foam extrusion systems

7/29/2019 FOAM EXTRUSION SYSTEMS

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FOAM EXTRUSION SYSTEMS



Davis-Standard’s foam systems are used in R&D and production applications by industry leaders in thepackaging, automotive, industrial, and graphic arts markets. Versatile, high performance, direct gas

injection foam systems are available in single screw tandem designs, as well as counter- or co-rotating

twin screw arrangements. Extruders are available 2 1/2- to 16-inch (64 - 400mm) diameters with L/D

ratios of 30:1 and higher. Coextrusion systems, turnkey equipment, and weight reduction solutions for

solid sheet applications are also available.

More Than 40 Years of Foam Extrusion

Experience at WorkWe believe that experience is the key to understanding our customers and their needs. Our reputation is

built on our ability to be able to supply you with the type of equipment and processing features that you

need to run a more efficient and more cost-effective business. Production of high quality foam products

with the best equipment in the industry is our goal.

SYSTEMS FOR M ANY APPLICATIONS

• Packaging: Meat trays, egg cartons, cups, plates, anti-slip mats, protective wrapping

• Automotive: Custom profiles, seals and gaskets, interior furniture padding

• Industrial: Ceiling tiles, insulation board, pipe insulation, furniture padding

• Graphic Arts: Point-of-purchase displays, poster board, signage

Foam End Products



SPECIALTY DIE OFFERINGS

Sheet Die:• On-the-fly remote die lip adjustment

• Adjustable choke distribution ring

• For open cell absorbing foam

• Mono and coextrusion dies available

• Die sizes from 1/2-inch (13mm) to 12-inch (300mm) lips

Board Die:• Die for 24” (600mm) to 48” (1200mm) wide board

BLOWING AGENTS

• Hydrocarbon

• Atmospher ic

• Blends

MATERIALS

• PS

• LDPE

• PET

• PP

• Ot her s

SPECIALTY MANDREL AUXILIARY COOLING EQUIPMENT

• Machined aluminum construction

• Segmented nose cooling• Specialty non-slip coatings

• Auxiliary air cooling blowers

• Close approach and standard blow-up air ring designs for skin surface effect

• Designed for quick mandrel changes

LABORATORY CAPABILITIES

• R&D facility in Pawcatuck, Connecticut

• Equipment available for developing/testing new blowing agents, screws, and die designs

• Customer demonstrations and specialty product developments

Quality Components Built To LastInvesting in the right foam extrusion system is an important decision and involves a significant financial

commitment. We strive to provide you with the greatest return on your investment by supplying

equipment that meets demanding production requirements while providing you with many years of

reliable operation. We also take pride in being able to supply you with complete systems

equipped with the best components available in the industry.

PRIMARY EXTRUDERS

• Single or twin screw Davis-Standard Thermatic® series extruders

• Patented screw designs for foam

• Dual T/C temperature control

Cooling Mandrel, Stand with External Sheet Cooler

Cooling Mandrel with Dual Slitting Arrangement

165-225mm with Annular Foam Die



INJECTION SYSTEMS

• Hydrocarbon and atmospheric blowing agents• Mass flow meter flow control

• Multi-gas and/or blending systems

SCREEN CHANGERS

• Slide plate and continuous styles

MELT TRANSFER PIPE

• Built for 10,000 psi (680 bar) operation

• Spherical joints for thermal expansion

• Static mixer

• Melt pump

COOLING EXTRUDERS

• Davis-Standard Thermatic® series extruders

• Self-starting polymer sealing system

• Wet barrels for 30% more cooling

• Dual pass heater coolers

• Low torque high output screws

CLOSED LOOP COOLING SYSTEM

• Multiple closed loop temperature control systems

• Designed for 100ºF (38ºC) plant cooling water

ANNULAR FOAM DIE

• Spider and spiderless designs

• “On the fly” gap adjustment

• Mono-layer and coextrusion available

AIR & WATER COOLING RINGS

• Internal and external air rings

• Compressed air and blower type available

• Water rings available for product flatness

SIZING MANDREL

• Cast or machined aluminum construction

• Single, dual or multiple slitting arrangements

S-WRAP PULL ROLL

• Single and dual sheet arrangements

• Cantilevered designs available

• Tension control loop coordinated with winder

Gas Injection System

Annular Foam Coextrusion Die

Dual Sheet S-Wrap



WEB GUIDE SYSTEMS

• Optional driven and manual edge guide system

WINDERS

• Dual cantilevered design with pneumatic push-offs

• Surface winder designs for PE foams

• Accumulators for high output lines

PROCESS CONTROLS

• EP IC III™ and Mesa III process control systems

• Allen-Bradley PLC or Siemens control systems

• Complete line integration with touch screen computer

• Recipe storage and production reporting and troubleshooting

• Discrete controls available on request

Advanced TechnologyTechnology is what sets extrusion equipment apart in performance and quality. We have a dedicated

Technology Center that focuses on finding ways to make existing equipment and processes better.

From feedscrews to die designs, we always want to stay on the cutting edge of technology, so that our

customers have the best tools available.

AB COEXTRUSION DIE

• 4-to-1 blow-up/stretch ratio

• Requires use of fewer blowing agents to achieve a high density product • Capable of processing rigid and foam structures simultaneously

• AB, ABA, and ABC coextrusion designs ideal for barrier packaging, absorbent

foam technology, and food tray processing

HIGH-OUTPUT FEEDSCREWS

• System outputs up to 3,600 pounds (1630 kg) per hour

• Dynamic seal design prevents gas from leaking in tandem arrangement

• Minimal shear while providing efficient cooling and mixing

Name the Application – We Have a SolutionFLEXIBLE SHEET ON A ROLL

We supply both PS and PE winding equipment for flexible sheet applications.

RIGID BOARD

We supply equipment fo r foam board f rom 3/4-inch to 6 inches (20 to 150mm) thick, cut to size at

any length. We work with several leading companies to integrate technology for cooling, conveying,

printing, finishing, sizing, and shaping of board material products.

Dual Cantilevered Sheet S-Wrap

Two Dual Canti levered Sheet Winde rs

Dual Cantilevered Sheet Winder



PS FOAM SHEET LINES

We supply PS foam sheet systems for thermoformed and flexible packaging applications. These systemsare available with tandem single screw extruders with gas injection, or with twin screw extruders with

gas injection.

PS FOAM BOARD LINES

Davis-Standard supplies flat die and calibration systems for the continuous extrusion and shaping of

foam boards used for temperature insulation. Adjustment features are incorporated within the die and

calibration unit to maintain uniform thickness with minimal edge trim.

PE FOAM SHEET LINES

PE foam sheet systems for processing the protective material used in packaging fragile items and for

insulation are available with tandem single screw extruders or twin screw extruders with gas injection.

PP FOAM SHEET LINES

These systems, primarily used for thermoforming food containers and for producing automotive parts, are

available in both tandem single screw and twin extruder arrangements based on application.

TANDEM EXTRUDER SIZ ES AND NOMINA L OUTPUT CHART

PS PE/PP

Extruder Sizes kg/hr lb/hr kg/hr lb/hr

2 ½ - 3 ½ in. 125 - 150 275 - 330 110 - 130 240 - 285

3 ½ - 4 ½ in. 225 - 275 500 - 600 200 - 250 440 - 550

100 - 130mm 250 - 320 550 - 700 225 - 285 500 - 625

120 - 165mm 500 - 600 1,100 - 1,300 450 - 540 990 - 1,200

130 - 165mm 550 - 650 1,200 - 1,450 500 - 585 1,100 - 1,285

6 - 8 in. 600 - 750 1,300 - 1,650 540 - 675 1,200 - 1,485

165 - 225mm 680 - 900 1,500 - 2,000 600 - 800 1,320 - 1,760

8 - 10 in. 900 - 1,000 2,000 - 2,200 800 - 900 1,760 - 1,980

8 - 12 in. 1,100 - 1,350 2,400 - 3,000 990 - 1,200 2,200 - 2,640

250 - 400mm 1,400 - 1,600 3,100 - 3,600 1,260 - 1,440 2,800 - 3,700

Flat Die Forming Box assembly for Foam Board

XPS Shaping System

XPS Haul Off

XPS Calibration Unit

Get to Know Us Davis-Standard has set the standard in foam equipment

and systems. We hope you will take the time to get to

know us. Our capabilities go far beyond our equipment.

They extend to our professional training experts,

laboratory personnel, design engineers, and hands-on field

engineers who will work with you every step of the way.



1) Primary Extruders• Single or twin screw Thermatic ® series extruders• Patented screws designs for foam• Dual T/C temperature control

2) Gas Injection Systems• Hydrocarbon & atmospheric blowing agents

• Mass flow meter flow control• Dual gas blending systems

3) Screen Changers• Slide plate and continuous styles available

4) Melt Transfer Pipe• Built for 10,000 psi (680 bar) operation• Spherical joints for thermal expansion

5) Cooling Extruders• Thermatic® series extruders• Self starting polymer sealing system• Spiral wrap barrels for extra cooling• Dual pass heater coolers• Low torque high output screws

6) Closed Loop Cooling System• Two closed loop temperature control systems• Designed for 100˚ F (38˚ C) plant cooling water

7) Annular Foam Die• Spider & spiderless designs• “On the fly” gap adjustment

• Monolayer & coextrusion available8) Air & Water Cooling Rings

• Internal & external air rings• Compressed air & blower type available• Water rings available for product flatness

9) Sizing Mandrel• Cast or machined aluminum construction• Single, dual or triple slitting arrangements

10) S-Wrap Pull Roll• Single & dual sheet arrangements• Cantilevered designs available• Tension control loop coordinated with winder

11) Web Guide Systems• Optional driven & manual edge guide systems

12) Winders • Dual cantilevered design or pneumatic push-offs

• Surface winder designs for PE foams• Accumulators for high output lines

13) Process Controls• Epic III™ and Mesa III process control systems• Allen-Bradley PLC or Siemens control systems• Complete line integration with touch screen computer• Recipe storage & production reporting & troubleshoot ing• Discrete controls available on request

DAVIS-STANDARD FOAM SHEET SYSTEMS

DAVIS-STANDARDFOAM BOARD SYSTEMS

See Above for Descriptions 1 - 6

7) Board D ie

8) Board Calibration Unit

9) Primary Haul-off Unit

10) Cooling Transport Conveyor

11) Secondary Puller

12) Edge Profile Station

13) Process Controls• Epic III™ and Mesa III process control systems• Allen-Bradley PLC or Siemens control systems• Complete line integration with touch screen computer• Recipe storage & production reporting & troubleshootin g• Discrete controls available on request

14) Cross Cutting Machine

15) Board Stacker

16) Packing Unit

17) Control Station

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Davis-Standard Business Areas

46 North First StreetFulton, NY 13069-1297USATel: +315-598-7121Fax: +315-593-0396www.bc-egan.com

Room 1007, Jing An China Tower1701 Beijing (W) RoadShanghai 200042 P.R. CHINATel: +86-21-5150 1908Fax: +86-21-5150 1906www.davis-standard.com

#1 Extrusion Drive | Pawcatuck, CT 06379-2313 USA | Tel: +860-599-1010 | Fax: +860-599-6258 | www.davis-standard.com

Unit 33 Hainge RoadTividale, Oldbury, West MidlandsB69 2NY UNITED KINGDOMTel: +44-121-522-0030Fax: +44-121-522-0031www.davis-standard.com

Mettmanner Strasse 51D-40699 Erkrath/DüsseldorfGERMANYTel: +49-211-2404-0Fax: +49-211-2404-281www.er-we-pa.de

36 South Adamsville RoadSomerville, NJ 08876-0671USATel: +908-722-6000Fax: +908-722-6444www.bc-egan.com

2007 Davis-Standard, LLC. All Rights Reserved. JWR

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