This year’s K show saw the world premier of new extrusion products and technologies from system supplier KraussMaffei Berstorff. The KME 60-41 B/R single screw extruder series is designed for PO pipe processing; ZE BluePower twin screw extruder is intended for plastics processing; and the C6 control system enables constant fast, direct access to the individual units of a machine, extruders and downstream equipment. Also presented at the show was the KM-7L-RKW 01-32 pipehead system, which produces up to seven layers.
(f.l.t.r.) KraussMaffei exhibits at the K show included the KME 30-30 B/R with seven-layer pipehead system; KM-7L-RKW 01-32 system solution for hot water application; ZE Blue Power twin screw extruder; Schaumtandex ZE 40 / KE90 ISO-Board foam extrusion line
“When we were redeveloping the KME 60-41 B/R single screw extruder series we incorporated elements from our 36D series, which has enjoyed significant success for some time and has customers across the globe. We combined these elements with a new processing concept and are delighted to be able to present this world first to our customers at the K 2013 trade show,” said Peter Roos, President of the Extrusion Technology segment and of the KraussMaffei Berstorff brand. (photo: KraussMaffei Berstorff)
New single screw extruder series
The new KME 60-41 B/R single screw extruder series has an actual processing length of 41L/D. On the stand it was combined with the KM-RKW 34-250 internal pipe cooling system (IPC) pipehead to enable cost-effective pipe processing and increased output. It is suitable for high-performance PE and PP pipe extrusion.
KraussMaffei Berstorff KME 60-41 B/R single screw extruder features a very long processing unit, for disproportionately high output. (photo: KraussMaffei Berstorff)
Peter Roos, President of the Extrusion Technology segment and of the KraussMaffei Berstorff brand said: “When we were redeveloping this series we incorporated elements from our 36D series, which has enjoyed significant success for some time and has customers across the globe. We combined these elements with a new processing concept and are delighted to be able to present this world first to our customers at the K 2013 trade show”.
The new series, with its patented processing concept and 41L/D screw, is said to deliver a disproportionately increased throughput while, at the same time, maintaining low melt temperatures and high product quality.
The screw has been designed to exploit the entire length for melting and homogenising. This reduces the amount of stress to which the polymer is subjected, as well as ensuring that plasticisation has a reduced impact on the material properties during the melting process. In addition, an improved combination of heating and cooling means that the barrel can ensure optimal heat dissipation.
The modification of the length and dimensions of a filling opening, in order to accommodate the increased throughput, is claimed to guarantee linear throughput development across the entire speed range. The design of the spiral-grooved bush provides low-impact material handling alongside feed stability.
The new extruder series is equipped with bimetal barrels and can, optionally, be fitted with through-hardened grooved bushes, which provide good wear resistance. The 41D series is available with 45, 60, 75, 90, 105 and 125mm screw diameters.
KraussMaffei Berstorff pipehead with IPC technology (photo: KraussMaffei)
New twin screw extruder series
The ZE BluePower twin screw extruder series combines operating point optimisation of the drive system, including water-cooled three-phase motor and high-efficiency gear unit, with a completely redesigned processing section.
ZE Blue Power twin screw extruder and Schaumtandex ZE 40 / KE90 ISO-Board foam extrusion line
“The new ZE BluePower enables our customers to meet ever increasing market demands for output rate, product quality, process reliability and flexibility,”explained Roos. “Compared with the previous ZE UTX series, ZE BluePower features an increased OD/ID diameter ratio of 1.65, which gives a 30% higher torque density of up to 16Nm/cm³.”
KraussMaffei Berstorff says that it has optimised the tooth profiles of the screw shaft and screw elements, the screw preloading system and the geometry of the connecting sleeves, in order to transmit and fully exploit the high torque in the process, safely.
A number of technical improvements implemented in the ZE BluePower series provide increased availability and ease of maintenance in 24/7 production mode, the company says. In the drive to achieve effective wear protection for all applications, KraussMaffei Berstorff has complemented the range of patented induction hardened or powder-coated barrel sections with new wear liners. High fitting accuracy and axial fastening enable the elliptical collar liners to provide good heat transfer and tightness in the processing chamber.
The modular range of barrel sections with 4 and 6D lengths – equipped with the established C-clamp system for rapid barrel section replacement – and a variety of different screw elements are intended to provide flexibility in solution customisation for specific applications. The company claims that increased free volume in the processing section and higher torque combine to give cost-effective compounding. Improved side feeders and various hold-down devices have increased the extruder’s output rates.
The ZE BluePower series features a new base frame concept, which is designed to provide easy and rapid access to the different machine components. Peripheral equipment and control systems can either be integrated into the base frame or mounted separately.
Modular design for seven-layer, multi-functional pipes
The KM-7L-RKW 01-32 pipehead system, which produces up to seven layers, is intended to meet the rising demand for complex pipes with multiple functional layers.
F.l.t.r.: KM-7L-RKW 01-32 seven-layer pipehead; ZE Blue Power twin screw extruder; Schaumtandex ZE 40 / KE90 ISO-Board foam extrusion line; mini roller head system for tyre component production; Ecoline microwave channel for vulcanisation of rubber profiles; conical twin screw extruder for profile extrusion
The multilayer pipehead is capable of producing pipes with more layers than any other in the company’s existing product portfolio. In combination with the new KME 30-30 B/R coextruder, the concept seeks to guarantee a constant output unaffected by counter-pressure, as well as delivering high product quality in seven layer pipes.
Seven-layer pipehead for the production of seven-layer, multi-functional PO pipes (photo: KraussMaffei Berstorff)
“Our new pipehead’s modular design is made up of between two and seven radial distributors, with various spiral inflows,” Roos explained. “As a result, we can achieve the lowest possible tolerances in the production of each individual layer. We support extrusion shops in their efforts to achieve sustainable production, since this allows material consumption to be reduced in expensive, thin layers such as barrier or adhesion-promoting layers”. The modular design principle also allows the processing system to be adapted quickly, from producing seven layers to five or three, for example. In addition, improved flow-channel technology leads to shorter flushing times. The exhibit is designed for outputs of up to 500kg/h for a diameter range of between 8 and 32mm.
C6 central line control system
KraussMaffei Berstoff premiered the new generation C6 control system at the show. “In our new C6 control system, we have systematically implemented features that have worked well in the past and we have combined these with state-of-the-art hardware components,” said Roos. KraussMaffei Berstorff says that its multiple monitoring and closed-loop control functions enable the C6 control system to offer fast, direct access to the individual units of a machine, to the extruders which work conjointly to produce the product, and to downstream equipment, at all times. The C6 control system is equipped with the latest software, which sets it up for future machine concept requirements.
C6 control system – standard version: swivel-mounted on switching cabinet (photo: KraussMaffei Berstorff)
The clear screen layout provides a comprehensive process overview. The company states that units and functions can easily be operated and activated via the touchscreen display. Non-contact identification using RFID readers is said to enable fast, secure access to the machine.
KraussMaffei Berstorff has placed great emphasis on designing a system that is versatile for the operator. The composition of parameter pages can be chosen freely, display and parameter texts can be tailored to individual requirements; and system components can be switched on and off as required. The system also benefits from remote diagnostics via the internet and data interfaces, to connect to the company network.
Exhibits KME 60-41 B/R and KME 30-30 B/R at K 2013 had the new C6 central line control system installed.
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