MANUFACTURING | SMALL BATCH COMPOUNDING
machines dedicated to one type of base polymer, and choosing the right extruder size. There are also technical challenges to overcome, such as avoiding cross-contamination between batches. “In addition, downtime in production must be
Above: Placing tools where they are required
—point-of-use — is a simple way to speed up changeovers
Right: Feddem says its kneading block-free screws are well suited to small-batch work
compounding can be seen in its QC³ line of extruders, where the name stands for Quick Change, Quick Clean, Quality Control. The com- pany says QC3
extruders incorporate a number of
lean features that help minimise downtime. These include point-of-use tools (meaning tools placed where they are needed), self-aligning screw shafts, patented quick change couplings and a reduced number of retained fasteners. The machines also feature hinged stainless guards and panels that are easy to clean, as well as pivoting stuffers that can be used for feeding or vacuum.
Taking stock German extruder manufacturer Feddem also reports growth in the small-batch compounding sector, which it sees being driven by the demand for a faster response to changes in the market as well as the need to cut tied-up capital through reductions in stock materials. The company says this particularly applies to the production of masterbatches, but adds that small-batch com- pounding is also ideal for production of speciality compounds, such as special colours and haptics for high-prestige fashion accessories and luxury goods, as well as for applications in medical and aerospace where high-temperature resist- ance materials are required. The company says careful planning is part of the strategy in running a frequent changeover, small-batch compounding operation. “This will minimise the need for extensive cleaning during product changeovers,” says Klaus Hojer, Feddem Business Development Manager. “Measures can include running batches from light to dark colours, keeping
40 COMPOUNDING WORLD | April 2021
kept low by minimising the need for changing the extruder set-up through changing screws or the location of raw material feeders. Balancing ma- chine volume with batch size is also important. A compact volume in the process chamber of the extruder reduces waste when purging during product changeover. However, a compact volume often also means lower throughput rates, which increases the time required for processing the batch,” he says. Feddem believes its kneading-block-free screws enable its extruders to better meet small-batch compounding tasks. The claimed extended processing range of extruders fitted with kneading- block-free screw configurations can deliver compatibility between compounding performance of different extruder sizes, which the company says eases the pressure on machine selection. Feddems adds that its
recently-developed FSK- series strand dies, which offer a low chamber volume and good melt distribution across the entire width of the die plate, can also play a role. “Some customers report up to 50% reduction in start-up time and considerably less waste - the time between starting the
extruder and being able to get a
balanced strand flow to the pelletiser,” says Hojer. “For more complex stranding applications, we
also offer a curved die plate, which minimises ‘curling’ of the outer strands in low-filled or unfilled polymers. Curling produces odd-sized pellets that are taken out of the good product stream by the classifier. Feddem is also looking at further widen-
Above: Entek’s QC3
machines offer quick product change and cleandown features
www.compoundingworld.com
IMAGE: ENTEK
IMAGE: FEDDEM
IMAGE: ENTEK
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