Your Global Partner in Extrusion, Coextrusion, and Converting

Extrusion Dies Industries, LLC
911 Kurth Road
Chippewa Falls, Wisconsin 54729 USA
Tel: (715) 726-1201
Fax: (715) 726-2205
E-mail:sales@extrusiondies.com
EDI GmbH
EDI Precision Dies (Shanghai) Co., Ltd.
99 Zhongde Road
Songjiang Science & Technology Park
Songjiang, Shanghai P. R. China 201614
Tel. +86-21-57850918 Fax. +86-21-57850698
E-mail: edishanghai@extrusiondies.com
Kastanienweg 8
51580 Reichshof-Wehnrath, Germany
Tel: 49-2265-980627
Fax: 49-2265-980690
E-mail: info@edi-gmbh.de
Your Global Partner in
Extrusion, Coextrusion, and Converting
Designers and manufacturers of high performance die systems
www.extrusiondies.com
www.reworkdies.com
6-2008
O
ur name says it all. Extrusion Dies Industries, LLC designs and
builds flat extrusion dies and coating heads for plastic processors and
web converters. This was our mission back in 1971, when EDI started out
as a machine shop of four people in a small town in the U.S. Midwest.
Now we are a global force–a leading international manufacturer of flat
dies and the field’s technological partner. But our sole business is still
the same: to provide producers of film, sheet, coatings, and
laminates with value, quality, and dependable service.
To help our customers innovate and grow, we are constantly
developing new die systems with enhanced capabilities. EDI’s initial
innovations were the Autoflex® and Ultraflex® dies, now worldwide
industry standards in gauge control. Today we are the only flat die
builder whose manufacturing capabilities are totally three-dimensional,
from initial concepts through engineering to the cutting of tool steel.
This enables us to produce dies with flow-channel geometries that used
to be impractical, if not impossible, to achieve. The result: dies that
provide better product quality, greater raw-material economy, and
higher productivity than ever before.
Chippewa Falls, Wisconsin, U.S.A. remains our world headquarters,
but we also serve customers through our European and Asian subsidiaries,
EDI GmbH, in Reichshof-Wehnrath, Germany and EDI China, in Shanghai
P.R. China. In Latin America, Europe, Asia, and Australia, our extensive
network of agents provides comprehensive sales and technical support.
EDI’s dedicated remanufacturing facilities in Chippewa Falls, China
and Germany–along with licensed rework technology in Japan–help
customers protect their investments in EDI equipment by returning dies
to original specifications and upgrading them with advanced systems.
Besides innovation and worldwide access, EDI helps processors and
converters succeed by assuring them of dies that arrive on time,
start up quickly, and run reliably for years to come. Some of our original
dies, in fact, are still in full production. Our design and manufacturing
operations are ISO 9001:2000-compliant, and our commitment to quality embraces not only performance but service—before, during, and after
the sale. This is what brings customers back to EDI time and again.
1
Cast Film
2
Oriented Film
Sheet
Extrusion
SYSTEMS FOR EVERY
FLAT-DIE PROCESS,
ANYWHERE IN THE WORLD
~ Paulo, Beijing –EDI dies are
Chicago, Milan, Sao
hard at work wherever manufacturers process polymers or coatings. EDI has been a leading supplier of
flat die systems in the U.S. for over three decades–all
the while winning customers in every other part of the
world. Today more than half of the dies and feedblocks
we produce are delivered to customers outside the U.S.
To help customers succeed no matter where they
do business, we have an international support network
that provides rapid access to sales services, technical
assistance, spare parts, and die rework. Besides supplying die systems directly to customers, we also
design and build them for turnkey processing lines
supplied by the world’s major OEM’s.
Every die from EDI is a custom-engineered product. Working with each customer, our engineers determine the manifold design, die body materials, flow surfaces, temperature controls, thickness adjustment,
deckling and other basic elements that best meet the
needs of the application. EDI coextrusion systems
range from feedblock-fed single-manifold designs to
multi-manifold dies for seven layers or more. Our coextrusion feedblocks provide precise on-line adjustment
of layer thickness and sequence. Deckling options
span a wide range of internal and external systems.
EDI systems have been installed for every flat-die
extrusion and converting technique:
Cast film. Our proprietary manifold designs and
gauge profiling systems provide tight control over
material consumption, increase product consistency,
and prevent defects and roll distortions. Specially
designed dual-chamber vacuum boxes ensure stable,
uniform roll development.
Oriented film. Lip-adjusting technology developed
for this application ensures critical gauge control for
the downstream tentering process.
Sheet. EDI builds dies for applications that range
from stress-free optical sheet to thick, heavy-duty products, and from narrow strips to multi-meter-wide
geomembranes. Rapid width and thickness adjustment features provide production versatility for custom
processors.
Extrusion coating. Dies are available with edge profile control, full internal/external deckling, and motorized deckles that permit fast adaptation to changes in
web width.
Fluid coating. Inherently more productive than roll
coaters, EDI’s slot die coating heads can be configured with internal deckling and automated thickness
control.
Coating
Fluid Coating
3
H E L P I N G C U S T O M E R S
T O S U C C E E D
In extrusion processing and web converting, technology is
the most powerful force for success. Many EDI customers are
engaged in competitive markets where even a slight saving in
raw material cost or a marginal increase in throughput can
yield a significant advantage. EDI is a reliable technological
resource for these companies, providing a steady stream of
innovations with real benefits. Often these competitive
advantages are neither “slight” nor “marginal” but dramatic
and decisive. Here are some examples:
Higher Productivity. Our proprietary three-dimensional flow-simulation software optimizes flow surfaces in Multiflow® manifolds and Ultraflow® feedblocks.
And the Autoflex® automated gauge control system provides greater adjustability,
shorter response times, and finer resolution than competitive equipment.
Material Cost Savings. Manufacturers large and small cut resin consumption
and reduce scrap with EDI’s Ultraflex® manual and Autoflex® automated gauge
TM
control systems, and Edge Profile Control (EPC) dies for edge-bead reduction in
extrusion coating.
Reduced Downtime. EDI technologies for quick on-line product changeovers
make flexible manufacturing practical. These include: FastGap® systems for
TM
changing product thickness, Accuflow online-adjustable coextrusion feedblocks,
TM
and Fast Deckle to vary product width without stopping production. To reduce
downtime for maintenance, EDI has developed Autoflex VI gauge-control modules,
Multiflow manifold designs that prevent polymer degradation and plateout, and
Ultracart® rapid die servicing systems.
Enhanced Product Quality. Multiflow manifolds provide precise melt flow
distribution and layer-to-layer uniformity in coextrusion. Ultracoat ® slot die coating
heads eliminate the airborne contaminants (and throughput limitations) of roll
coating. EDI’s advanced engineering and machining capabilities, combined with a
company-wide quality assurance system, result in high-precision dies that meet
exact product specifications year after year.
Process Laboratories. The company’s Technology Center can be used to “test
drive” virtually any extrusion or coating process that involves flat dies. Not far from
EDI world headquarters in Chippewa Falls, WI, the Center includes multiple selfcontained process laboratories that companies can rent for product development
and process testing. Recognizing that our customers seek to maximize production
of saleable goods, EDI has established the process labs as a way for them to
explore all alternatives
without incurring the high
material costs and lost
output of trial runs on their
own commercial-scale
production lines.
4
S A L E S A N D S U P P O R T
A R O U N D T H E G L O B E
To provide customers with comprehensive sales assistance
and technical support anywhere in the world, EDI has established
an extensive sales network of U.S. offices and international
agents. This global force, combined with specialists at our U.S.
headquarters, EDI GmbH, and EDI China gives customers access to:
Experienced sales engineers who consult with customers to identify the
best die systems for their specific end-product requirements. Since virtually every
EDI die is built on a custom basis, sales engineers play a crucial role.
Skilled technicians who provide customers around the world with on-site
startup assistance and troubleshooting.
Extensive spare parts departments in the U.S., Europe and Asia that maintain
inventories of most standard parts and ship them within a day. Elsewhere, EDI
agents stock frequently requested components and instantly refer special orders
to the U.S. headquarters. With direct access to customer engineering records, EDI
can quickly produce custom parts to get lines back up and running.
In addition to supporting European and Asian agents by providing technical
service and spare parts, EDI GmbH and EDI China manufactures die components
to meet regional standards and expectations. The ultimate goal of this EDI whollyowned subsidiary is to produce “completely European and Asian dies for European
and Asian customers.”
5
Using proprietary
software, EDI
engineers can
model in three
dimensions the
flow of molten
polymer through a
manifold (shown
here) or feedblock.
Five-axis
machining
center at EDI's
headquarters
can produce
complex, streamlined
flow surfaces that
previously were
too costly or even
impossible to
manufacture.
In manufacturing dies,
EDI combines extensive
computerized automation
with skilled metal-working
craftsmanship, such as that
required for hand-polishing
all die surfaces.
6
Controls for EDI's computerized machining
centers are linked to the company's simulation
software, making possible fully three-dimensional
die production, from initial concepts to the
cutting of steel.
For die surfaces that must be
exceedingly smooth and flat, EDI
operates a climate-controlled
micro-grinding plant and a laser
system (shown here) for sub-micron
measurement of flatness.
C O M P A N Y - W I D E
O N
Q U A L I T Y
F O C U S
Quality assurance plays a central role in EDI’s entire
enterprise.
From the moment we start work on an order,
our objective is to design and build a die that is complete
in every detail, arrives on schedule, starts up trouble-free,
meets end-use product specifications, and runs efficiently and
consistently.
long
after
Quality also means assuring customers that,
the
sale,
they
can
maximize
productivity
by readily accessing technical support, spare parts, and
remanufacturing services.
Key capabilities of our ISO-9001:2000-compliant design
and manufacturing operations include:
Custom engineering. Our experienced engineers design dies that exactly meet
specifications for polymer types, throughput rates, number of layers, and other
parameters. Using resin data from our rheology lab and advanced flow simulation
software, EDI engineers determine optimal flow paths for manifolds and feedblocks.
Our company-wide “intranet” gives instant access to design standards for all die
components.
Precision manufacturing. Divided into focused manufacturing cells
to speed workflow and maximize quality, EDI’s production facilities employ CNC
milling machines capable of producing dies with widths from 15 cm to 10 m (6 in.
to 33 ft.). Skilled craftsmen hand-polish all die surfaces. For critical-performance
dies with exceedingly smooth, flat surfaces, EDI operates a climate-controlled
micro-grinding plant containing super-precise surface grinders and a laser system
for sub-micron measurement of flatness.
Fully ‘3-D’ machining. EDI’s fully three-dimensional production system
begins with unique software for 3-D modeling of polymer flow through a die.
This proprietary software is directly linked to computer-controlled milling centers,
enabling us to machine complex surfaces rapidly and within extremely narrow
dimensional tolerances.
The two 5-axis machining centers for flat-die production represent a further
leap forward in our 3-D manufacturing capabilities. These advanced systems, first
used in the aerospace industry, machines along two more axes than conventional
milling centers. It reduces the number of times that a die must be re-oriented
beneath cutting heads before milling of all surfaces is complete, enabling us to
produce new dies in less time. The additional axes also increases EDI’s capabilities
to produce complex, streamlined flow surfaces that are too costly– or even
impossible to manufacture–with conventional technology.
Extensive rework services. In the U.S., Germany, and China, EDI operates
dedicated remanufacturing cells for EDI dies and ones produced by other suppliers.
A licensee of our unique rework technology operates a plant in Japan. These
facilities enable customers to protect their investments by repairing and refurbishing
weary dies, returning them to original—or even better—performance. We can also
redesign flow surfaces, install new-generation technology, or add new capabilities
like automated gauge profiling.
7
SERVING EVERY FILM, SHEET,
AND COATING MARKET
The breadth of EDI’s expertise in
matching dies to specific applications
can be seen in the thousands of
our
dies
Customers
operating
range
Medical patches
Containers &
Appliance liners
Optical Film
Shelf-stable juice boxes
Solar Panels
worldwide.
from
custom
processors to multinational corporations. Installations range from small
shops to mass-production plants to
clean-room operations for transdermal
medical patches or optical films.
Major markets for the film, thermoformable
sheet,
and
coatings
processed with our dies include:
Packaging and disposables: bags and wraps;
barrier films; retort containers; see-through windows;
dairy tubs and lids; blister packs; ovenable trays;
meat, produce, and cookie trays; egg cartons;
“clamshell” containers; coatings on paperboard
milk cartons; plates and cups; stretch wrap.
Building and construction: vinyl siding;
glazing; vapor barriers; pool and pond liners;
geomembranes; insulation board; flooring;
wallboard; specialty tapes; window film; door shells;
shutters; corrugated panels; shower-stalls and
sanitaryware.
Durable goods: refrigerator and other
appliance liners; luggage shells; housings and
enclosures; sporting goods; pallets.
Transportation: windshield interlayers; mud
flaps; camper tops; panels and housings; fuel tanks.
Medical: blood and solution bags; disposable
and surgical kit trays; transdermal patches; adhesive
liners; hospital hygiene products;
pharmaceutical and device packaging.
Flexible packaging
Capacitor film
Sustainable Energy Technology: hybrid
automobile batteries; rigid and flexible photovoltaics
solar cells; optical films; water filter membranes.
Coatings on paperboard
8
Vinyl siding
lids
Barrier Technology
Medical blood & fluid bags
Spas & hot tubs
Package windows
Electronic packaging
Auto windshield interlayers
Disposable dinnerware
Battery Technology
Bubble Wrap
Stretch wrap
Produce packaging
Foam Board
Blister packaging
9
A CATALOG OF EDI DIE SYSTEMS,
COMPONENTS, AND ACCESSORIES
EDI designs and manufactures a wide spectrum of flat-die extrusion and coating
equipment–from leading-edge technology for ultra-precise applications to workhorse
systems proven in thousands of installations worldwide.
Our team of seasoned sales engineers and exclusive agents around the globe can
guide you through the sometimes complex process of choosing the right die system. With
a thorough understanding of your company’s needs and expectations, they can quickly
provide you with the best possible system.
In many applications the solutions are simple.
Yet in others there are routes to
success not readily apparent–even to process engineers with decades of experience. Many
times, investing right from the start in a flat die system with greater capabilities results in
process flexibility and productivity that yield better products and faster payback.
Here is an overview of EDI’s flat-die equipment and systems. In virtually all cases, dies,
feedblocks, and other critical components are custom engineered for specific customer
requirements.
EXTRUSION AND
COATING SYSTEMS
EDI supplies equipment for the full
range of mono- and multi-layer flat-die
processes: film, sheet, and extrusion
coating. Our dies are also used widely
to produce extruded webs for the
manufacture of biaxially oriented
polypropylene (BOPP), polyester
(BOPET), and nylon (BOPA) products,
as well as oriented polystyrene (OPS).
EDI slot-die systems are installed for
coating a wide range of polymeric and
non-polymeric substances onto paper,
film, and many other substrates.
Flat dies from EDI
range from widelyused industry
workhorses to
specialty types
like this die for
twin-wall sheet.
Regardless of type,
all EDI dies are
custom-engineered.
ULTRAFLEX® DIES
Our Ultraflex system is the industry-standard flat die, a workhorse used by thousands of processors
and converters around the world. Each Ultraflex die incorporates a flexible-lip adjustment system for
controlling profile thickness and ensuring consistent, defect-free products. Contributing to the precision of the die is the close spacing and steady compression of the adjusting bolts on the flexible lip.
(EDI dies with Autoflex® automatically adjustable thickness control are described in
a later section.)
Ultraflex dies feature streamlined flow surfaces for long production runs. Their basic two-piece
design simplifies disassembly, cleaning, and other routine maintenance. Specially designed endplates
simplify maintenance of end seals. Die-body geometry is customized to minimize the air gap between
the die exit and roll.
All Ultraflex dies can be provided with coextrusion capability. Die bodies are produced from
enhanced high-purity alloy tool steel (exceeding AISI P20 specifications) through-hardened for
extended die life. Flow surfaces are plated with industrial hard chrome at an average thickness of
0.001 to 0.0015 in. (25 to 38µ) and polished to a mirror finish. Exteriors are flash chrome-plated for
ease of maintenance and rust prevention. Dies are supplied completely wired with cartridge heaters.
10
THE ULTRAFLEX SERIES INCLUDES:
Lightweight and laboratory dies (L40 series) for low-pressure and narrow-web use.
Standard dies (U40 series) for extrusion coating, film, and thin sheet.
Heavyweight versions with bigger, stronger die bodies to handle higher throughput rates,
wider viscosity ranges, and greater product widths. Models range from light-heavyweight (LH
series) to heavyweight (H series) to extra-heavy weight (HM series).
Restrictor-bar models for sheet production, which provide uniform melt distribution over a wide
range of material viscosities and throughput rates. EDI restrictor bars are machined from hardened, corrosion-resistant stainless steel. These dies feature the patented Krupa® stud adjusting
system, which permits on-the-fly stud replacement in minutes. Restrictor bars can be at 45, 70,
or 90 degrees.
HEAVY DUTY™ AND MAGNUM™ SHEET DIES
Designed for products with thicknesses ranging as high as 0.700 in. (17.8 mm), Heavy Duty
and Magnum dies are sheet-industry workhorses, widely used by custom processors. Sliding
upper lips provide gauge versatility while replaceable lower lips afford versatility in gap opening
and land length. Lip lengths from 3.0 to 6.0 in. (7.6 to 15.2 cm) are available. Restrictor bars are
typically at 90 degrees.
TM
Heavy Duty Sheet Die
TM
Magnum Sheet Die
11
DIES TYPICALLY RECOMMENDED FOR SPECIFIC APPLICATIONS
(Recommended options: Edge Profile Control ™ (EPC) internal deckling)
12
L40
U40
LH40
H75
LR100
R100
RC100
HR100
HRC100
HRMC 100
13
AFVI
IV H75
®
AUTOFLEX DIES WITH AUTOMATED GAUGE PROFILING
Installed on more than 2000 dies worldwide, EDI’s Autoflex automatic thickness control system is the premier
technology for precisely controlling the thickness profile of film, thin sheet, and coatings. In addition to making
possible higher-quality, more accurate products, the Autoflex system can generate substantial raw material savings
compared to conventional manual adjustment.
All Autoflex systems center on a series of closely spaced thermally-actuated adjuster blocks arrayed along the
flexible lip of the die. These blocks operate in response to feedback from computerized downstream gauging
systems. When a thicker-than-target area is detected in the extrudate, power to the cartridge heaters at
corresponding points in the lip is automatically increased; this
causes the blocks to thermally expand, which tightens the lip gap
in the area. Conversely, thinner-than-target areas are addressed
by a reduction in power. All Autoflex systems have forced-air
This cast film
cooling to optimize response times.
system
The industry-standard Autoflex IV system is used widely in film
includes
and extrusion coating applications, making possible corrections
Autoflex ® die
within the +/- 200µ (0.008-in.) range. Dies in the more widely
and
adjustable Autoflex VI series nearly double the range to +/- 380µ
Accuflow®
(0.015 in.). In addition, the gauge-profiling system in the Autoflex
feedblock.
VI-R model is a module that can be readily disengaged from the
die for fast and easy maintenance.
Also available, for applications where ultra-fine gauge-control
may be required,
are specially designed Autoflex VI models with
TM
Microflex technology, which incorporates reduced adjusting-block centerlines and other measures to increase
resolution.
CONTOUR DIE FEATURE
The uniquely ‘sculplted’ geometry of the Contour Die assuring uniform dynamic die body deflection across the
die width, reducing the time required to adjust the die to within target parameters. Unlike conventional “constantdeflection” dies, however, the Contour Die has a coathanger manifold that provides streamlined flow allowing for
a significant reduction in scrap. As a result of these features, processors may be able to increase throughput,
within the production capabilities of their extrusion equipment.
FASTGAP® SYSTEM
World renowned for the manufacturing flexibility and
streamlined maintenance it provides, EDI’s patented
FastGap®
FastGap system available for most Autoflex and
single-point
Ultraflex dies permits processors
adjustment
to vary the lip gap within a range of 0.250 in.
system
(shown here
(6.4 mm) without taking a die off line. A single-point
on an
adjustment mechanism allows operators to quickly
Autoflex die)
change thickness settings for new runs, and return to
makes it
previous settings after purging or die lip cleaning, savpossible
ing valuable production time and reducing scrap.
to
vary the
Now installed on many EDI dies, FastGap
lip
gap
operates by means of “separate lip responsibilities,”
within
a wide
with gauge profile control carried out by the flexible top
range without
lip and gap adjustment by the operation of the
taking the die
FastGap system on the movable lower lip. EDI’s
off line.
TM
Advanced Lip Technology ( ALT ) system can be used
in conjunction with FastGap to further increase production flexibility. It employs interchangeable lip land
inserts that permit the processing of a wide range of products on the same die.
14
MULTIFLOW® MANIFOLD DESIGNS
The heart of an extrusion die, the manifold is the flow channel machined into the
die body that distributes molten polymer from an extruder into the required endproduct width and thickness. EDI supplies a range of Multiflow manifold designs
to meet the specific requirements of different materials and applications. Some of
the designs are:
Multiflow I, a standard coathanger design whose teardrop-shaped cross section
provides streamlined flow suitable for all polymers. Applications include mono-layer
products, as well as coextruded structures of heat-sensitive materials.
Multiflow I-R, whose almost completely rounded back wall provides processors
of heat-sensitive resins with the highest degree of protection from polymer
degradation.
Multiflow II , a standard coathanger manifold whose elongated-teardrop crosssection minimizes interface deformation in coextrusions of polymers with differing
rheological properties.
Multiflow II-G, center of channel has an elongated teardrop shaped diminishing
cross section coathanger for optimal coextrusion performance. Each die end is of
constant cross section to allow for streamlined full manifold internal deckling.
Multiflow IV, a “T”-shaped design with an elongated-teardrop cross section
whose volume is constant. Widely used in mono- and multi-layer extrusion coating,
TM
this design is the basis for EDI’s Edge Profile Control system for reducing or
eliminating edge-bead formation when product widths are changed
frequently. The design features full internal manifold plug deckling and deckle
blades, which can be quickly adjusted for different widths, rates, and materials.
Multiflow V, an advanced design with an elongated-teardrop cross section
(similar to that of Multiflow II) whose aspect ratio increases towards the ends of
the die and whose backline is parallel to the die lip exit. By placing all body bolts
at the same distance from the exit, this configuration minimizes differential die body
deflection. The complex cross-sectional design promotes the lowest degree of
interface deformation possible in coextrusion on a single-manifold die. The curved
preland provides uniform distribution of the polymer across the die width, addressing the phenomenon of “M” and “W” patterns.
Multiflow I
Multiflow I-R
Multiflow II
In these cross sections, with manifold back walls at top and
die exits at bottom, colors represent polymer speed. Dark
blue is slowest, orange is fastest. Multiflow I is standard
coathanger design for all polymers, including heat-sensitive
materials used in coextrusion. Multiflow I-R is a streamlined
manifold whose rounded back wall helps eliminate
degradation of heat-sensitive polymers. Multiflow II is an
advanced design that minimizes die body deflection, as
well as interface deformation in coextrusion.
STRAND PELLETIZING
Used by compounders, EDI strand dies have high-quality chrome-plated
steel bodies, stainless steel strand plates, and manifolds designed for
specific polymers and melt flow behavior. Each die is a custom product
that comes with a wide range of options, like low-wear strand plates,
explosion-proof and high temperature-resistant wiring, liquid temperature
control, and manifold designs incorporating restrictor bars.
DIES FOR FLUID COATING
ULTRACOAT PRECISION SLOT DIE COATING HEADS
For applying low-viscosity coating materials, Ultracoat dies provide a high
precision coating system. Since all of the coating material is applied to
Ultracoat® adjustable dies and
the substrate in a metered fashion, significant savings in raw materials
Liberty fixed lip dies are used for applying
can be realized. EDI’s manufacturing capability ensures die flatness, and
low-viscosity or wet coating materials.
optimum coat weight uniformity. Ultracoat dies incorporate a flexible lip
feature to refine coat weight distribution across the substrate and are
available with manual or automatic lip adjusting mechanisms (application specific lip face designs are available).
Ultracoat dies incorporate corrosion-resistant body materials, removable
lip inserts, and computer-engineered coathanger manifolds. The Ultracoat
Die Support System positions the coating die at the best possible angle
and proximity to the roll. This provides the accuracy and repeatability that
are essential, given the tight operating windows for backup roll applications.
LIBERTY FIXED LIP SLOT DIE
EDI’s Liberty fixed lip slot dies are precise coating devices that are used for a wide range of products in the paper industry,
medical field, electronics, solar panels and flat panel displays. When surrounded by the proper equipment, Liberty dies yield
excellent coating results. By using an internal shim to establish the slot gap our dies can handle fluid viscosity from 1 to over
100,000 cps. The coating thickness can be as low as 1 micron (0.000039”) to as much as 1.27mm (0.050”) making the fixed
lip slot die a very versatile tool.
15
COEXTRUSION
SYSTEMS
EDI is your international partner in coextrusion technology. Whether your product is
multi-layer stretch film, thermoformed rigid packaging, biaxially oriented film, or specialty
coatings, we have the right equipment to cost-effectively manufacture high-quality products.
In addition to manifold designs optimized for coextrusion in single-manifold systems
(see the section on Multiflow manifolds above), we offer a wide range of other system
TM
components to fit specifications and budgets. EDI feedblocks include Accuflow systems
that are fully adjustable on-line; Ultraflow® fixed-geometry models; designs that permit
rapid changes in the sequencing of layers; and simplified general-purpose types. Multimanifold dies are available for structures of up to seven layers. And for specialty coextrusions such as those with multiple colors or stripes in the machine direction, EDI develops
a variety of die designs on a custom basis.
EDI FEEDBLOCK SYSTEMS
Feedblocks are a critical component of coextrusion systems. They shape each molten polymer into
a layer, and then combine all layers into a single “sandwich” structure that is distributed by the die
manifold into film, sheet, or coating. This centimeters-wide structure requires extraordinary dimensional
precision as it will be distributed into a meters-wide end product.
Paired with Multiflow manifolds, EDI’s Accuflow and Ultraflow feedblocks can be used for the full
range of two- to seven-layer coextrusion applications with multiple advantages versus other systems.
All have totally stainless steel construction, easy to clean split-body construction, and optimal melt
streamlining to prevent the formation of gels and other defects.
Both Accuflow and Ultraflow feedblocks can be designed to incorporate EDI’s I-S series of interchangeable flow spools, which make it possible to change the sequence of material layers without
having to block off flow channels or disassemble the feedblock (see photo next page). This feature
provides versatility for processors who periodically switch material from the core layer to the skin layer,
for example, or from the inside skin to the outside skin.
At top is assembled
Accuflow® feedblock
for five-layer (ABCBA)
coextrusion. Rectangular exit
from feedblock channel is at
front. Entry from primary
(core-layer) extruder is at
back, not visible. In exploded
view at bottom, one of two
black-colored spools has
been removed from top half
of feedblock. At right is an
adaptor that feeds skins to
each side of core. Visible in
bottom-half spool is a taper
at its front surface, which
is adjusted to vary width
of skin layer.
16
ACCUFLOW® PATENTED FEEDBLOCKS
The patent-pending Accuflow adjustable feedblock redefines flat-die coextrusion technology as the first feedblock to provide precise on-line control over the quality and consistency of multi-layer film, sheet, and coatings
with up to seven layers. Conventional fixed-geometry feedblocks can be modified to accommodate variations in
product requirements by changing flow inserts, but making these changes involves downtime or longer startups.
By fine-tuning the transverse thickness profile of coextruded products during production, Accuflow adjustable
feedblocks accelerate line startups, simplify repeat runs, and boost productivity.
While conventional feedblocks incorporate solid metal spools or other devices that create “dead spots” and
stagnate polymer flow, Accuflow feedblocks employ highly streamlined, combining spools to minimize the
potential for degradation and permit finer adjustment of layers as they are combined. Each feedblock contains
one fewer combining spool than the total number of layers in a given product (i.e., two spools for a three-layer
product, six for a seven-layer structure). In operation, combining spools consecutively add layers to each side of
a central “core” layer. In a five-layer A-B-C-B-A structure, for example, the B sub-skin layers would first be added
to the C core layer, followed by the A skin layers.
Accuflow feedblocks can also be equipped with heating elements that refine the dimensions of the combined
structure by controlling viscosity at points along the width of the feedblock channel.
The precision and repeatability of the adjustments afforded by the Accuflow system make it possible to obtain
levels of product quality and consistency not achievable with conventional feedblocks. Specific improvements
include:
Finer layer and thickness adjustment, resulting from fast, accurate changes in the height and width of the
channel for each layer at the point in the feedblock where layers are combined.
Elimination of viscous encapsulation, which occurs when a less viscous polymer becomes thicker toward the
sides of the die by encapsulating a more viscous core layer. This is especially troublesome when the coextruded
skin layers are very thin. To correct viscous encapsulation, the combining spools can be rotated to make the exit
gap smaller and narrower. With thicker skins, where viscous encapsulation is less likely, the spools can be
opened to allow for increased melt flow.
Prevention of ‘M’ or ‘W’ flow patterns that result in non-uniform layers and defective products. These
irregularities can be removed by coupling the adjustments of the combining spools with profiling of the miniature
heaters in the feedblock channel.
ULTRAFLOW® FEEDBLOCKS
Unlike the adjustable Accuflow system, the Ultraflow I feedblock is a fixed-geometry unit. In most applications,
machined flow inserts-small distribution manifolds-permit the melt flow of each polymer to be fine-tuned prior to
the combining point in the feedblock. These inserts can be easily changed to accommodate more or fewer layers
without disassembling the feedblock or adaptor network.
The Ultraflow II-C feedblock is designed for production lines running dedicated coextrusion structures at low to
moderate throughput rates. The simplicity of its captured-insert design renders the feedblock compact and
affordable. Since the inserts are captured within the feedblock body, full disassembly is required to exchange the
flow distribution inserts. For less demanding coextrusion applications (i.e., well matched viscosities or thick skin
layers), this simple, clean design is highly effective.
Ultraflow® I-S
feedblock
enables
coextrusion
processors to
quickly change
the sequencing
of layers by
changing
flow spools,
an example
of which is the
cylindrical
component at
left in photo.
17
MULTI-MANIFOLD DIES
An alternative to feedblock technology, Isoflow multi-manifold dies from EDI provide more precise
control over polymers with different viscosity ratios, accommodate critical processing parameters, and
eliminate viscous encapsulation in wide webs. With Isoflow multi-manifold dies, coextruded layers are
combined before the die lip land for unsurpassed layer distribution.
Ultraflow feedblocks can be incorporated into these multi-manifold dies to feed multi-layer structures
into different manifolds in the same die. The dies can also be engineered to include EDI’s fixed restrictor
bars in one or more manifolds to provide ultra-precise skin-layer distribution.
Autoflex VI-R die
shown here is a
five-manifold
system. EDI’s
multi-manifold die
technology provides
precise control
over polymers with
different viscosity
ratios, accommodates
critical processing
parameters, and
eliminates viscous
encapsulation
in wide webs.
POLYSIDE® TECHNOLOGY
Polyside coextrusion dies make it possible to produce side-by-side structures–typically different
colored stripes-or a combination of side-by-side and multi-layer structures. Available in single or
multi-manifold versions, they create new design opportunities. Customized side-by-side “striping”
dies from EDI can produce webs with from two to several hundred machine-direction stripes of
varying colors and layer configurations.
18
SUBSYSTEMS AND
ACCESSORIES
DUAL VACUUM BOXES
EDI’s unique dual vacuum boxes provide better stabilization of extruded film than alternate
web-impingement devices. In operation, the pre-sweep chamber removes entrained air
between the casting roll surface and the film. A second chamber develops a higher vacuum
to stabilize the film forming area, reduce neck-in, and control film edge movement.
Constructed of stainless steel, EDI’s dual vacuum boxes feature swing-out, split chambers
that simplify cleaning, maintenance, and installation. Various blade
configurations–which are adjustable at the pre-sweep section and between
pre-sweep and primary chambers–can be supplied.
More effective than
alternate web-impingment
devices, EDI’s
proprietary vacuum box
technology removes
entrained air from
between film and roll,
then uses high vacuum
to stabilize film.
DECKLING SYSTEMS
Deckles are adjustable devices that vary end product width by blocking off portions of the
die slot from both ends of the die. EDI offers a wide range of external and internal types.
External systems available from EDI include: fixed-side deckles, flex-side deckles, sliding
cantilevered wedge-style deckles, and EDI’s Fast Deckle.™
Internal deckling systems offered by EDI include:
TM
• EPC full-bore internal/external deckle with edge profile control.
TM
• EPC-R partial internal deckles (lip-land blades) for edge profile control.
• “Gull-wing” deckles in Multiflow® V-G manifolds, with specific design
enhancements customized for each application.
All of the above internal deckling options are available in motorized systems.
TM
Fast TM
Deckle
External
Deckling
System
TM
EPC-R Partial
Internal Deckle for
Edge Profile Control
EPC
Full-Bore
Internal/External
Deckle
with Edge
Profile
Control
TM
Motorized EPC
Deckling System
19
SUBSYSTEMS AND
ACCESSORIES
ULTRACART® DIE SERVICE SYSTEMS
Ultracart die handling systems enhance worker safety, reduce downtime, simplify die
disassembly and reassembly, and help prevent costly damage to critical die surfaces during
maintenance. With these systems, die halves are easily rotated to access flow surfaces and
streamline cleaning procedures.
While basic Ultracart systems are for use with single-manifold dies, the Ultracart Rapid
Servicing System is especially designed for triple-manifold coextrusion dies. Fully mechanized,
the system can be wheeled to the processing line for off-loading of the die and moved to a
workplace for die cleaning and maintenance. Technicians can offload, disassemble, clean,
reassemble, and return the die to operation–all without removing die components from their
secure mounting on the cart.
Designed
for rapid
maintenance of
triple-manifold
coextrusion
dies, EDI’s
Ultracart®
Rapid Servicing
System makes
possible full
mechanization
of die handling,
from taking
the die off
line, through
disassembling
and cleaning,
to returning
the die to
operation.
ADAPTORS AND MELT FEEDPIPES
In designing and manufacturing these ancillary components, EDI pays the same attention to
detail as it does for dies and feedblocks, whether the customer requires small transition plates,
sophisticated distribution blocks for routing multiple flow streams to multi-channel dies, or lengthy
feedpipe networks. Our key design criteria are flow streamlining and engineering safety factors.
Adaptors and melt feedpipes are machined from high-quality steel forgings and are beautifully
polished.
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Extrusion Dies Industries, LLC
911 Kurth Road
Chippewa Falls, Wisconsin 54729 USA
Tel: (715) 726-1201
Fax: (715) 726-2205
E-mail:sales@extrusiondies.com
EDI GmbH
EDI Precision Dies (Shanghai) Co., Ltd.
99 Zhongde Road
Songjiang Science & Technology Park
Songjiang, Shanghai P. R. China 201614
Tel. +86-21-57850918 Fax. +86-21-57850698
E-mail: edishanghai@extrusiondies.com
Kastanienweg 8
51580 Reichshof-Wehnrath, Germany
Tel: 49-2265-980627
Fax: 49-2265-980690
E-mail: info@edi-gmbh.de
Your Global Partner in
Extrusion, Coextrusion, and Converting
Designers and manufacturers of high performance die systems
www.extrusiondies.com
www.reworkdies.com
6-2008