PROCESSING | SMALL BATCH COMPOUNDING


Below: Some quick-change features can be quite simple, such as the on-machine tool rack on this Entek extruder


appearing that need higher degrees of specialisa- tion, combined with reduced material need for start-ups and for shortening time to market/ flexibility, for example. Another important point is the huge concentration of compounding compa- nies in the last few years. Reducing the number of independent compounders means the remaining ones become more specialised in small batch production. Lechner: We see our customers asking for flexible compounding lines so we can interpret that, yes, [the market] is going in the direction of small batches. We call these lines multi-purpose lines. This means lines able to run multiple recipes, not just standard recipes. Customers want to be prepared for the future. It is not very often that we specify an extruder with seven or eight barrels, mainly its 10 or 12 barrels, where they can do everything [barrels here refers to individual 4D barrel elements]. For example, the customer says: ‘I want a machine that will run polycarbonate 24/7.’ Then you can dedicate a machine, with eight barrels. But if the customer says: ‘In one year, I want to run glass fibres,’ then it’s not possible. Where the customer looks into the future and sees demands they do not have at the moment they want to be prepared. This means a so-called multi-purpose set-up – a flexible line, a minimum of one side feeder, and prepared for FET maybe. Customers more and more ask for multi-pur- pose lines and quick-change features. We have a side feeder, the ZS-B easy, with C-clamps so you can remove it very fast and clean it within less than, I would say, 30 minutes. We also have easy access opening at the gearbox lantern as well as quick screw shaft couplings with no bolts, for example, and the same for the die head. This is important for frequently changing recipes.”


Right: Feeders such as Coperion K-Tron’s ZS-B easy, include quick- change features


CW: Organisation is key for effective small batch operation. What advice can you provide to com- pounders in terms of production planning and job scheduling? Roca: I think one of the most important points is when we are not producing. Normally delays are caused by problems in secondary operations — as- sembling, cleaning, repairing, etc. How can we shorten changeover times, purging, cleaning? Compounding lines must be thought of as Formula One cars not boxes. Procedures for all tasks must be adjusted. Another key point is to send compound orders to the appropriate extruders, balancing quantity and quality. There should be a clear methodology for selection of the extruder for each type of compound. This should go beyond just extruders for black colours or mineral fillers. Lindsey: Forecasting and planning production runs is an important part of optimising equipment uptime. To help reduce changeover time between product lots, it’s a benefit if manufacturers can group product lots by type. For example, begin with lighter pigments and lower viscosity materials, then move toward darker pigments and more viscous products. Building time into the production schedule to account for ‘hot’ projects that arise helps ensure there is capacity to respond promptly on critical timelines. Lechner: What we have, and we showed at the K show, is the C-Beyond platform. Using this the customer can track the OEE (the overall equipment effectiveness). C-Beyond offers, among others, downtime tracking and an intelligent empty run function for feeding systems so all or selected feeders run concurrently empty at a particular point


30 COMPOUNDING WORLD | April 2023 www.compoundingworld.com


IMAGE: COPERION


IMAGE: ENTEK


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