COMPLETE SYSTEM SOLUTIONS PVC sheet and film … / Electronics Packaging Complete system solutions...

COMPLETE SYSTEM SOLUTIONS

PVC sheet and film extrusion

IN PARTNERSHIP WITH INDUSTRY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Whatever you aim to achieve in plastics or rubber

processing, KraussMaffei is your partner. We are

the only company with intensive expertise across

the three main engineering fields. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

Ready for any challenge

Our Injection Molding Machinery Division

supplies machinery and systems from 35 to 4,000

tonnes for standard applications and for all

processing variants, together with fully automated

solutions. We have a strong customer base in all the

relevant industries worldwide.

Our Reaction Process Machinery Division supplies

machines and complete systems for processing

polyurethanes and other reactive materials.

Completing our product portfolio, Automotive

Component Systems supplies foam molds, cutters

and routers. Our customer base is wide, with a

focus on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems for compounding, for pipe,

profile and sheet extrusion, physical foaming, and

the production of technical rubbers and inter-

mediates for tire production. Machinery from the

company’s range – from single extruders to

complete extrusion lines – is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, furniture and packaging.

People for Plastics

We are the “people for plastics”. We are your

partners from the first exploratory discussion,

through development to commissioning, servicing

and operating your system, and final disposal. At all

times, you are assured of outstanding competence

in planning and engineering, as well as reliable and

fast spare parts, service and support.

Adding value for customers

We put our expertise to work for your success.

With machine ranges engineered for modular-

ity, we can deliver application-specific solutions

based on our wide range of standard modules and

specially engineered solutions. This strategy offers

customers technical and cost advantages.

Close to customers around the world

As an international company, KraussMaffei has

a presence in all the major markets for the plastics

and rubber processing industries and employs

around 3,000 people worldwide. Our sales and

service network keeps us close to all our

customers around the world.

Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive

Electrical / Electronics Packaging

Complete system solutions for cost-effective PVC sheet extrusion PVC sheet – whether compact, foamed or coextruded – is a modern alternative to wood, fiberboard and other compact materials. It can be processed and enhanced in various ways and is widely used in the construction and advertising industry. As a system supplier of vast experience, KraussMaffei Berstorff has been providing complete integrated system solutions for a wide range of PVC film and sheet products for many years. Your investment in our extrusion lines will pay for itself in a very short time. And your products will combine high quality with low manufacturing costs. The out-standing process and application know-how of our ap-plication engineers and the fact that we supply com-plete single-vendor systems reduce your effort and costs for production start-up and in all production pro-cesses.

Roll cooling zoneCools the sheet

Unwinding unit for protective plastic film Top and bottom

4-roll haul-off

Longitudinal parting saw

Crosscut saw/guillotine combination· setting device for right-angled cut· lengths accurate to +/- 0.2 mm

StackerStacking inline or right/left/both sides

TRANSPARENT TECHNOLOGY

Meet the machine: take a tour of a complete PVC sheet extrusion line

Edge trim hacker

32D twin-screw extruder

GravimetricsVolumetric/gravimetric metering

Coex adapterCombines material from the main extruder and coextruder to produce coextruded sheet

Sheet dieFor compact, transparent, free-foamed and coextruded PVC sheet with special melt channel geometry for a wide thickness range and special lip system· oil-cooled die lips

PrecoolingUsed in production of foamed sheet

Polishing stand · Rolls · chrome-plated · indiv idually dr iven· Play-free nip adjustment even under load· Nip monitoring using electronic sensors

Laminating unit Unwinds a laminating film

Embossing unitTo produce embossed sheet

Roll cooling zoneCools the sheet

Gangway

Cooling unit

Longitudinal cutting knife Movable


Whether you’re producing compact, coextruded or

integral foam sheet, KraussMaffei Berstorff offers

you proven technology for highly cost-effective,

and, above all, complete system solutions.

The right machine to match your requirements

32D technology, which has long proved successful

in profile extrusion, is now becoming generally

accepted for PVC sheet production as well. While

the KMD 164-32/PL is noted for its high output

of foamed sheet, the KMD 114-32/PL and KMD

133-32/PL are ideal for producing top-quality ther-

moformable compact sheet – and for foamed sheet.

These two machine types are thus the ideal choice

for the most common product applications.

Intensive experience in all aspects of

PVC sheet extrusion

It takes expertise and experience to engineer the

optimum system for production of high-quality

foamed sheet. Our know-how starts with the extru-

der, but also encompasses the dies and downstream

units as well – critical elements in the extrusion

process. We have long experience in working with

and optimizing sheet dies, so that you can be sure

our dies represent mature technology. One benefit

to you is that you can produce different types of

sheet using one and the same die merely by swap-

ping one of the die lips.

DETAILED PRODUCT INFORMATION

32D twin-screw extruders set new standards in PVC sheet extrusion

Technical data KraussMaffei Berstorff sheet extruders

Technical data Coextruders

KMD 90-32/PL KMD 114-32/PL KMD 133-32/PL KMD 164-32/PL KMD 184-32/PL KMD 75-26/PL KMD 90-32/PL

Output range [kg/h] 210–520 300–700 450–1100 600–1400 800–2000 80–240 180–390

Motor power output [kW] 64 100 155 230 320 32 64

Gear torque max. [Nm] 18 000 35 700 56 000 90 000 140 000 9400 18 000

Screw speed, max.. [min-1] 32 25 25 23 20,5 30,5 32

Screw length [L/D] 32 32 32 32 32 26 32

Screw diameter [mm] 90 114 133 164 184 75 90

Screw heating/cooling external external external external external external external

Extrusion height [mm] 1150 1150 1150 1150 1400 1150 1150

Dimensions [mm]

Length incl. intake 5075 6250 7425 9625 10 350 3800 5075

Width incl. operator console 1400 1650 1850 1540 3270 1280 1400

Height incl. hopper 2600 2650 2650 2600 3450 2400 2600

Detailed product information Page 7

Coextrusion for new products and new markets

Coextrusion offers you interesting prospects for

developing new product properties and to tap into

new markets. These could include precise, repeat-

able pigmenting, sandwich-structure sheet with

outstanding mechanical properties, versatile surface

design and the use of lower-cost materials. We offer

two coextruder models for sheet extrusion, the

KMD 75-26/PL and the KMD 90-32/PL.

Integral foam extrusion for sheet up to

2 m wide

Our concept for integral foam extrusion is a

recipe for success in every way: high output rates,

single-vendor sourcing for the complete system, all

engineering work carried out by an experienced

team of experts, and the latest computer simulation

of the cooling process for optimal design of the

cooling zone.

Coextrusion system

The process engineering behind the 32D sheet

extruder

The production of high-quality PVC sheet demands

one thing above all else: absolute melt homogeneity.

Two features of the 32D twin-screw sheet extruders

guarantee that this is achieved even for very long

production runs. These are the optimized screw

geometry and high-precision control of tempera-

tures in the processing unit. The screws have

molybdenum wear protection as standard. They are

completely chrome-plated and fitted with an exter-

nal temperature control system. This ensures opti-

mum processing and control of melt flow. An

optimized vacuum unit with twin solids separators


Optimized screw geometry and precise tempera-ture control for outstanding melt homogeneity

Vacuum pump with twin separatorsScrew outlet to the adapter


maintains a constant vacuum. The system is easy to

clean and very user-friendly. The barrels of the

KMD 90-32/PL, the KMD 114-32/PL and KMD

133-32/PL are air-cooled while those of the KMD

164-32/PL and the KMD 184-32/PL are oil-cooled,

in all cases by means of aluminium pads. In 32D

sheet extruders, the screw flights protrude into the

adapter to prevent the melt from stagnating. Besides

a twisted adapter, designed to create a perfect sheet

surface, we also supply open and spider-channel

adapters.

Mobile operator panel

(option)

KraussMaffei Berstorff standard operator panel:

integrated in the control cabinet

Swivel-mounted operator panel (option)


The C5 control – one of the most advanced control and monitoring systems in the industry

Centralized control of the extrusion line

Meeting tough specifications for product quality and

output demands a stable, reliable production process.

This is where the C5 control system scores. As one of

the most advanced systems in the industry, it offers

dependable technology and intelligent functions for

centralized control and monitoring of extrusion lines.

For the operator, the C5 ensures optimal set-up and

start-up, and a clear, consistent overview of the pro-

duction process. Monitoring and control is facilitated

by efficient visualization of the status of different

extrusion line components on a series of screen pages.

Central synchronization of the whole line, including

multiple extruders, is fast and simple. The operator

panel allows direct intervention in the operation of

all key elements in the extrusion line. The current

operating status of the whole line is always displayed,

together with a customizable selection of seven actual

parameters. Prompts and alarm messages flash up

in your chosen language. The C5 offers extensive

documentation options and easy connection to a host

computer. The standard design features an integrated

operator panel; swivel-mounted or mobile panels are

offered as options. The swivel-mounted panel, for

example, enables the operator to run the whole line

from a position near the die.

Detailed product information

TRANSPARENT TECHNOLOGY

Meet the machine: take a tour of a 32D twin-screw sheet extruder

Vacuum degassingWith high-performance pump and twin solids separators

MotorChoice of AC or DC version

GearingRugged, with high torque

Gravimetric metering

Vacuum linesFlexible, large cross-section,easy to maintain 32D processing unit

With molybdenum-plated screws (external temperature control) and air-cooled barrel

Venting aperture

Small-volume metering unitFor example, for color masterbatch

PVC sheet and film extrusionPage 12

Profit from the many benefits of our sheet

extrusion systems to increase your competitive

advantage.

Outstanding machine technology

The extruder’s long processing unit (32D) offers

optimum melt homogeneity, a very wide processing

window and very high output. The external screw

temperature control boosts melt homogeneity even

further – helping the system to deliver quality

products with outstanding consistency. Higher

screw torque, combined with the longer preheating

section, raises specific throughput, resulting in

higher output at lower screw speeds. In short, 32D

machines are engineered for very efficient sheet

extrusion and a high return on your investment.

Practical product properties

Compact PVC sheet, foamed PVC sheet and coex-

truded foamed sheet are notable for:

· High surface hardness

· Very good rigidity

· Thermoformability

· Corrosion resistance

· Low product cost

· Low water absorption < 0.5%

· Low thermal conductivity

· Absorption of oscillations and vibrations

· Can be treated with an antistatic

Integral foam sheet is notable for:

· Low weight and a hard surface

· Smooth surface

· Narrow thickness tolerance

· Absolute flatness

C-PVC sheet is notable for:

· Extremely good chemical resistance

· Very good scratch resistance

· High flame resistance

· Very good mechanical properties at elevated

temperatures

PVC sheet is used in many industries

· Automotive: caravans and mobile homes, trailers,

commercial vehicles

· Architecture and furnishings: balconies, facades,

shopfitting, paneling, shelving, storage units,

door panels

· Construction: shuttering, air-conditioning and

ventilation shafts, insulation and interior walls,

siding, corrugated sheet

· General industrial: machine housings, containers,

cold-storage facilities, thermoformed parts

· Shipbuilding: outfitting, lightweight furnishings

· Electrical engineering: switching cabinets, cable

conduits

CUSTOMER BENEFITS AND APPLICATIONS

Our 32D twin-screw extruders meet the high quality specifications for extruded sheet

Laminated thermoformed PVC sheet

Printed PVC foam panels

Embossed PVC foamed sheet

Embossed transparent PVC sheet

Flexible PVC sheet and film are used for special

purposes

· Medical technology: blood and urine bags,

hygienic film

· Office equipment: floor mats, desk pads

· General industrial: curtain doors, strip curtain-

ing, tarpaulins

With KraussMaffei Berstorff lines, you can

produce a multitude of products

· Compact U-PVC sheet, opaque: 0.8-30 mm;

transparent: 0.8-20 mm

· Foamed PVC sheet: 1-25 mm; (32 mm on request)

Density 0.55- 0.75 g/cm³, depending on sheet

thickness

· Lightweight foamed sheet PVC: 3-12 mm

Density 0.45-0.5 g/cm³, depending on sheet

thickness

· Coextruded foamcore sheet: 2-12 mm

(> 12 mm on request), optionally 1 or 2 compact

outer layers; 0.2-0.6 mm

· Coextruded thermoformable compact sheet;

1-4 mm

· C-PVC compact sheet 1-13 mm;

(> 13 mm on request)

· Integral foam sheet 8-20 mm;

(> 20 mm on request)

· PVC-U sheet: 1-8 mm

· PVC-P film: 30-500 µm single and multiple layers

Applications and customer benefits Page 13

Your benefits at a glance::Your benefits at a glance::

· · Optimum melt homogeneityOptimum melt homogeneity

· · Very wide processing windowVery wide processing window

· · Very high outputVery high output

· · Outstandingly consistent product qualityOutstandingly consistent product quality

· · Extremely long service lifeExtremely long service life

· · Rapid return on your investment Rapid return on your investment

High-quality surfaces enable high-

quality digital printing, for example,

information and advertising panels

made of thin, foamed PVC

(1.5-3 mm thick)

Rely on us for a fast and competent response to

all your service needs anywhere in the world.

Whatever you need – from troubleshooting and

training to spares or repairs – we’re on the job.

We’re dedicated to supplying service quality on a

par with the outstanding quality of our machines

and systems. We offer far more than spare parts

and hotlines. We’ll work with you to choose the

best and most cost-effective solution for your

operation. We’ll help you test new applications

and we’ll plan customized service packages.

All-round service

Our service offering is broad. We’ll configure your

system, install and commission it, train your staff,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. You’ll find us fast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

If necessary, we’ll get a technician to you quickly.

Remote diagnosis, interfacing directly with your

machine’s control system, can be a practical

alternative. Spares for all important wear parts are

available at short notice. We’re continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution for your business.

Customer trials and prototyping in our test lab

The Extrusion Division operates a test lab fitted

with the latest machinery and equipment. We can

run trials, produce prototype parts and fine-tune

processes on your behalf. We can work with you

to test and evaluate processes, machines and

equipment in order to identify the best approach

for a particular project. Our highly-qualified

application engineers are there to help you.

Training with high hands-on content

Courses are held in our lab and training centre,

or, optionally, on your premises. We offer

clearly-structured basic and advanced training in

operation, process control and maintenance for

KraussMaffei extrusion systems. On request, we’ll

plan and hold special courses on topics of your

choice. All participants spend a high proportion

of their training working hands-on with original

KraussMaffei machines. A well-structured

training program produces skilled operators

and technicians, which will positively impact

your up-time and productivity.

SERVICE WORLDWIDE

Service, support and spare parts – when you need them, where you need them

Worldwide hotlineWorldwide hotline numbersnumbers

Extrusion Technology ServiceExtrusion Technology Service

KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Contacting us by postContacting us by postIf you need to contact any of our

international service or spare parts teams

by post, use this address:

KraussMaffei Technologies

India Pvt. Ltd.

Pune, India

Phone: +91 20 41404610

Fax: +91 20 414046 99

Email: [email protected]

Krauss-Maffei Extrusion

Technology (Zhejiang) Co., Ltd.

Jiaxing City, China

Phone: +86 573 86973888

Fax: +86 573 86967111


KraussMaffei Technologies GmbH

Munich, Germany

Customer Service

Phone: +49 89 8899-2273 (electrical systems)

Phone: +49 89 8899-4380 (mechanical systems)


Application Engineering

Phone: +49 89 8899-4094

Fax: +49 89 8899-2161


Krauss-Maffei Italiana S.r.l.

Abbiategrasso, Italy

Phone: +39 02 94963181

Fax: +39 02 94699482


Berstorff Krauss-Maffei OOO

Moscow, Russia

Phone: +7 495 9377554

Fax: +7 495 9701731

Email: [email protected] Krauss Maffei Corporation

Florence, USA

Phone: +1 859 2834307

Fax: +1 859 2830290


Krauss Maffei de México

S. de R.L. de C.V.

Mexico City, México

Phone: +52 55 53082383

Fax: +52 55 53081727


Krauss Maffei do Brasil Ltda

São Paulo, Brazil

Phone: +55 11 46129171

Fax: +55 11 46128366


Krauss-Maffei (U.K.) Ltd.

Warrington, UK

Phone: +44 1925 644100

Fax: +44 1925 234284


KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2546 ··· Fax +49 89 8899 - 4043www.kraussmaffei.com

KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

KraussMaffei Berstorff is a system supplier for complete integrated production lines for all kinds of PVC film and sheet products. Our 32D extruder series meets the exacting quality criteria imposed on PVC sheet extrusion, enhance production efficiency and quickly pay for themselves. Expert process engi-neering improves melt homogeneity, widens the processing window, increases process reliability and yields products of consistently outstanding quality. The outstanding process and application know-how of our application engineers and the fact that we supply complete single-vendor systems reduces your effort and costs for production start-up and in all production processes.

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COMPLETE SYSTEM SOLUTIONS PVC sheet and film … / Electronics Packaging Complete system solutions...

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Transcript of COMPLETE SYSTEM SOLUTIONS PVC sheet and film … / Electronics Packaging Complete system solutions...