Sheet Extrusion Systems - Adams Engineers and Equipment, Inc.

SHEET EXTRUSION SYSTEMS
Davis-Standard’s sheet systems are recognized around the world for reliability, accuracy, high outputs, and
processing efficiency. Our process knowledge and experience is unsurpassed. We manufacture equipment
for foam, flexible and rigid sheet extrusion, and single and multi-layer coextrusion applications utilizing the
latest feed block technologies available.
Processing capabilities include common packaging resins such as APET, CPET, PETG, high-density PE, PS,
PP, PA, and any other extrudable thermoplastic materials. We supply integrated systems and solutions
incorporating single screw or twin screw extrusion technology, in single or multiple extruder arrangements,
XP Express® Series
process optimized feedscrews, melt filtration systems, polymer melt-pumps, flat sheet dies, roll stands,
hot melt laminating and protective substrate let offs, solution applicators, winders, shears, saws, online
thickness measurement systems and more, so that you can rely on us for all of your sheet extrusion needs.
We also focus on providing customers with versatile and cost-effective options with a fast delivery, as seen
with our XP Express® roll stand system. Whatever your requirement, we have the resources and expertise
to engineer a solution.
Single Source Responsibility
We pride ourselves in supplying fully integrated sheet systems. Our single-source extrusion capability
enables us to provide unsurpassed uniformity in system components and performance. We offer customers
a sheet extrusion package with all major components such as extruders, roll stands, controls and winders
manufactured in-house. All equipment not manufactured in-house is sourced from a reliable network of
vendors. Customers look to us as their source for:
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Extruders
Melt stream filtration systems
Roll stands
Winders
Process control systems
Feedscrews
Coextrusion technologies
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Sheet dies
Melt pumps
Dual laminating pay-offs
Auto reverse roll coaters
Rotary shears
Thickness measurement systems with
thickness optimization
Systems for a Variety of Applications
Our customers produce a broad range of products for many different markets. Examples include:
Packaging
Cups, plates, tubs, domes, frozen food, blister/point of purchase, extrusion
for roll feed thermoforming applications, high output capacity extrusion for
end user inline thermoforming
Automotive
Fender liners, splash guards, truck bed liners, interior sound absorption
Dunnage
Slip sheets, thermoformed pallets, waste containers
Building
Wall partitions, interior/exterior lighting, drainage, pail liners
Medical
Saline solution bags, instrument packaging
Custom
Circuit breakers, geomembranes, tank liners, refrigerator liners, roofing
membranes, carpet coating
Extruders and Feedscrews
6-inch (150mm) 30:1 Thermatic ® extruder
For over 50 years, the Davis-Standard name has been synonymous with quality extruders and feedscrews.
We view the extruder and feedscrew as the foundation of your sheet system. Our Thermatic® extruders are
built for high outputs, efficiency and years of trouble-free operation. The advanced technology and track
record of our feedscrews is unsurpassed. Our goal is to provide you with the best extruder and feedscrew
combination for your process(es).
THERMATIC® EXTRUDER ADVANTAGES
• All Thermatic models are built with rugged “H” beam steel construction to provide maximum stability
and minimal vibration.
• Cast aluminum heaters are bolted together for better temperature control and longer life.
• Davis-Standard’s horizontal, helical gearbox uses labyrinth seals to reduce leakage and maintenance.
Standard units available as single motor input or synchronized dual motor inputs.
• Bearings are pre-loaded to generate a truer power transmission underload.
Feedscrews
• A dual thermocouple micro-processor system provides anticipatory temperature control for
high accuracy.
• Extruders are supplied with air-cooled or water-cooled systems depending on barrel
cooling capacity.
• The motor is available in AC or DC variable speeds, externally vented or fan-cooled.
FEEDSCREW ADVANTAGES
• Davis-Standard barrier technologies exceed the most sophisticated sheet process requirements for
pressure stability and melt temperature uniformity while providing maximum productivity.
• Feedscrews are designed for consistently higher output rates, process stability, distributive and
dispersive mixing properties, and minimal polymer degradation.
• Feedscrews are manufactured from a variety of metals for corrosion and wear resistance.
• R&D facilities in the United States and Europe enable us to research, test, and supply custom
feedscrew designs.
FLATPAK FOR TIGHT COEXTRUSION LAYOUTS
• This configuration is engineered specifically for plants with space limitations that inhibit the use
of traditional “fan” design or “straddle frames.”
• Designed with a vertical gearbox that saves space through close coupling.
• Compact set-up can accommodate a common cooling manifold and heat exchanger for
added efficiency.
• Access to individual machines for normal operation and routine maintenance is possible due to a
sub-base mounting system with slide rails.
• Applications: Monolayer, Coextrusion, Roll Stock, Cut-to-length, and In-line Extrusion
and Thermoforming
Controls, Dies, and Coextrusion
Sheet extrusion often calls for complex systems capable of handling a range of processing requirements
and resins. This is where controls, dies, and coextrusion technology can lead to improved processes,
greater efficiency, and processing versatility. We are well equipped in these areas to help you fine-tune
your system.
EPIC III ™ – High-Level Control
• Windows®-based plant management and extension process control capabilities with adaptable and
expandable touch screen displays.
• Supervisory features including event logging, customized reports, SQC, historical trending,
maintenance/troubleshooting, pressure set-up and more.
• Partial and complete line overview, detailed extruder data, recipe creation/storage, etc.
• Connectivity solutions available for remote data access via laptop as well as network capability for
remote monitoring of multiple systems.
EPIC III™ controls with a sloped front console.
• System includes Dynamic Data Exchange (DDE) and Object Linking and Embedding for Process
Control (OPC).
• A multiple-level security system protects set-up functions and accessibility.
DIE DESIGNS FOR EVERY NEED
• Die designs are engineered for monolayer and conventional coextruded structures up to twelve
layers, and micro layer structures comprised of hundreds of layers.
• A broad range of dies are available from the widest to the narrowest application.
• Manual or automatic die lip adjustment is available as required and is integrated into the system.
• Computerized internal designs are used based on the rheology of the specific polymer and use.
Assembly and Test
COEXTRUSION FOR BALANCE AND CONTROL
• Coextrusion capability for fixed-ratio coextrusion blocks to multi-adjustable ratio and distribution
devices for complex barrier composites.
• Adjustment features for proper flow balance and distribution.
• Multi-manifold dies are supplied either as independent units or in conjunction with custom
designed feedblocks.
Barrier Coextrusion Sheet Systems
Superior Roll Stand Technology
Our XP Express® and EX-M-PLAR® series roll stands are engineered to simplify and improve sheet
processes across the board. These models are available in standard or customized versions in upstack,
downstack, vertical, horizontal, offset top roll or offset bottom roll J configurations. Roll stands can
include three or more cooling rolls, as well as automatic drive controls and hands-free nip gap adjustment.
XP EXPRESS ® ADVANTAGES
XP EXPRESS ® PS MODEL – PACKAGING SHEET APPLICATIONS
Standard features include:
• Individual roll drive for precise web tension control and optimized sheet polish
• Web cooling train sized for application with matched roll diameter and heat exchange system
• Dual flow rotary union design locates water on non-operator side of the machine
• Direct acting roll actuation to maintain precision roll gap
• Compact footprint for space challenged facilities
XP EXPRESS ® CS MODEL – CUSTOM SHEET APPLICATIONS
• Same standard features as the PS model except the CS model utilizes an individual roll gear
drive train system to facilitate quick embossing roll removal without disturbing the AC drive train
mechanics and electronics.
• Both models are competitively priced and pre-engineered for a fast delivery.
• Capabilities include production of polished or embossed roll stock and cut-to-length sheet or inline
extrusion to thermoforming applications. Each unit is supplemented with optional ancillaries such
as laminating unwinds, solution applicators, cross-axis roll feature, integral air-knife assembly,
auxiliary cooling, slitting and trimming, embossing, on-line annealing and protective film let offs.
Scrap Reclaim Extruder
• Equipped with high-speed features for thin gauge sheet applications with the heating and cooling
capacities to match operating line speeds. Standard pressurized water systems up to 275ºF roll
temperature set point, or optional oil heating systems for high temperature applications.
• Can be configured in upstack, downstack, and offset top or offset bottom arrangements with three
primary cooling rolls and multiple supplemental cooling rolls.
• Easily accessible with operating features such as dynamic nip force (PLI) control or roll
position control.
• Custom models available for sheet and packaging applications.
EX-M-PLAR® SERIES ADVANTAGES
• Robust design, engineered for the most demanding applications of superior sheet quality finish or
those that require wide width and heavy gauge sheet.
– Features a heavy duty split arm roll actuation device, with standard straight bore bearings
or a tapered bearing design for optimized tolerance control.
• Utilizes a coordinated AC drive system for each drive section throughout the line.
• Hands-free technology eliminates manual and mechanical operator adjustments of the flex lip
die bolts via integration of an inline automatic lip profile control system, and closed loop roll gap
control via a hydraulic jack closed loop controlled through a PLC unit to improve repeatability of
machine set points and consistently produce sheet of minimal thickness variation.
– Capable of attaining a nip gap resolution of 0.0005 inches (0.0127mm) or less and
feedback device resolution of 0.0001 inches (0.00254mm).
– Processors can adjust the system while in operation under full pressure, make
immediate set point changes, control the new gap set point, and reduce setup and
job changeover time.
• Drive trains available in chain, gear, or as individual roll drives for optimized sheet tension control in
the system.
• Configurations comprised of upstack, downstack, vertical, horizontal, orbital or angled at 45° can
be customized to include four, five or more cooling rolls.
Heavy Gauge Sheet
Roll Stand Configurations
Intergrated Ancilliary Equipment
Ancillary Equipment Advantages
Details are important to us and our customers. From the design of our roll stand rolls, to cooling and
polishing units, to auxiliary equipment, we want to ensure that every square inch of your system is ready
to meet or exceed your expectations.
ROLL STAND ROLLS
• Available with pneumatic or hydraulic roll actuation.
• Automatic roll force control system minimizes roll deflection allowing processors to polish thinner
gauge sheets than previously possible.
• A manually actuated worm-wheel, jack-screw device at the nip outlet provides consistent roll
gap position.
• Rolls are constructed of a mild steel shell with a 400 series stainless steel overlay hardened to
48-52 Rockwell “C.”
• Rolls are machined, chrome plated and polished to a matte or mirror finish quality with a standard
1-3 RA, .5 RA, or tighter, for optical grade sheet.
• A standard high-pressure design utilizes shrunk fit outer shells to improve strength and
minimize deflection.
• Optional rolls are available for embossing and other high-quality surface requirements.
• AC roll drive system corrects speed differentials and eliminates need for four-speed transmission.
COOLING AND POLISHING UNIT
• Features a modular design with side supports consisting of blanchard-ground side plates that are
drilled and bored in pairs to align roll mounting and support girts for improved web guiding.
• Precise roll stand height adjustment by means of cross-shafted jacks to precisely position the melt
curtain onto the rolls.
• Local HMI controls are fixed or pendant arm mounted.
Gear Drive System
• Fixed, collapsible, and rollover type conveyor designs available.
• Supplemental sheet cooling systems include controlled flow convective cooling air circuits, cooling
cans, and quench systems.
• Annealing sections provide sheet stress relief.
HEAT EXCHANGE SYSTEM
• Provides uniformity through proper temperature control during roll heating or cooling process
with roll temperature tolerances within 1 to 3ºF.
EX-M-PLAR Roll Stand
• Consists of a centrifugal pump, tube, and shell heat exchanger, and an individual expansion tank
sized for specific heat loads. Direct injection systems are also available for low temperature
process applications.
• Common pressurized fill system with valving to each roll reduces maintenance and limits
run disruptions.
END-OF-THE-RUN TENSION CONTROL
• Standard haul-off system consists of two hardened neoprene rubber rolls.
• The nip gap is actuated by a straight-acting pneumatic cylinder and rolls are driven by an AC drive
identical to the polish roll drive unit.
AUXILIARY EQUIPMENT
• Options for slitters, laminating un-winds, specialized conveyors, water baths, thickness gauges,
winders, and loading devices.
• Thickness measurement systems available with thickness optimization control for sheet from
.008-inches (0.2mm) to over 1-inch (25mm).
Packaging Sheet Line
Growing Process Technology
We are always working to expand our processing technology to accommodate the changing needs of
the marketplace and the world. A significant example of is the demand for PET processing technology,
reflecting environmental concerns and the importance of recycling.
Our PET capabilities include technology to process multiple materials such as recyclable PET in flake
form, and low bulk density PET ranging from 100 percent post consumer waste to virgin APET. This
includes sheet structures for running monolayer, coextrusion and side-by-side sheet. Our customers have
experienced ongoing business success using our systems for PET and other packaging material processes
while reducing waste and helping the environment.
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 is focused on supporting our customers’ investment.
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 is 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.
Technology Center
Each feedscrew is manufactured on the basis of individual customer parameters encompassing
output rate, melt temperature, pressure requirements, output consistency of extruder stability, melt
homogeneity, and melt quality.
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 shipments, 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. For parts and service call +800-480-8105.
Spare Parts
SHEET BUSINESS SERVICES
Systems Engineering and Integration
Davis-Standard provides the necessary mechanical/electrical engineering and integration to interface
all sheet line components into a fully functional production line. On system orders, the project manager
interfaces with the buyer’s personnel to coordinate all aspects of the line being manufactured.
Pre-Shipment Testing and Inspection
We offer complete set up and electro-mechanical testing prior to shipment at our manufacturing facility.
Customers are welcome to inspect their lines prior to shipment.
Mechanical and Electrical Checkout
Our process experienced engineers and technicians perform a thorough check of both mechanical and
electrical functions of the entire line and any associated equipment supplied by Davis-Standard.
Our Brands
ß Black Clawson
Converting
Machinery
ß Sterling
ß Egan
ß Hartig
ß Killion Extruders
ß ER-WE-PA
ß Repiquet
ß Johnson
ß Merritt Extruder
ß Goulding
ß DS Brookes
ß NRM Extrusion
PROCESS VERIFICATION AND OPERATOR TRAINING
Davis-Standard personnel are available to train your operators in the use and operation of the line.
CONTRACT INSTALLATION SERVICES
We provide installation contract services for our supplied equipment when required.
EXTRUSION LAB TESTING
Extrusion lab testing at our facilities on a customer supplied resin formulation is available at an additional
charge in accordance to fees in effect at the time the lab service is rendered. Our knowledgeable and
experienced technical staff has solved many challenging extrusion process applications, improving
productivity on many customer machines.
Get to Know Us
Davis-Standard has set the standard in sheet
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.
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 06379-2313 USA | Tel: +860-599-1010 | Fax: +860-599-6258 | www.davis-standard.com
Room 1007, Jing An China Tower
1701 Beijing (W) Road
Shanghai 200042 P.R. CHINA
Tel: +86-21-5150 1908
Fax: +86-21-5150 1906
www.davis-standard.com
© 2007 Davis-Standard, LLC. All Rights Reserved.
Unit 33 Hainge Road
Tividale, Oldbury, West Midlands
B69 2NY UNITED KINGDOM
Tel: +44-121-522-0030
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www.davis-standard.com
46 North First Street
Fulton, NY 13069-1297
USA
Tel: +315-598-7121
Fax: +315-593-0396
www.bc-egan.com
36 South Adamsville Road
Somerville, NJ 08876-0671
USA
Tel: +908-722-6000
Fax: +908-722-6444
www.bc-egan.com
Mettmanner Strasse 51
D-40675 Erkrath/Düsseldorf
GERMANY
Tel: +49-211-2404-0
Fax: +49-211-2404-281
www.er-we-pa.de
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