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machinery feature | Twin-screw compounders

frames. These have the dimensions of a sea container for ease of shipping. The modules are tested at Berstorff’s Hannover

facility in Germany before delivery. They can be simply installed in an empty factory, and do not usually require additional steel construction, significantly reducing costs, according to the company. “The modular design is ideal for meeting tight deadlines and specific demands, such as small batches with different formulations, or just-in-time production runs”, explained Matthias Sieverding, director of extrusion technology at KraussMaffei Berstorff in the USA. “The modules are fully wired and piped so that the customer only has to supply power and water connec- tions.”

The modular lines use the company’s EasyClean compared to field construc- tion, minimal plant site interruption,

A “ready to connect” packaged compounding installation by KraussMaffei Berstorff

and shorter fabrication schedules. Once the line is built and shipped, Apex says its system takes 17-20 days to unpack, install, and get running. Businesses that can benefit most from modular systems are those that are racing to get capacity to an emerging market, says West. KraussMaffei Berstorff says that its turn-key lines

can be either conventional configurations or modular designs. At NPE it highlighted its modular “ready-to- connect” compounding systems. All of the major components, such as metering units, the extruder, control systems, side feeders, vacuum units and filter units are fully wired and installed into various base

system for fast and simple machine conversions. Special clamp and flange connections, which can be released without tools, are used on the hoppers and product lines to feeders and buffer hoppers. The example shown at last month’s NPE incorpo-

rated a ZE 60 A UTXi twin-screw extruder and an underwater pelletizer complete with a control system and switching cabinet installed onto the base plate. The electrical system and water pipes were also integrated into the base plate and the base frame. A built-in stairway provided access to the gravimetric metering on the second level. Coperion’s Modular Turn-key Systems (MTS) lines

are also pre-tested modules integrated into a steel structure, designed for shipping in a sea container, and connecting in “plug and play” manner so that lines can

Entek charges ahead with turn-key contracts

Entek Manufacturing is providing complete turn-key plant expansion services for its sister company Entek International, which produces polyethylene battery separators for automotive applications at its plants in Lebanon, Oregon, USA, and at Newcastle in the UK. A new 77,000 ft2 (7,200 m2) extension to the Lebanon plant will

increase its floorspace by more than 50%. It will house two new lines each incorporating an Entek 133 mm twin-screw extruder. The first is expected to be operational by 2013. “Entek Manufacturing is managing 100% of this project,” said Dr. Kirk Hanawalt, the company’s president. “This includes manufactur- ing all of the machinery and equipment that will be used in the plant, as well as managing the overall design and construction.” The initial phase of the two-year project will bring up to 20 new jobs at Entek International, and has already brought at least 30 new jobs to Entek Manufacturing, with more on the way. ❙


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