machinery feature | Twin-screw extruders Leistritz will
show a ZSE-27 Maxx extruder as part of a “direct to
sheet” system at NPE
on skids, which provide a signifi cant reduction in installation and commissioning costs. Spearing says that the modular designs also make it much easier for customers to redeploy lines in new facilities. “In the past, compounding lines were installed in multi-storey buildings, so to pack them up and move to a new location was pretty diffi cult,” he says. “With these systems, we have the mezzanines built in, so they can be installed in more open buildings, and everything sits on the main fl oor. Building construction is much cheaper with this philosophy.” ICMA San Giorgio of Italy has also been highlighting its abilities to supply complete turn-key compounding lines based around its tried and tested twin-screw extruders. For example, it recently supplied two such lines to a South American factory operated by a major global appliance manufacturer. Each of the lines is capable of producing mineral-fi lled compounds for white goods at throughputs above 3,000 kg/hour. The lines were supplied with materials handling,
pelletizing and fi nal compound storage and distribution systems. “This is an excellent example of ICMA’s ability to tackle complete and complex compounding projects that require a high level of engineering and reliable execution,” says Giorgio Colombo, the company’s managing director. The lines were built and tested at ICMA’s factory prior
to installation and start-up at the customer’s site. They feature energy-saving enhancements and noise reduc- tion features built in to the extruders and pelletizers. “We have developed specifi c, in-depth experience in
Toshiba’s latest TEM-58SSG is designed to improve yields for compound makers
the white goods industry over the years,” says Colombo. “Appliance manufacturers recognize that our high effi ciency compounding lines can make a substantial difference in productivity and energy savings”.
Speed control Steer managing director Babu Padmanabhan highlights the ability of the company’s Mega Special Plus extruder to use the full power of the motor at four different speeds, thanks to its four-speed transmission. “A
standard extruder with high speed/high torque requires a high investment cost as the power supply to be installed is high,” he says. “To utilize the full power of such a machine, all applications would have to be run at high speeds, which is practically not possible. Many applications run at speeds of only 600-800 rpm.” A low-power high-torque extruder would lack the ability to run at higher speeds. On the Mega Special Plus, however, the power
supply required is smaller than a high speed/high torque (160 kW vs. 250 kW on the standard Mega 50), and the initial investment cost is less. “The full power of the motor can be utilized at lower speeds to run the majority of the applications,” says Padmanabhan. “This ensures that all applications are run effi ciently with high throughput rates without having to compromise.” Leistritz will exhibit its latest twin-screw extrusion
technologies at NPE 2015. These include the ZSE-87 Maxx twin-screw extruder system with 52 L/D and two side stuffers. The ZSE-87 Maxx (ZSE-90 Maxx in North America) is a heavy-duty model designed to process highly-fi lled polymer compounds and engineering resins. It features segmented screws made of high- abrasion powdered metallurgy (PM) with a soft core, assembled on high-torque asymmetrical splined shafts. The OD/ID ratio is 1.66. Modular 4-D barrels with PM high-abrasion-resistant insert liners are internally cored for cooling. There are two LSB side stuffers to deliver fi llers
and fi bres into the melt via downstream ports in the extruder process section. A vacuum system with a rotary “dry claw” vacuum pump with a
condenser/fi lter design facilitates continuous operation during maintenance. The LSB side stuffers
are said to integrate a number of design enhancements to facilitate high-level fi ller loadings. For example, they have an increased OD/ID ratio, upgraded metallurgies for increased abrasion resistance, and a modular screw design. Side stuffer screws can also be cored for liquid
38 COMPOUNDING WORLD | March 2015
www.compoundingworld.com
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