SMALL BATCH COMPOUNDING | MANUFACTURING
This automation system allows the machine to interface with auxiliary equipment by fieldbus. According to Dino Kudrass,
Head of Design and Engineering, and François Loviat, Head of Process, at Swiss co-kneader machinery maker Buss, small-batch compounding applications are gaining traction in markets where factors such as highly specialised materials, short lead times and innova- tion (R&D) play an important role. They cite, for example, development of new polymer materials, additives or compound recipes as one of the more common small-batch production application areas. In such applications, small changes in recipe, production parameters or machine configuration must be evaluated through laboratory analysis of the finished compound and this often leads to numerous iterations followed by subsequent evaluation of the desired material properties.
Size selection
When running these types of small-batch com- pounding operations, Buss says the specified throughput of the compounding line must be chosen with care as excessive material waste with each production cycle can be costly in the long term. The higher procurement and operational cost of larger equipment must also be weighed up against process scalability and the potential requirement for handling larger batches. The effort, time and cost associated with cleaning or re-con- figuration of equipment also plays a much greater role in small-batch duties, where the frequency of these tasks increases. A compounding machine that provides good
flexibility and allows fast and easy material changeo- vers offers a significant advantage in small-batch compound production, according to Buss. It adds that a large process window or throughput range is also a highly desirable trait, but says this posts technical chal- lenges as the drive system must be designed to handle a greater speed range and the feed and dosing systems must provide greater flexibility. Buss says the process geometry inside the compounder must also be able to handle lower fill levels and the temperature control must compen- sate for potentially higher residence times. Other useful considerations for small-batch compound- ing work include carefully-chosen plant layouts, optimised changeover routines, well-trained operating staff, flexible control systems and selecting the right compounding machine.
www.compoundingworld.com
Left: Buss says its Compeo co-kneader machine is designed to be flexible and future-proof
Buss says that its latest
Compeo machine design is well suited to the specific needs of small-batch production. Process parameters, such as screw configurations, feed systems and pelletising units, can be changed quickly and effectively while the machines provide good cleaning accessibility. In addition, the company says the Compeo design brief focused on future-proofing to ensure it could not only meet current compounding requirements but also potential future challenges. Demands on compounding machinery intensify as applications for polymer materials increase and compounds become more complex, according to Buss, so it aimed to create a flexible machine design that can be configured to process polyolefins, engineering plastics, biopolymers and elastomers. This requires accurate heat control of processing temperatures over the range from less than 100°C to 400°C, process chamber lengths from 11 to 25 L/D and adjustable shear intensity, for example. Buss says it is frequently asked by customers or universities to produce small batches of com- pounds for product development or marketing purposes. In one recent example, the company was involved in a collaborative project with the Swiss research institute EMPA to develop a new type of grafting compound. During the project, many small batches with different raw materials and processing conditions were produced as part of an initial development and fine-tuning process. The work contributed to the creation of a Swiss start-up – Si- loxene AG – which now specialises in production of functional polysiloxane materials for applications in the polymer processing industry.
CLICK ON THE LINKS FOR MORE INFORMATION: �
www.entek.com �
www.feddem.com �
www.centruyextrusion.com �
www.centuryextrusion.com �
www.leistritz.com �
www.mariscorp.com �
www.busscorp.com
April 2021 | COMPOUNDING WORLD 49
IMAGE: BUSS
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