PROCESS CONTROL | DIGITALISATION
screw extruder. With its torque density of 18Nm/ cm3
and Do/Di ratio of 1.61, this new extruder is
particularly suited for compounding and master- batch applications, including glass or talc-filled formulations. It also uses Entek’s new vacuum feed technology (VFT) to handle fluffy, low bulk density materials without an atmospheric vent. “Industry 4.0 is certainly in the forefront of our minds as we look at design,” says Linda Campbell, Vice-President of Sales at Entek. “Our customers have asked for equipment that is as efficient as possible. Features that increase up-time by decreasing unscheduled downtime and improve product quality are most requested.” A patent- pending vent flow sensor on the new extruder serves
this function. It can detect vent flow as it
Above: Bausano’s Orquestra software allows production data to be captured and visualised in real-time
begins, providing the operator with an opportunity to correct the problem before it becomes serious. The onset of vent flow is detected by a sensor, which sets off an alarm on the human-machine interface (HMI). The required response can be made by the operator. Alternatively, the equip- ment’s programmable logic controller can respond automatically and can shut off feeders, speed up extruder screws, turn off the vacuum pump, or shut down the extruder, according to Dean Elliott, Entek’s Technical Processing Manager. This ability to respond quickly can reduce scrap production and minimise downtime.
The HT72 also collects equipment data — such as oil life, oil quality and vibration — to give opera- tors real-time information about how the extruder is running. The operator is alerted by an alarm if there is excessive vibration, for example. Entek says a ‘process stability’ function will indicate whether the process is in range or unsteady based on the extruder torque value; if the value goes outside of a range set around the averaged torque over a recent time period the operator will be alerted. The new line also monitors and displays 24-hour uptime and current run completion. Data is said to be collected and archived and trends evaluated for a wide range of additional parameters.
Data capture Germany-based XanTec, which was acquired by the Maag Group in 2020, specialises in industrial control systems for plastics processing, including pelletising systems and extruders. “Digitalisation is an important trend in our industry, even more so in today’s economic environment,” says XanTec Managing Director Hilger Schürmann. The com- pany says the focus of control engineering now is on capturing data for analysis and for visualisation by operators.
While mining the wealth of available data for
better insight into the compounding process is one key benefit of Industry 4.0 tools, another benefit can found through connection of machines via the Industrial Internet of Things (IIoT); systems can then operate automatically with more efficiency. Italian extruder manufacturer Bausano, which manufac- tures extruders for a range of applications includ- ing production of PVC granules, recently launched
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IMAGE: BAUSANO
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