Firmenprsentation I 04/2006 I Page 1

Firmenprsentation I 04/2006 I Page 2

Coperion Processing of PVC

Dario SavinoSales Manager Coperion S.r.I., Ferrara (I)

Firmenprsentation I 04/2006 I Page 3

Processing of PVCAPPLICATIONS

Rigid PVC: Extrusion and Injection Moulding

Window profiles Technical profiles Pipes and Fittings Sheets

Rigid and Semi-rigid PVC: Calendering applications and Blow moulding

Rigid and semi-rigid sheets Packaging and Bottles

Firmenprsentation I 04/2006 I Page 4

Processing of PVCAPPLICATIONS

Plasticised PVC: Extrusion, Injection moulding, Cal endering

Cable Film Technical profiles Hoses Flooring

Plastisol

Artificial leather Coated Textiles Sealants Wallcovering Flooring Dolls

Firmenprsentation I 04/2006 I Page 5

CoperionTypical plant concept

Firmenprsentation I 04/2006 I Page 6

Raw Materials ReceiptBulk delivery by tank trucks

Firmenprsentation I 04/2006 I Page 7

Raw Materials ReceiptEmpting stations for 25 kg bags and jumbo bags

typical Installation hatch for 25 kg bags

Big-Bags loading nozzle

automatic filter

Firmenprsentation I 04/2006 I Page 8

Raw Materials ReceiptEmpting stations for 25 kg bags and jumbo bags

filter pocketscompressed air tank

filter control unit (timer)

solenoid valvestipping station (overall view)

Firmenprsentation I 04/2006 I Page 9

Raw Materials ReceiptOutdoor storage silos

Firmenprsentation I 04/2006 I Page 10

Raw Materials HandlingExtraction from storage silos and hoppers

Extraction by Fluidification Extraction by Bin Activator

Firmenprsentation I 04/2006 I Page 11

Raw materials handlingPneumatic conveying: suction box & rotary valves

suction box with suction nozzle for PVC

rotary valves for fillers and additives

Firmenprsentation I 04/2006 I Page 12

Vacuum dosing and weighingSuction scale

vacuum pocket filter(side removal)

weighing hopper with 3 load cells

discharging cone

opening hatch

Firmenprsentation I 04/2006 I Page 13

Vacuum dosing and weighingSuction scale

upper part

lower part with fluidizing discharge aid

side pocket filter

opening hatch

Firmenprsentation I 04/2006 I Page 14

Mixer feedingSuction scale

suction scale

Firmenprsentation I 04/2006 I Page 15

Additives handlingLemon hoppers: compact arrangement for the discharge stations

Firmenprsentation I 04/2006 I Page 16

Additives HandlingDischarge and Dosing Stations

tipping hoppers

Bin activators

Dosing screw

weighing scale

Firmenprsentation I 04/2006 I Page 17

Additives handlingDosing and weighing stations

additives dosing screws additives scale load cells (3)

elastic hopper of scale ensures complete discharge of weighed batch

minimization of tolerances between the batches is d ecisive for a constantly high qualityof the compound

Firmenprsentation I 04/2006 I Page 18

Additives handlingDosing screws

dosing screw easy cleaning typeeasy detachable cover

Firmenprsentation I 04/2006 I Page 19

Additives handlingLiquid additives dosing and weighing stations

load cellsload cell feeding valves

Firmenprsentation I 04/2006 I Page 20

Additives handlingPre-weighed pigments and microingredients

phase belt conveyorpre-weighed bags

feeding chute

Firmenprsentation I 04/2006 I Page 21

Mixer feeding

additivestipping

hoppers

additivesweighing

scale

dosing feeders

pneumatic conveying line

suctionscale

hot mixer

cool mixer

Firmenprsentation I 04/2006 I Page 22

Heating/Cooling MixerTypical capacities for rigid PVC production

7 to 8No. of batches per hour

45 C

120 C

0,5 to > 7 tons

60 to > 1000 kg

Cooling mixer end temperature

Heating mixer end temperature

Capacity per hour

Batch size

Firmenprsentation I 04/2006 I Page 23

Heating/Cooling MixerTYPICAL MIXER INLET ARRANGEMENTS

sealing butterfly valve

hot mixercover

additivesscale

pinchvalve

Firmenprsentation I 04/2006 I Page 24

Heating mixerFunction principle of the heating mixer

ideal vortex for high mixing quality

excellent self-cleaning

Cross section of a high efficiency mixer

Firmenprsentation I 04/2006 I Page 25

Heating mixerDetails of the heating mixer

mixing bowl with

dosing lance

deflector

mixing tool

Firmenprsentation I 04/2006 I Page 26

up to 4 times size of the hot mixer

sizes from 400 to 8000 l

extremely large cooling surface

high efficiency cooling based on

perfect heat transfer

Cooling mixerDetails of the cooling mixer

Usually direct feed of the dryblend from hot mixer t o compounder to save energy

cooling mixer is only required in special applicati ons: transparent and medical grades

Firmenprsentation I 04/2006 I Page 27

Extruder Feeding

Firmenprsentation I 04/2006 I Page 28

Extruder FeedingVacumat (Vacuum conveying)

Firmenprsentation I 04/2006 I Page 29

Automation by WPC Weighing and Mixing Process Control (WPC)

- More than 150 automated plants worldwide- More than 20 years of experience and continuous development- Automation system developed and designed in-house- A lot of features already in the basic package- Numerous useful options, individually for every plant- Multilingual (Russian, Chinese, etc.)- High level of standardisation- Through the integration in overlaid process-IT functions - more than

just an automation - The optimum automation for

PVC industryand...in every process with mixing, dosing and conveying

Firmenprsentation I 04/2006 I Page 30

Automation by WPCData management and visualization

Master data management Raw material entry and storage

including lot management Production planning, monitoring

and production data management

Plant operation handling byintegrated visualization system

Firmenprsentation I 04/2006 I Page 31

Automation by WPCTrend graphs: visualization of the mixing process

Firmenprsentation I 04/2006 I Page 32

Automation by WPCUseful and innovatives adds-on

Plant maintenance cycle control system VMI interface (Vendor Managed Inventory) Recording of production job batch data

Firmenprsentation I 04/2006 I Page 33

Equipment for material handling Roots type blowers: vacuum conveying assembly

roots blower(vacuum assembly)

vacuum Blower safetyfilter (cartridge type)

vacuum blower by-pass valve

filter (cartridge type)

Firmenprsentation I 04/2006 I Page 34

Equipment for material handling Roots type blowers

3-lobes pump

inlet silencer

outlet silencer

electric motorV-belt coupling

supporting frame with shock absorbers

overpressuresafety valve

Firmenprsentation I 04/2006 I Page 35

Compressed air

Compressed airCompressed air

Vibration

Vibrating bottom Fluidising cloth(Pulsating compressed air) (mechanical)

Raker

Horizontal valve Sinter bed for fluidisation(intermittent)

Fluidising nozzle(intermittent)

Air jet

Equipment for material handlingDischarge devices / discharge aids: various types and principles

Firmenprsentation I 04/2006 I Page 36

Equipment for material handlingRotary Valves program overview

1,51,53,50,11,51,51,53,53,5Pressure [bar]

Powder < 1 mm

Food

Minerals

General chemicals

Plastics / basematerials

ZGMZVB ZVDZVHZROZKDZRDZXDZAQZXQ

Pellets 1-10 mm

Firmenprsentation I 04/2006 I Page 37

Equipment for material handlingDiverter valves program overview

Principle

Pellets and powders

134 / 24,566Pressure [bar]

Pellets

Food

Minerals

General Chemicals

Plastics

WGVWHTWZKWYKWETWEK

Firmenprsentation I 04/2006 I Page 38

Equipment for material handlingBlow-through rotary valve

Characteristics:- Circular inlet flange

- Optimised blow-through channel

ZXD Model

Blow through operation Operation pressure max. 1,5 bar(g) Conveying of free flowing and cohesive powders

gear motor assembly

Firmenprsentation I 04/2006 I Page 39

Equipment for material handlingExtruder feeding by vacuum and mechanical conveying

Firmenprsentation I 04/2006 I Page 40

Equipment for material handlingLong Resistance Bends for abrasive dry-blend

Firmenprsentation I 04/2006 I Page 41

Equipment for material handlingAccessories

repair slide level switch

ATI cone

air knocker

Firmenprsentation I 04/2006 I Page 42

Equipment for material handlingAccessories

disk in SS 304

seat in Neoprene rubber

housing in cast aluminium

pneumatic actuator with limit switches and solenoid valve

Firmenprsentation I 04/2006 I Page 43

Equipment for material handlingAccessories

flange connection Morris type couplings

galvanized carbon steel

Neoprene rubber

flange in cast aluminiumcollar in SS AISI 304 welded on pipe

Firmenprsentation I 04/2006 I Page 44

Equipment for material handlingCoperion R&D technical center for material handlin g

Firmenprsentation I 04/2006 I Page 45

Thank you very much for your attention.