Innovative extrusion solutions from KraussMaffei Berstorff

On May 15, 2014 the subsidiary of the KraussMaffei Group in the USA is opening its doors to customers. As part of this event, which has already become a tradition, KraussMaffei Berstorff is displaying the efficient production of two-layered PE pipes on a running extrusion line, which is equipped with the KM-RKW 34-250 IPC multi-layer pipe head and the KMG 81-40/R twin-screw extruder. Another focal point is the recycling of polystyrene with a twin-screw extruder.

Efficient solutions for the trend toward multi-layered pipes
“With our pipe head system, which has proven itself for many years and been used successfully worldwide, we are responding to the trend toward multi-layered PE pipes that is also emerging in the USA,” points out Matthias Sieverding, head of Extrusion Technology for KraussMaffei Berstorff in the USA. “Our exhibit, the KM-RKW 34-250 IPC pipe head, is designed with an outer-layer adapter; it produces PE pipes with a diameter of 114.3 mm and a wall thickness of 12.7 mm (4" SDR 9 IPS), which are provided with an outer layer of 2 mm that serves as a protective layer,” he explains. Pipes of this kind are primarily used in drinking water applications when routing without a sand bed.

IPC (Internal Pipe Cooling) system for increasing productivity
Sieverding happily reports, “We are having great success with our system for efficient internal pipe cooling. Since the market launch in 2010, we have sold more than 20 pipe heads with the IPC system.” The system guarantees additional cooling of the pipe from inside using ambient air, which is sucked through the pipe opposite the extrusion direction using a side channel compressor. “This is an important advantage that our customers greatly value: The outputs are significantly increased (by a maximum of up to 60 percent), without having to extend the cooling section in the process,” he explains.

Direct extrusion process for highly filled materials
The pipe production system is equipped with the KMG 81-40/R corotating twin-screw extruder, which is used in the direct extrusion process for manufacturing PE pipes from highly filled materials in a way that is profitable and gentle on the material. With this process, the material is compounded and the product is simultaneously extruded in just one step. Thus direct extrusion cuts out a whole production step. The one-step process reduces manufacturing costs and is gentle on the material, since it has to be prepared in the heat only once. The KME 60 XS coextruder used for the outer layer features an excellent price/performance ratio.

36D single-screw technology for special material in the USA
In addition, the KME 75-36 B/R single-screw extruder can be seen as an exhibit. The extruders in this series are excellently suited particularly for processing the material mixes used especially in the USA (called salt and pepper mixtures = natural and masterbatch). Their process concept guarantees gentle melt processing and therefore optimum melt homogeneity as well as a perfect mixing of masterbatch.

Easy recycling of polystyrenes
KraussMaffei Berstorff is presenting an extrusion system specially for recycling polystyrenes with a residual moisture of up to 10 percent and contamination from cellulose residue, adhesive residue, label residue or organic contamination of up to eight percent. The core component is a ZE 40 A UTXi x 40 twin-screw extruder, which is fed with flakes and any required additives by gravimetric metering equipment. The front part of the process unit is designed for the melting. The extruder has various degassing units for evacuating the moisture. The melt is transferred from the extruder to an Ettlinger melt filter with a constant, open filter area and a high filter grade, which transfers the cleaned melt into a Gala underwater granulation system (UWG). When explaining the significance of the displayed compounding system Sieverding said, “From the standpoint of resource conservation, segregated recycling of waste materials has special significance above all.”

Color measurement system provides for faster coloring
KraussMaffei Berstorff is presenting an in-line color spec monitoring color measurement system specially for masterbatch manufacturing on a ZE 25 laboratory extruder. The system significantly reduces the downtimes of twin-screw extruders, because color matching is particularly fast and easy during compounding.

Source: KraussMaffei Berstorff