powder to profile

Powder to ProfileJELD-WEN Extruder Technology

Objectives

At the end of this module, you will be able to:

Break the profile equipment into sections and define the function of each piece as the PVC Compound is transformed into a profile.

Describe the status of the PVC Compound as it becomes a profile throughout the extrusion process.

OverviewPowder to Profile

Back

Extruder

Phase OnePVC Melt

Phase TwoRheology

Die Calibrator

Front

Phase ThreeEnd Product

Trouble Shooting

Haul-off

Visual Check Point – Trouble Shooting A B C D E

Phase One: Extruder & PVC Melt

PVC Compound Converted Into Fused MassPVC Compound Converted Into Fused Mass

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

CompressionCompression

Material Handling

From Rail Car to Storage Silo From Storage Silo to Day Bin From Day Bin to Vacuum Receiver Hopper

From the Vacuum Receiver Hopper,

the compound filters into the Surge Hopper

From the Surge Hopper, the compound is metered into the Extruder by the Gravimetrics hopper

11 22 33

44 55

Gravimetrics

Gravimetric unit measures, records, and controls the consumption of material into the extruder process.

GravimetricsHopper Levels

Shut-off Device

Load Cell

Stop

Receiver Fork

Weight Hopper

Collector Funnel

Impact Cone

GravimetricsReasons for Throughput Variation

- High Bulk Weight- Good Flow properties

- Low Bulk Weight- Poor Flow Properties

GravimetricsHopper Feeding the Screws Compound

Constant material flow in the feeding area of the extruder

Impact Cone

GravimetricsEffect of Throughput Variation

Weight Per Foot

Weight Per Foot

Haul-Off Speed

Haul-Off Speed

WallThickness

WallThickness

Throughput(Outlet)

Throughput(Outlet)

ScrewSpeedScrewSpeed

Throughput(Inlet)

Throughput(Inlet)

lb/ft ft/min in. lb/h RPM lb/h

GravimetricsIf Hopper Levels Drop

lb/ft Ft/min In. Lb/h RPM Lb/h

Weight Per Foot

Weight Per Foot

Haul-Off Speed

Haul-Off Speed

WallThickness

WallThickness

Throughput(Outlet)

Throughput(Outlet)

ScrewSpeedScrewSpeed

Throughput(Inlet)

Throughput(Inlet)

Gravimetrics

The compound is measured

Released on top of the screws

Heat & pressure push it through the

extruder barrel.Doser in Feed ThroatDoser in Feed Throat

Review Question

True or False

Gravimetrics measures, records, and controls the consumption of material throughputs in the extruder process.

True

Extruder: Barrel and Screws

Through the Feed Throat, the compound falls onto a set of screws that turn inside a barrel. The compound is converted into a molten state with the addition of heat & pressure.

Extruder Size: Barrel, Screws Dimensions, Number of Zones

Our conical extruder of 63mm has 4 zones

Our parallel extruder of 72 mm & 93mm have 5 zones

Phase One: Extruder & PVC MeltBarrel & Screw Zones

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Compression

Phase One: Extruder & PVC MeltBarrels and Heater Bands

Barrel, Heater Bands, & Cooling FansThe barrel is divided into sections called zonesHeater bands encircling the barrels define the zonesCooling fans

Review Questions

Answer the following question.

What is displayed in the picture below?

AnswerThe picture displays an air cooled barrel system.

Extruder: Barrel & Screws

Compression

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusion

Barrel & ScrewsParallel and Conical

Parallel ScrewsParallel Screws

Conical ScrewsConical Screws

Barrel & Screws take the powder compound, heats and mixes it into a homogeneous melt, and pushes it through the die.

Barrel & Screws take the powder compound, heats and mixes it into a homogeneous melt, and pushes it through the die.

Barrel and ScrewsParallel Screws

Molybdeum Coated ScrewsMolybdeum Coated Screws

Extruder: Barrel & Screws

Conical Two ScrewsNitrated steel-very hardOutlasts Screws’ BarrelMay be Chromed

Phase One: Extruder & PVC MeltCooling the Screw and Fused PVC

It is important to cool the tip and body of the screws to prevent sticking of the fused PVC Compound

Phase One: Extruder & PVC MeltBarrel & Screw Zones

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

CompressionCompression

Testing the Compound

Rheology: Fusion Time & Torque for JW FormulationRheology: Fusion Time & Torque for JW Formulation

Phase One: Extruder & PVC MeltFeeding Zone & Powder PVC on the Screws

Melting/ Degassing Metering/ Partial Fusing Final Fusing

Melting/ Degassing Metering/ Partial Fusing Final FusingFeedingFeeding

CompressionCompression

Phase One: Extruder & PVC MeltsGravimetrics, Feed Throat & Doser

Remember

The PVC Compound is vacuumed from the Daybin into the vacuum receiving hoppers

The compound is gravity fed from the vacuum receiving hoppers into the gravimetric

The gravimetric meters the virgin PVC, regrind & color concentrate into the Dosing Unit

Phase One: Extruder & PVC MeltsMelting/ Partial Fusing Zone

Feeding Feeding Degassing Metering/ Final Fusing

Degassing Metering/ Final Fusing

CompressionCompression

Melting/Partial Fusing

Melting/Partial Fusing

Phase One: Extruder & PVC MeltsIn-between Zone 1 & 2 Melting/ Fusion Mechanisms

Barrel

Screw

Solid Bed Interface

Pushing Flight

Melt Pool

Melt Film Trailing Edge

Dissipative Melting of Solid Bed

Phase One: Extruder & PVC MeltsIn-between Zone 1 & 2 Melting/Fusion Mechanisms

Barrel

Screw

Conductive Melting After Solid Bed Breakup

Phase One: Extruder & PVC MeltCompression Zone

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Compression

Phase One: Extruder & Raw MaterialDegassing Zone

Feeding Melting/ Metering/ Partial Fusing Final Fusing

Feeding Melting/ Metering/ Partial Fusing Final Fusing

CompressionCompression

DegassingDegassing

Phase One: Extruder & PVC MeltVacuum Port or Visual Check Point

Vacuum Port or Visual Check Point

An area to view the compound as it is being pushed through the barrel by the screw

Phase One: Extruder & PVC MeltMetering/ Final Fusing

Feeding Melting/ Degassing Partial Fusing

Feeding Melting/ Degassing Partial Fusing

CompressionCompression

Metering/Final Fusing

Metering/Final Fusing

Phase One: Extruder & PVC MeltSummary

Back Back Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

Feeding Melting/ Degassing Metering/ Partial Fusing Final Fusing

CompressionCompression

FrontFront

Review Question

True or False

The extruder combines PVC Compound with heat and pressure to fuse the material into a unified mass.

TRUE

Phase Two: RheologyDie Calibrator

Back

Extruder

Phase OnePVC Melt Phase Two

Rheology

Phase TwoRheology

Die Calibrator

Front

Phase ThreeEnd Product

Trouble Shooting

Haul-off

Visual Check Point-Trouble Shooting A B C D E

Review Question

Fill-in-the-Blank. Use 4 of the following words.

Die, Shape, Calibrator, Water Tanks, Extruder

The purpose the Rheology Phase is to ______ the molten mass from the _______ with the hot ___ and to cool and shape the profile with the ________.

The purpose the Rheology Phase is to shape the molten mass from the extruder with the hot die and to cool and shape the profile with the calibrator.

Phase Two: RheologyThe Adaptor & Y Block

The Y-Block is attached to the extruder with an adaptor

The die box is mounted either to the Y-Block or directly to the adaptor for single strand.

Adaptor Y-Block

End of Barrel Extruder Adaptor

Phase Two: RheologyThe Adaptor & Y-Block

The adaptor funnels the melt into the die or the Y-Block

A Ring or Breaker Plate are used to align the Die Box or Y-Block to the adaptor & they also provide a sealing surface.

The breaker plate provides a resistance of the flow from the extruder.

Phase Two: RheologyThe Die

The die box is attached to the extruder adaptor or directly to the Y-block.

The die is made to slide into the die box.

There is a clamping ring which holds the die into the die box.

Review Question

Fill-in-the-Blank

The die box or “Y” block is attached to the extruder with an ____________.

The die box or “Y” block is attached to the extruder with an adaptor.

Phase Two: RheologyThe Die

The die shapes the PVC melt from the extruder into the desired shape

Review Question

Fill-in-the Blank

The purpose of the die is to _______ the _______ or extrudate from the extruder into the desired shape.

The purpose of the die is to shape the PVC Melt or extrudate from the extruder into the desired shape.

Phase Two:JELD-WEN Die Parts

Distance Distribution Mandrel Plate Entry Side

Torpedo

Mandrel Plate Exit Side

Mandrel

Compression #2 Outlet #1 Outlet Mandrel Top

Review Question

Fill-in-the Blank

The die contains the following plates:

Distance

Distribution

Torpedo and __________

______________

#2 and #1 Outlet and Mandrel Top

The die contains the following plates:• Distance • Distribution• Torpedo and Mandrel• Compression • #2 and #1 Outlet and Mandrel Top

Phase Two: RheologyMelt Rheology

The extruder fuses the material into a unified mass, called PVC melt and is exerting pressure to move it forward

Flow is how the PVC melt movesforward from the extruderthrough the die

Review Question

Fill-in-the Blank

The extruder fuses the PVC Compound into a unified mass called _______ and exerts pressure to move it forward.

The extruder fuses the PVC Compound into a unified mass called PVC Melt and exerts pressure to move it forward.

Phase Two: RheologyScience of Flow

Basic Measurements

Shear Stress

Shear Rate

Melt Temperature

Melt Viscosity

Is this a good melt?

Phase Two: RheologyStress, Rate, Temperature & Viscosity

Shear Stress =Melt Pressure

ViscosityTemperature 380º F

Temperature 360º F

Shear Rate = Screw RPM

Higher Stress + Shear Rate = More Melt Flow, Plasticity, or Viscosity

Review Question

Fill-in-the Blank

Higher Shear Stress plus Shear Rate = More Melt Flow, Plasticity or ______________

Higher Shear Stress plus Shear Rate = More Melt Flow, Plasticity or Viscosity

Phase Two: RheologyLaminar Flow: Static Wormy Polymer Chains

O PSI

Melt Temperature 385º FPolymer chains are in static form-worm like

0 Flow

Die Opening

Review Question

Fill-in-the Blank

Shear stress is another word for melt _____. Shear stress is another word for melt pressure.

Phase Two: RheologyLaminar Flow: Activation Energy

Low to Medium PSI

Activation Energy

Melt Temperature 385º FPolymer Chains

Stretching to Form Layers

0 Flow

Die Opening

Review Question

Fill-in-the Blank

Shear _____ refers to Screw RPM. Shear Rate refers to Screw RPM.

Phase Two: RheologyLaminar Flow Achievement

Medium to High PSI

Melt Temperature 385º FExceed activation energy

polymer layers slide by each other

Flow

Review Question

Fill-in-the Blank

Melt viscosity refers to the ________ of the PVC Melt exiting the die.

Melt viscosity refers to the stiffness of the PVC Melt exiting the die.

Review Question

Fill-in-the Blank

The molten plastic mass that has no Shear Stress or Shear Rate will not ______.

The molten plastic mass that has no Shear Stress or Shear Rate will not flow.

Phase Two: RheologyLaminar Flow: Melt Fracture

Increase in shear rate and/or shear stress beyond quality limits adversely effects the melt and the end product

Review Question

True or False

By decreasing shear stress and the raising of shear rate, the higher your viscosity of melt through the die.

FALSE

The higher the pressure (Shear Stress) and the higher the screw RPM (Shear Rate), the higher your viscosity or flow of your melt.

Phase Two: RheologyDie Swell

Die

Extruder

Review Question

Fill-in-the Blank

Shear Stress is the amount of energy that is being applied to the melt. Shear Stress refers to the __________ behind the die. This pressure is being generated by the __________.

Shear Stress is the amount of energy that is being applied to the melt. Shear Stress refers to the melt pressure behind the die. This pressure is being generated by the extruder.

Phase Two: RheologyCorrect Flow Properties

Flow Challenges

Poor Surface, too dull or too shiny

Pock marks

Lumps

Internal walls separating

Wavy edges

Loss of definition on edges

Erratic flow may cause jam ups

Excessive die or calibration fouling

Wall Thickness

Review Question

Fill-in-the Blank

Examples of flow challenges are:

Poor surface-too dull or too shiny

_____________

Lumps

Internal walls separating

______________

Loss of definition on edges

Erratic flow and jam ups

Examples of flow challenges are:• Poor surface-too dull or too shiny• Pock Marks• Lumps• Internal walls separating• Wavy Edges• Loss of definition on edges• Erratic flow and jam ups

Phase Two: RheologyCalibration & Water Cooling

First Calibrator

Die

Blue HosesCool Water

Red HosesWarm Water

White Hoses

Vacuum

Phase Two: Rheology#1 Calibrator Cooling

Die Swell

Cool Water In Vacuum

Vacuum Slots & Hoses

Warm Water Out

Dark Area Cooler: 125 F – 135 F

Light Area Hotter: 250º F – 350º F

Calibrator

Review Question

Fill-in-the Blank

When flow occurs in the die, it will flow the fastest in the ______ of the flow and the ________ at the wall of the flow.

When flow occurs in the die, it will flow the fastest in the center of the flow and s l o w e s t at the wall of the flow.

Phase Two: RheologyWater Tank Calibrators

Water Tank Calibrators

Series of water tanks

Sizing elements

Vacuum

Long

Numerous elements

Review Questions

Work in teams and answer the following questions.

The instructor will assign questions for you to answer.

Use your books to find the answers.

Review as a group.

Review Question

Fill-in-the Blank

The die takes the PVC Melt and refines the shape into a _______ using pressure. The calibrator continues to refine the profile by _____ it using water and a vacuum.

The die takes the PVC Melt and refines the shape into a profile using pressure. The calibrator continues to refine the profile by cooling it using water and a vacuum.

Review Question

Fill-in-the Blank

Shear Rate is the _____ at which Shear Stress (or energy) is being applied behind the die. To measure Shear Rate, use RPM of the extruder screw.

Shear Rate is the speed at which Shear Stress (or energy) is being applied behind the die. To measure Shear Rate, use RPM of the extruder screw.

Review Question

True or False

The molecules in a molten plastic mass that have flow, will have no organization and look like a cluttered mess of strings.

FALSE

Molecules in a molten plastic mass with NO FLOW will have no organization and look like a cluttered mess of strings.

Molecules WITH FLOW have organization and are stretched to form layers.

Review Question

True or False As the melt is forced to flow through the die, the

polymer strings do not stretch and remain disorganized. When the melt exits the die, the pressure is released and the polymer strings will recoil back. This is known as die swell. This is a know % for each type of compound, for PVC window profiles it is 2 – 8%.

False

As the melt is forced to flow through the die, the polymer strings do stretch.

Review Question

Fill-in-the Blank

When Shear Stress and Shear Rate are applied, the unorganized polymer molecules begin to shift into organized layers and are stretched. The amount of energy to make this happen is called, ___________ ___________.

When Shear Stress and Shear Rate are applied to a PVC Melt, the unorganized polymer molecules begin to shift into organized layers and are stretched. The amount of energy to make this happen is called, Activation Energy.

Review Question

Fill-in-the Blank

Flow is achieve by exceeding ______ Energy, forcing the polymer molecules to slide by each other. The polymer layers slide the slowest at the ____ of the die and the fastest in the _________ of the flow.

Flow is achieve by exceeding Activation Energy, forcing the polymer molecules to slide by each other. The polymer layers slide the slowest at the wall of the die and the fastest in the middle of the flow.

Review Question

True or False

If the Shear Rate and/or Shear Stress is increased beyond certain limits, the PVC Melt exiting the die can be adversely affected. Initially, one may see irregularities like pock marks and tear drop shaped lumps in the surface.

TRUE

Review Question

True or False

If the limits of Shear Rate and/or Shear Stress are increased too far, the strings of material that are stretched may break and melt fracture may occur.

True

Review Question

True or False

To get the correct flow properties there must be a balance of Shear Rate, Shear Stress, and Melt Temperature. If these are not correct, flow problems will occur.

True

Review Question

True or False

The temperature of the PVC Compound exiting the adaptor is melt temperature. This is monitored through the Operator’s Panel.

TRUE

Phase Three: End Product & Haul-off Station

Back

Extruder

Phase OnePVC Melt

Phase TwoRheology

Die Calibrator

Front

Phase ThreeHaul-Off

End Product

Haul-Off

Visual Check Points- Trouble Shooting A B C D E

Visual Check Points- Trouble Shooting A B C D E

DownstreamAncillary Equipment

Air Showers

Blow excess moisture off the profile as it moves out of the water tanks

Bow Heaters

Heaters positioned on any side of a profile to correct bow created during the cooling process

Weather Strip

Inserts the pile weather strip

Nail Fin Pinch

Punches holes in nail fin of frames

DownstreamHaul-Off Station

The Haul-Off Station pulls the profile through the calibrator, cuts the cooled profile to size, and releases it to a tilt table for packaging.

DownstreamHaul-Off

Haul-Off

Pulls the profile through the calibration system at a precise rate of speed.

Pads

DownstreamHaul-off Station - Guillotine

Guillotine

Cuts the profile to length

Phase Three: End ProductPulled by the Haul-off

Haul – Off Station

Pulls profile through the calibration process

Guillotine cuts profile to length

Moves the profile to a tilt table for storage collection

Final Visual Check Point for Quality & Trouble Shooting

Trouble Shooting 5 Visual Check Points On-the-Floor

Back

Extruder

Phase OnePVC Melt

Phase TwoRheology

Die Calibrator

Front

Phase ThreeEnd Product

Haul-off

Visual Check Points- Trouble Shooting A B C D E

Visual Check Points- Trouble Shooting A B C D E

Trouble ShootingVisual Check Point: Feed Port & Control Panel

Back

Extruder

Phase OnePVC Melt

Visual Check Point A

Feed Port&

Control Panel

Trouble ShootingVisual Check Point: Vacuum Port

Visual Check PointB

Vacuum Port

Visual Check PointB

Vacuum Port

Look for Crumbly Belt orStrip with broken edges

Back

Extruder

Phase OnePVC Melt

Trouble ShootingVisual Check Point: Melt Exiting Die to Calibrator

Phase TwoRheology

Phase TwoRheology

Die Calibrator

Visual Check Point C Melt Exiting DieEntering the Calibrator

Visual Check Point C Melt Exiting DieEntering the Calibrator

Melt, Die & Calibrator

Trouble ShootingVisual Check Point: Extrusion Exiting Water Tanks

Phase TwoRheology

Phase TwoRheology

Die Calibrator

Visual Check PointD

Extrusion Exiting Water Tanks

Visual Check PointD

Extrusion Exiting Water Tanks

Trouble ShootingVisual Check Point: Haul-Off Table

Front

Phase ThreeEnd Product

Haul-off Station

Visual Check Point E

Haul-Off Table

Visual Check Point E

Haul-Off Table

Trouble ShootingVisual Check Point: Guillotine

Front

Phase ThreeHaul-Off

End Product

Haul-off

Visual Check Point E

Haul-Off Table

Visual Check Point E

Haul-Off Table

SummaryTrouble Shooting