Materials handling | processing feature
Effi cient materials handling is a critical part of productive compounding. Pat Toensmeier reports on the latest
equipment and on how extruder makers are getting more involved
Handle with care: conveying, feeding and dosing systems
Materials handling has usually operated in the shadow of compounding. But recent developments in equipment and systems are pushing these operations into the spotlight by increasing their precision, effectiveness and impact on formulation capabilities and profi tability. The latest equipment not only effi ciently conveys,
feeds and doses materials such as additives, fi llers, masterbatches, reinforcements and recyclate. It also speeds up product changeovers, simplifi es cleaning and, with ever-more-sophisticated controls, minimizes or eliminates operator errors. Factors driving innovations in this area include
growing demand for highly fi lled formulations, as end-users seek greater performance from a variety of cost-effective compounds including many based on commodity resins. Materials handling equipment plays an obvious role
in productivity and manufacturing effectiveness. Conveying and metering ingredients accurately minimizes downtime, improves compound quality and facilitates the ability of processors to execute multiple jobs on a just-in-time basis. Advances in materials handling also support a trend
toward higher feed-rates. For example, some European compounders have recently increased their volumes by 50% or more, says Jan Rickenbach, regional sales manager at Motan-Colortronic. It is not unusual, he notes, for compounders that averaged 1,500 kg/hour to now run at 2,000 to 2,500 kg/hour. This improves the economies of scale on dedicated runs and permits more compounding of smaller lots. Either way, compounders need auxiliary equipment that meets demanding production requirements with no trade-offs in reliability or formulation quality. With only so many hours in a day, Rickenbach says, the ability of compounders to maximize production time through their equipment is critical. Developments in materials handling are evident in new and recent products, and in ventures between
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equipment makers and the producers of compounding extruders and systems. Three such arrangements were highlighted at the K show in October: Leistritz and AZO are collaborating on turnkey compounding plants with a particular focus on highly fi lled materials; KraussMaffei Berstorff and Zeppelin Systems have formed a strategic partnership to build turnkey compounding plants for technical plastics; and Coperion and K-Tron, both now owned by US-headquartered Hillenbrand, are being brought together under the Coperion K-Tron brand.
Heading upstream These partnerships are intended to improve the productivity and fl exibility of operations, by giving compounders greater access to materials-handling equipment and process machinery that will extend their capabilities and make them more competitive and profi table.
February 2014 | COMPOUNDING WORLD 39
Leistritz and AZO jointly
developed this turnkey plant
for highly fi lled formulations
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