines, including gear pumps, screen changers, and both
underwater and strand pelletizers. We also offer a special test line for
elastomer intermediates. The valuable data obtained through this precisely controlled testing, such as flow consistency, surface finish and
processing temperature, helps you to maximize your product quality.
The Maag development and testing center also offers a drop pelletizing tower for low-viscosity melts and liquids.
If interdependent components are to seamlessly work together as an
integrated system, they must be more than just “compatible”. The
entire product range of Maag gear pump, filtration and pelletizing
components is designed from the very start to fit together and work
together perfectly. The end result to you is a highly efficient, troublefree production line which delivers best possible product quality and
output. Our commitment to technical excellence means that long
operating life and the highest possible energy efficiency are more than
just vague promises. And our commitment to you, the customer, is ontime delivery of the ideal solution at a highly competitive price – integrated and complete, from initial requirements analysis through to installation and start-up, and with training, maintenance and support
you can count on from day one.
5
GEAR PUMPS
We have the appropriate solution for every application
The compact, durable gear pumps made by
Maag Pump Systems meet highest requirements for thermoplastic applications. Thanks
to optimized flow channel geometry, short
and quality-supportive dwell-times are feasible even for temperature-sensitive products.
The gear pumps are easy to handle and guaranteee reliable and quick start-up and shutdown processes for processing extruders and
compounding extruders.
High conveying stability and task-oriented
configuration in combination with a high level
of reliability support production stability for
repeatable processes. The Maag gear pumps
convey the medium in a low-pulsation way
even when exposed to high differential pressures. Special materials and material process-
6
ing steps as well as innovative bearings, mainly made from highly wearresistant tool steel, allow high revolutions with corresponding high
throughput rates. The excellent degree of efficiency is also due to the
flow-optimized design of the flow channels. The modular design and
three different series meet varying requirements: extrex® GP is the
allrounder, extrex® HV features a 25% higher pumping volume, and
extrex® HP is capable of dealing with a differential pressure of up to
400 bar.
The trudex® gear pumps have been especially designed for high-pressure applications. These high-pressure gear pumps ensure reliable supply quantities at up to 700 bar. This guarantees highest possible product quality. Special, spur-toothed shafts and special sliding bearings
ensure excellent efficiency factors while the conveyed medium is
stressed only to a very little extent.
Optional accessories such as cooling for shaft seals, melt pressure sensors, or temperature sensors complement this efficient gear pump line.
extrex® HV
High Volume
extrex® GP
General Purpose
Technical data:
Technical data:
Sizes:
20-180
Throughput rate:
4 to 15,000 kg/h
Specific volume:
Sizes:
45-90
Throughput rate:
80 to 4,000 kg/h
10.2 to 3,224 cm /U
Specific volume:
57.6 to 453 cm3/U
Temperature:
Up to 350 °C
Temperature:
Up to 350 °C
Heating:
Electric or liquid
Heating:
Electric or liquid
Inflow pressure:
Up to 120 bar
Inflow pressure:
Up to 120 bar
Outflow pressure:
Up to 350 bar
Outflow pressure:
Up to 300 bar
3
extrex® HP
High Pressure
trudex®
High Pressure
Technical data:
Technical data:
Sizes:
36-140
Sizes:
36-140
Throughput rate:
10 to 6,000 kg/h
Throughput rate:
60 to 4,205 kg/h
Specific volume:
15.6 to 959 cm /U
Specific volume:
11 to 690 cm3/U
Temperature:
Up to 350 °C
Temperature:
Up to 350 °C
Heating:
Electric or liquid
Heating:
Electric or liquid
Inflow pressure:
Up to 120 bar
Inflow pressure:
Up to 120 bar
Outflow pressure:
Up to 500 bar
Outflow pressure:
Up to 700 bar
3
7
8
SCREEN CHANGERS
Best product purity for any filtration application
Depending on the particular application, there are various screen changers available for extrusion processes.
The sturdy CSC screen changers are based on the proven
double-piston design, which operates in a leak-free mode
without any additional seals.
Rheologically optimized flow channels result in minimized
pressure losses. CSC-PE screen changers are particularly
CSC Continuous double-piston screen changer
Technical data:
suited for applications under restricted space-related conditions. CSC-DV screen changers are perfect at extruding, for example, start-up melt from twin-screw extruders
or also change material. The continuously operational
CSC-BF/4F backflush screen changer is used for the purification of highly contaminated polymers mainly in recycling
processes.
CSC-PE Screen changer with
optimized filtration area
Technical data:
Screen diameter:
30 to 400 mm
Screen diameter:
159 to 560 mm
Filtration area:
14 to 2,513 cm2
Filtration area:
266 to 3,312 cm2
Operating temperature:
350 °C
350 °C
Operating pressure:
500 bar
Operating pressure:
350 bar
Differential pressure:
100 bar
100 bar
CSC-DV Screen changer with
start-up valve
Technical data:
CSC/BF-4F Backflush screen
changer
Technical data:
Screen diameter:
30 to 508 mm
Screen diameter:
30 to 300 mm
Filtration area:
14 to 4,052 cm2
Filtration area:
28 to 2,826 cm2
350 °C
350 °C
Operating pressure:
500 bar
Operating pressure:
350 bar
100 bar
100 bar
9
SCREEN CHANGERS
Minimum pressure loss and leak-free operation
The C-SSC single-piston screen changers are based on the
proven design which operates with two screen cavities.
These two screen cavities are also well suited for continous
operation thanks to simple screen aeration. DSC and
SSC are an alternative for extrusion applications which
accept a disruption in melt flow during the screen changing process.
for the handling of thermally sensitive materials. The continuously operational C-FSC screen changer allows a
screen change without any melt flow disruption thanks to
several screen cavities. The manual screen changer HSC is
available in size 45 with a transmission which allows easy
screen changing even when space is limited and the device
is exposed to high sealing forces.
The FSC plate screen changers are all equipped with a
pressure-related sealing system and are particularly suited
DSC Single-piston
screen changer
C-SSC Continuous
screen changer
Technical data:
Technical data:
Screen diameter:
58 to 270 mm
Screen diameter:
30 to 508 mm
Filtration area:
27 to 572 cm2
Filtration area:
7 to 1,256 cm2
350 °C
350 °C
Operating pressure:
350 bar
Operating pressure:
700 bar
100 bar
300 bar
FSC
Plate screen changer
Technical data:
10
C-FSC Continuous plate
screen changer
Technical data:
Screen diameter:
45 to 300 mm
Screen diameter:
45 to 180 mm
Filtration area:
16 to 707 cm
Filtration area:
32 to 1,414 cm2
340 °C
340 °C
Operating pressure:
700 bar
Operating pressure:
550 bar
200 bar
220 bar
2
HSC
Manual screen changer
Technical data:
SSC
Compact screen changer
Technical data:
Screen diameter:
20 to 160 mm
Screen diameter:
30 to 200 mm
Filtration area:
3 to 201 cm2
Filtration area:
7 to 314 cm2
340 °C
350 °C
Operating pressure:
700 bar
Operating pressure:
350 bar
200 bar
100 bar
START-UP VALVE
Process-reliable start-up and shutdown
of extrusion lines
The DV melt valves are based on the proven bolt design
operating without any mechanical seals. Such melt valves
are applied as diverter valves, safety valves, or start-up
valves in plastics production and extrusion and compounding applications. The sturdy design and a reliable electric,
liquid, or steam-driven heating system ensure leak-free
and trouble-free operation for years, e.g. as start-up aid
for underwater pelletizing processes or when start-up material has to be discharged in extrusion applications.
When set to “production”, the melt stream flows down
the melt channel and reaches the next downstream station. In order to divert the melt to “start-up”, the bolt is
activated hydraulically. This switching can be slow or quick,
depending on the individual process control-related needs
and is ensured through various hydraulic systems.
DV Start-up valve
Technical data:
Channel diameter:
25 to 100 mm
Operating temperature: Up to 350 °C
Operating pressure:
500 bar
Advantages:
Compact dimensions
Any installation position feasible
11
SYSTEM CONTROLS
For integrated systems
The automation systems of the maax® series are especially
suited for retrofitting and for comprehensive modifications
on extrusion and compounding systems in combination
with the installation of a melt pump or a screen changer.
Central operation, optimal control circuits, and permanent
monitoring through maax® control systems ensure a significant rise in quality of the final product due to the interaction with the new components.
The maax®100S with its well-adjusted standard version
covers another system range and gives access to a production routine under optimal and repeatable conditions. The
maax®600S is particularly suited to equip entire and complex coextrusion and compounding systems requiring tailored solutions.
maax® 100S for common
extrusion processes
Technical data:
Display:
5.7” colour touchscreen
Temperature zones:
Up to 16
Features:
Integrated filter monitoring
Configurable control function for
pump inflow pressure
Monitoring of all desired process
values
Quick fault detection due to plain text
messages
Online language changeovers
maax® 600S for complex
extrusion processes
Technical data:
Display:
15“ colour touchscreen
Temperature zones:
Up to 48
Features:
Integrated melt pump control and
filter monitoring
Semi-automatic lifting and retracting
of the extruder and of the gear pump
Freely configurable control functions
for all components
Drives for downstream devices can be
synchronized
Monitoring of all desired process
values
Quick fault detection due to plain text
messages
12
13
CONTROLS
Automated processes do a better job
maax®3 is a control concept for small extrusion units with
low throughput rates and thus reduced investment volume. The pre-pressure control for gear pumps integrated
in the frequency converter in combination with the simple
operation and information display offers considerable savings if a gear pump is retrofitted and integrated into the
existing system.
The maax®BF automation system, especially designed for
our continuously operational CSC BF/4F backflush screen
changers, is the proven control system for recycling applications. As a tailored solution, it offers simple filter operation as well as fully automatic screen cleaning and multiple
screen utilization to the fabricator of highly contaminated
polymer melts.
maax® 3
cost-effective solution
Technical data:
Display:
Operating panel
Temperature zones:
Optional
Features:
Simple and unambiguous operation
Integrated pressure control
Price-optimized for reduced investment volume
Fault detection through diagnostic
trouble code
maax® BF optimized for
backflush screen changer
Technical data:
Display:
5,7“ colour touchscreen
Temperature zones:
Optional up to 6
Features:
Anti-blocking mode with movement
monitoring
Integrated melt pressure measurement
Composition memory
Integrated heating zones
Screen changer mode
Manual or fully-automatic backflush
mode
14
RETROFITTING FOR EXTRUSION SYSTEMS
Improving quality and results
The expac® system made by Maag Group reduces negative impacts such as the pulsation of an extruder. Pulsations may lead to dimensional deviations of up to 5% on
the final product due to wear or added recycling material.
The expac® system significantly reduces such deviations and
thus improves product quality. The quality of the material,
and of the product later on, also depend on short dwelltimes of the melt inside the pumps, screens, and mixing
elements. The speed of the entire process and resourceconscious usage of energy define process productivity.
expac® systems are mainly intended to retrofit already existing systems but can also be integrated into new systems.
expac® consists of:
Drive unit with gear motor and drive shaft
Pump
Control system, installed in switch cabinet
Corresponding instruments
Interfaces to already existing systems
Screen changers, if applicable
15
PARTS, ACCESSORIES, SERVICE
AND SUPPORT
For maximum productivity and production reliability
Products from Maag Group are known
not only for their superb operating performance but also for their durability and
long operating life. Tailored to materialspecific and customer-specific requirements, they help to maximize process
efficiency – and thus ultimately profitability. Our customers can count on us for
comprehensive technical and operating
advice, for a complete range of accessories, and for fast, reliable service and
parts delivery – where you need it, and
when you need it.
Process reliability and precisely controlled product quality are critical to
your competitiveness in the marketplace – and a promise that Maag
Group makes to its customers from planning and start-up through to
maintenance and ongoing system operation. Our gear pumps, screen
changers and pelletizing systems are installed and put into service by
our experienced technicians, working closely with the customer to optimize operating parameters and system configuration according to
technical requirements. Following successful installation, we then provide comprehensive, hands-on training to your operators and production staff. And needless to say, the technical support team at Maag is
always just a phone call away, whether for routine maintenance or any
other needs. This ensures maximum availability and minimum downtime.
Maag offers its customers the benefits of a truly global service network, including the world’s largest network of rotor and knife regrinding services in the pelletizing industry. This enables us to provide fast,
reliable, expert service and support which is close to where you are.
Rounded out with our pump repair service, our comprehensive range
of service offerings means that you can rely on us to meet all your
needs. Maag repairs and overhauls gear pumps for an extremely wide
range of chemical, extrusion, polymer, compounding and other industrial applications.
The engineering team at Maag Group is constantly working to offer
upgrades for existing systems, so that your production line is always at
the leading edge. This serves not only to improve production reliability
but also to improve process efficiency, such as by reducing energy
costs. Maximizing the operating life of your capital equipment, minimizing production waste, improving operator convenience and safety,
and ultimately helping you to achieve the best possible final product
quality at the lowest cost – these are our objectives in serving you.
Because of our installed worldwide base of thousands of systems,
along with our own commitment to ongoing R&D, our customers are
in a unique position to benefit from our expertise in providing state-ofthe-art solutions tailored to individual process requirements. Superior
product quality together with high operating productivity – that’s our
commitment to you.
16
17
YOUR BENEFITS WORLDWIDE
Reliable, expert service and support

Our global team of experts and qualified engineers ensure that your production equipment is correctly maintained for maximum reliability.
Your components and systems are tailored to your exact requirements, thus optimizing production efficiency
from the very start.
Your system is installed and put into service by our own
qualified engineers.
Maag components and systems are designed to work
together perfectly and built to ensure long, trouble-free
operation, thus yielding excellent production economics
and reliable operation long into the future.
We provide you with a single comprehensive source to
furnish and maintain all your production equipment,
thus reducing the cost and administrative burden associated with purchasing, operation and maintenance –
and eliminating the “finger pointing” among different
individual providers.

You can count on fast, guaranteed repair and maintenance service from our experienced, highly trained
specialists.
Because your production availability depends on getting
critical parts quickly, our global service network puts
our spare parts and accessories close to your doorstep.
We offer training for your staff – on your premises, or in
our service centers – helping you to motivate your employees while maximizing operational efficiency, thus
ultimately lowering production costs.
Our technical support is ready to assist you, or to
answer your questions, quickly and unbureaucratically,
saving you time and money.
Among our application-related services are viscosity
measurements and flow simulations by our experienced
application engineers, bringing process transparency to
help you (and us) perform better.
Switzerland
Oberglatt
Russia
Moscow
India
Mumbai
Germany
Grossostheim
France
Lyon
China
Shanghai
Italia
USA
Milano
Charlotte
Taiwan
Taipei
Brazil
Sao Paulo
Malaysia
Kuala Lumpur
Singapore
Singapore
18
Maag Group has business roots extending back more than 100 years. The foundations for today’s Maag Pump Systems
AG were laid by Max Maag in the year
1910, beginning with gear manufacture.
The business grew, and in 1928 the company’s factory in Zurich shipped its first
gear pump. In the decades to follow,
Maag engineers developed ever more
sophisticated and capable gear pumps.
Today, these process pumps are in operation around the world, serving customers
in the plastics, chemical, petrochemical
and food processing industries. At the
start of the new millennium, Maag Pump
Systems expanded its product range to
include high-performance screen changers and large-area filtration units so that,
since this time, it has been able to offer
complete systems.
After more than six decades serving the plastics industry, it is
hard to even imagine this market without pelletizing systems
from Automatik Plastics Machinery. Originally founded in 1947
as Automatik Apparate- und Maschinenbau GmbH, the company began developing strand pelletizing systems from its earliest days, bringing the first automated strand pelletizer to the
market in the 1960s. The 1970s saw a further burst of innovation, particularly the company’s launch of the first underwater
strand pelletizer in the middle of that decade. In the late 1990s,
Automatik went on to bring its unique drop pelletizing system
for low-viscosity products to the market, filling yet another industry need. The company completed its product portfolio in
2003 with the introduction of its SPHERO® underwater pelletizing technology. Since this time, Automatik has offered solutions covering a comprehensive range of pellet shapes, operating throughputs and production requirements.
The paths of these two extraordinary companies have crossed
many times over the years, as both have long been providers of
complementary, superior quality systems and components to
the plastics processing industry. With their merger in 2010,
Maag Pump Systems and Automatik Plastics Machinery were
brought together under the umbrella of Maag Group, offering
complete and highly efficient production solutions from a single
source. Maag Group has been a part of Dover Corporation, a
U.S. industrial conglomerate, since 2012.
19
Switzerland
Maag Pump Systems AG
Aspstrasse 12
8154 Oberglatt
Switzerland
P +41 44 278 82 00
F +41 44 278 82 01
Welcome@maag.com
www.maag.com
Germany
Automatik Plastics Machinery GmbH
Ostring 19
63762 Grossostheim
Germany
P +49 6026 503 0
F +49 6026 503 110
Info@maag.com
www.maag.com
Brazil
Maag Automatik Do Brasil, Ltda.
Alameda Rio Preto, 165 Sala 3
Centro Empresarial Tambore
06460-050 Barueri - SP
Brazil
P +55 11 4166 4975
F +55 11 4195 3840
InfoBrazil@maag.com
www.maag.com
Italy
Maag Automatik s.r.l.
Viale Romagna 7
20089 Rozzano (MI)
Italy
P +39 02 575 932 1
F +39 02 575 932 32
MaagItaly@maag.com
www.maag.com
China
Maag Automatik Plastics Machinery Co., Ltd.
Room 1204A, Silver Tower
218 South Xi Zang Road
200021 Shanghai
China
Malaysia
Automatik Plastics Machinery Sdn Bhd
(845544-M)
14 Jalan PJU 1A/8 Ara Damansara
47301 Petaling Jaya Selangor
Malaysia
P +86 21 6334 3666
F +86 21 6334 3336
P +6 03 7842 2116
F +6 03 7845 4363
MaagChina@maag.com
www.maag.com
InfoSEA@maag.com
www.maag.com
France
Maag Pump Systems SAS
111, Rue du 1er Mars 1943
69100 Villeurbanne
France
Singapore
Maag Pump Systems Pte Ltd
25 International Business Park
No. 04-73 German Center
609916 Singapore
Singapore
P +33 4 72 68 67 30
F +33 4 72 68 67 31
MaagFrance@maag.com
www.maag.com
India
Maag Automatik India
105 Thacker Tower Plot 86, Sector 17, Vashi
Navi Mumbai 400 703
India
P +91 22 2789 3645
F +91 22 2789 4407
MaagIndia@maag.com
www.maag.com
P +65 65 62 87 20
F +65 65 62 87 29
MaagSingapore@maag.com
www.maag.com
Taiwan
Automatik Plastics Machinery Ltd.
Room 619, 6F., No.6
Hsinyi Rd., Sec. 4, Da-an District
Taipei City 106
Taiwan
P +886 2 2703 6336
F +886 2 2708 4856
InfoTaiwan@maag.com
www.maag.com
USA
Maag Automatik Inc.
1500 Continental Boulevard
Charlotte, NC 28273
USA
P +1 704 716 9000
F +1 704 716 9001
MaagAmericas@maag.com
www.maag.com