home - plast control - bro38-gb16-rz4k …...years extrusion control solutions reliable automation...

38 EXTRUSION CONTROL SOLUTIONSYEARS

RELIABLE AUTOMATION

AND OPTIMIZATIONOF EXTRUSION

PROCESSES

BRO38-GB16-RZ4K 26.09.2016 13:48 Uhr Seite 2

We continuously develop our technologies and of-fer nowadays complete solutions, among others,in these areas:

y Material conveying PRO-VAC (p. 8-10)

y Gravimetric weighing PRO-GRAV (p.5)

y Dosing:continuous PRO-DOS (p.6)

batch PRO-BATCH (p.7)

y Profile automation:Profile measurement PRO-FIL (p.12)

Profile control PRO-CON u.PRO-JET (p. 13-15)

y IBC with width measurement and control PRO-SONIC, PRO-WIDE (p.17-18)

y Laboratory measuring tools PRO-LAB (p.19)

y Systems for the central control PCC (p.11)

PLAST-CONTROL …A STORY OF SUCCESS

For more than 38 years PLAST-CONTROL has beenautomating extrusion processes. From the onset,we focused on the supply of equipment for blownfilm extrusion lines expanding into other extrusionprocesses. Today we are the leading manufacturerin this worldwide market.

Meanwhile, around 30% from all produced sys-tems are delivered in other areas of the plastic in-dustry: production of cast films, sheets, tubes,spunbond or injection molding. PLAST-CONTROLproduces exclusively in Germany and deliverstheir products worldwide. At the headquarters inRemscheid more than 22 million euros were gene-rated in the years 2015/2016 with about 85 em-ployees on around 6,000 square meters.

Our branch offices and representations ensure asmooth, global distribution. Around 20,000PLAST-CONTROL systems were successfully in-stalled and working worldwide.

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y Branch officesy Representations


PLAST-CONTROL is the only company in our mar-ket which produces all critical components in-house. This in-depth knowledge of the principlesand hardware gives you, the customer, the chanceto use the process knowledge to the greatest ef-fect.

Our position of being able to design and buildcomplete control systems without using third par-ty devices and software is unique for the industry.

Complete responsibility of the control technologyand the ability to produce custom made applica-tions offers unrivalled experience and technicalcompetence.

We can fully automate your extrusion line. Do nothesitate to contact us!

Advantages:

y Waste reduction and material savingsy Fast product changesy Higher outputsy Reproducible productsy Reduction of operator faults

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AUTOMATION & QUALITY ASSURANCE

A Central Operator StationS Material conveying (vacuum loading) with intelligent controlD Gravimetric extrusion control systems, up to 7 dosing units

per extruder or six batch feedersF Thickness profile control, patented air ring technologyG PRO-SONIC internal bubble cooling controlH PRO-CAGE sizing cageJ IBC, internal bubble cooling hardware K On-line profile measurementL Haul-off measurement, haul-off controlÖ Width measurement

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The complete range of profile representation andanalyzer tools is customizable. The client canchoose between a monitor with key buttons orwith touch screen.

A powerful GDC-N computer grants a fast and ef-ficient control, being the right choice for simplegravimetric, batch-blending systems or contin-uous gravimetric dosing systems with up to 15components. Additional functions such as IBCand width measurement/control can be integra-ted.

ACS is the ultimate solution of the product rangeand can include all of the functions and featuresthat PLAST-CONTROL offers in one package. Theoperation is simple and very easy to handle withthe large 19”color TFT touch screen display.

ALL SYSTEMS …GT3+, GDC-N, ACS

The GT3+ is an economic but yet powerful systemfor the gravimetric control of an extrusion line. Itis designed for the control of up to 3 gravimetricweighing hoppers (e.g. a mono line with a mainhopper and 2 dosing units, or a 3-layer co-ex linewith 3 main hoppers without dosing units).

The GT3+ could also be used when it comes topure conveying, width or IBC control – require-ments that do not require an extensive visuali-zation.

The GDC-N is the compact specialist. The systemhandles up to 15 gravimetric weighing hoppers,temperature control or the profile measurementand control.

For a simple profile measurement and control sys-tem, the GDC-N is the economic solution. Pro-duction data is displayed on an easy to read10.4“ color TFT display with optional touch screencontrol for specific functions.

And there are even more benefits. In addition, allPLAST-CONTROL systems can handle these func-tions:

Advantages:

y Capacitive online gauge measurementy Width measurement and controly IBC controly Material flow control MFC (vacuum loading)

A System GT3+S System GDC-ND System ACS

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All our automation principles over the last 38 yearshave been based on gravimetric extrusion con-trol. The “loss in weight” principle guaranteesprecise measurement of throughput and controldesigned for all types of extrusion processes.

This approach of control is the only suitable prin-ciple when it comes to mono- and co-extrusionapplications. This concept works for all contin-uous extrusion processes. Needed in the processare a gravimetric weigh hopper frame, a slidevalve and a PC System.

In case of co-extrusion lines, the control of layerthicknesses is done by the adjustment of the in-dividual extruder throughput, matching the tar-get entry. If the production level is increasedthrough changing the haul off speed, all extru-ders will simultaneously react and the productparameters will remain constant even during theorder change phase.

The systems are capable to control the filmweight with a resolution of ± 0.1% from the av-erage. The system will compensate for deviationseven if the filter from the extruder gets cloggedor a heater band fails. The deviation from the tar-get value will be detected and accordingly cor-rected so that the film is still produced with thebest quality.

Experience shows that commonly, up to 4% ofthe raw material can be saved. The return of in-vestment is normally 6 to 12 months.

Advantages:

y Raw material savingsy No dependence on the bulk densityy Fast order change timesy Constant product qualityy Simple user interfacey Customized solutionsy Rugged, durable constructiony Easy cleaning through the removable hoppery Fast return of investment

GRAVIMETRIC EXTRUDER CONTROLPRO-GRAV

A Hopper frameS GT3+ Screen displayD “Loss-in-weight“-principle

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The new MICRO-DOSING units follow the trend tomore components and smaller dosing amounts. The new units can cover a range from 100 g/h upto 8 kg/h.

Advantages:

y Considerable saving of aggregatesy Independent from bulk densityy Fast product changey No pre-mixed materialy Precise dosing of small volumesy Easy operation and simple target entryy Up to 8 components per extrudery No dosing screw changes necessaryy Easy cleaning due to removable hoppers

GRAVIMETRIC CONTINUOUS DOSINGPRO-DOS

Optical, mechanical or functional requirementsfor the final product usually require the use ofseveral types of material per extruder. Various ad-ditives ensure as for UV-stability, good printabili-ty, good weldability etc. All these additives arevery expensive and must therefore be dosed asprecisely as technically possible.

The best technical solution, is the gravimetric dosing. In this case, additives are dosed precise-ly into the main material stream. The assemblyprevents demixing. The measuring is made follow-ing the “loss-in-weight“ principle, and the accu-racy is of 0.1%.

Fully modular construction allows up to 7 dosingunits plus main material to be fitted to each ex-truder (including co-extruders). All dosing unitsoutputs are synchronized with the main hopperoutput to guarantee an accurate product recipe.

The latest generation of dosing unit now incor-porates a high torque motor delivering a widespeed range. This minimizes the need for dosingscrew changes. Advanced software control guar-antees accurate control from very low to highoutput rates.

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A Continuous gravimetric dosingS Gravimetric frame with dosing unitsD Servo-Drive Motor (RCM)

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Compared to the continuous dosing, the batchblender works according to the “gain-in-weight“-principle. The material gate opens for a pre-deter-mined time and registers the gain in weight inthe weighing chamber. When the batch is com-plete, the material is discharged and mixed in themixing chamber. The accuracy is of ± 0.3%.

The PLAST-CONTROL batch blenders can beused off-line as a general purpose blender, onlineor on-line with extrusion control. The mixinghopper itself, works as a gravimetric weighinghopper in a "loss in weight" process.

The low-cost PRO-BATCH-devices are built for 4 to6 materials and several types of throughputs.

The new PRO-BATCH series combines many posi-tive features and the experience of the recent de-cades. In the developing process, we especiallypaid attention to the compact construction, easyhandling and operation, high precision and simplecleaning of the batch.

The new design of the slide valves, the effectivehelix mixer and transparent construction are meantto assist the user.

For special requirements, a combination of bothdosing principles (batch and continuous dosingprinciple) is also possible.

Advantages:

y More precise batch mixery Compact constructiony Usable in various situationsy Highly accessible

GRAVIMETRICBATCH DOSINGPRO-BATCH

A PRO-BATCH 4-180S PB-4-180 on a Co-Ex-line

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PB4- PB4- PB6- PB6-Model 180 450 150 300

No. comp. 4 4 6 6

Max. outputkg/h 180 450 150 300

Max. outputlbs/h 400 990 330 660

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Advantages:

y Layout for low abrasive weary High flexibilityy Centralized control

GRANULE CONVEYING PRO-VAC

Every extrusion process starts with the feeding ofthe materials to the system. The right layout ofthe system is a warrant for a high availability, lowdust contamination and energy efficiency withgreat flexibility.

In order to choose the right concept, talk to ourexperts right from the beginning phase of yourplanning.

We have the appropriate technicalsolution and the right vacuumsystem for both conveying ofsmall amounts of a singlematerial over a short distanceor tons per hour through ahuge production hall.

The standard decentralizedprinciple of material convey-ing (see picture 3) is simple:Each component is equippedwith a PCH material con-veyor. When the conveyorrequests a material, the systemwill connect the vacuum from thepump. The conveyor will start to transport thegranule from the day bin or silo into the storagehopper. Once the storage hopper is full, the mate-rial is drained into the extruder's weighing hopper.

In the central conveying principle, the main differ-ence is that more conveyors will simultaneouslytransport material. A more powerful pump will beneeded in the process, but in most cases smallerconveyors can be used.

A Conveying system with PCH 400S Layout of a conveying systemD Material-Minimising Control (MMC)F Vacuum pump with PCP pre-filter

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conveyor

storage hopper

material pipe

weight

day bin

vacuum pumpwith central filterPCP


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More and more extrusion companies are chang-ing to a centralized vacuum supply (moving awayfrom the system related vacuum production),needed for the feeding of the raw materials fromsilos to the machines.

Advantages like energy efficiency, noise reduc-tion at the work station and a significant higheroutput at lower cost are only a few reasons. Theuptime is increased while the maintenance effortis decreased.

For the central vacuum, more powerful vacuumpumps and pre-filters will be installed in a closedroom. The whole production plant will be sup-plied with vacuum through this central air line.The conveyors can access the vacuum streamand supply themselves as needed.

In addition to the optional hardware solutions forvacuum supply, PLAST-CONTROL also offers manysoftware solutions for this specific application.

Material Minimizing Control (MMC) has been de-veloped to reduce the amount of scrap and wastedue to changeover of products and recipes. Theprogram makes sure that the material storagehoppers of the dosing units are empty when thechangeover is initiated and that only a small amo-unt of material is left in the weighing hoppers.

Advantages:

y Noticeable lower energy consumptiony High flexibilityy Centralized controly No dust contamination in the production hally Less noise in the production hall

CENTRAL VACUUMPRO-VAC

AA Pump roomS Central vacuumD Material conveyors

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pump roomline 1 line 2 line 3

line 4 line 5

3xfilterpump 1 pump 2 pump 3


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Dust and contamination filtration with PCH-E

Dust and contamination of the virgin material of-ten creates problems in the extrusion process.Long transport distances and many elbows be-tween the silos and the machines produce angeldust and angel hair. These contaminates shouldbe removed before entering the extruder by usingfiltration devices.

For this type of problems, there are many solu-tions available. Just ask our engineers.

Advantages:

y High transparencyy Energy efficiencyy Customized designy High reliabilityy Efficient filtering of dust and angel hair

SOLVE PROBLEMS WITHPIPE IDENT & PCH-E

Coupling identification with PIPE-IDENT

PIPE IDENT was developed to eliminate the incor-rect connection of material feed hoses.

PIPE IDENT uses a wireless sensor (RFID) on theremovable flex hose which does not need a powersource. The fixed pipe side is connected to thecontrol system. The flex hose and the fixed pipeside are paired via the system software. If the hoseis connected to the wrong pipe, then a visual in-dication is displayed on the coupling as well as onthe operator display. In this case the start-up ofthe loading system is not allowed.

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A PIPE-IDENTS Dust and contamination filtration with PCH-ED PCH-E conveyor

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maschine in production,dedusting active

switched to silo PCH-E switched backon

12 min.reaction time

12 min.reaction time

reel change

levelgood production

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– 200 µm– 350 µm– 600 µm– 1000 µm> 1000 µm


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The PLAST-CONTROL Central PCC ensures plant-wide connection of your extrusion lines. The PCCis a powerful and convenient tool for accessingand storing all production data – in real time.

All production data is displayed centrally and op-tionally on Personal Computers integrated intoyour plant-wide network.

Precise material balance sheets, quality control,central data saving and production supervisingare possible without the need of large Informa-tion Technology budgets. The basic software pack-age includes a number of sophisticated data log-ging and order database applications. Customscreens can be implemented for a specific cus-tomer request.

Optionally, production specific data from yoursystem network can be sent to the PCC.

REAL TIME PLANT-WIDEMONITORING WITH PCC

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A PCC-ScreenS OEE-DiagramD PCC-Scheme

Advantages:

y OEE (Overall Equipment Efficiency)y Manufacturing transparency in real timey Material balance sheety Central data storage and retrievaly Online access to all production parametersy Material database capabilityy Scrap accountabilityy Central logging of machine status and alarmsy PLAST-CONTROL remote support via modemy Connection to plant network


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New C-SCAN solutions for barrier and cast film

An effective capacitive alternative to radioactivesources is available with the new C-SCAN, mountedafter the collapsing frame on blown film lines orafter the chill rolls on cast lines and measuresacross the web.

Advantages:

y The right measurement solution for all applicationsy Measurement of sticky (i.e.EVA) and soft film

without damage with AirCCy Integrated film temperature measurementy Barrier film measurement with C-SCANy Non-contact measurement of overall thickness

PROFILE MEASUREMENT PRO-FIL

Non-contact AirCC sensor

PLAST-CONTROL’s experience in building anddesigning measurement sensors for the on-linegauge measurement of films has given rise to sev-eral new technologies. The patented sensor AirCCwas developed especially for sticky and surfacesensitive films.

The AirCC has two parallel working sensors whichcreate different capacitive fields. This combina-tion allows calculation of film thickness regard-less of gap to film. Even a constantly changing airgap (from 100 to 350 µm) doesn't influence theresult.

Capacitive Measurement sensor

Capacitive measurement sensors from PLAST-CONTROL in combination with direct driven scan-ner rings in low-weight aluminum design are theguarantee for low maintenance profile measure-ment without any slip (precise allocation).

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A Profile displayS Measuring headsD Profile measuring with round scannerF C-SCAN

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PLAST-CONTROL, as one of the pioneers in thedevelopment of automatic systems for the reduc-tion of transverse direction (TD) profile toleran-ces has continuously developed and refined itssystems.

Functionally, the computer opening or closing ofactuators within the PRO-CON air ring will in-crease or decrease the volume of air in each seg-ment. This influences the melt temperature andin turn the film thickness during film blowing step.

The existing thin areas in the film are directlycooled when the melt comes out of the die andtherefore can no longer expand as much. Thefilm will remain thicker in this area.

PRO-CON has the same good response when itcomes to thick areas in the film. Depending onthe material and product, PRO-CON will correctthick spots by decreasing the cooling air in thisarea. Depending on the raw material and the pro-duct specifications, the film profile tolerances arereduced to a possible minimum.

The air rings are available in 6 sizes.

Advantages:

y 50% reduction of the base tolerancesy No additional energy inputy Output increase with MAGIC FLOWy Simultaneous control of thin and thick film areasy Easy retrofity Retrofits of rotating/oscillating dies possibley Fast return on investmenty Auto profile shift compensation

PROFILE CONTROLPRO-CON

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PRO-FILsensor

System ACS

profile measurement

profile control

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A PRO-CON displayS PRO-CON C-400 air ringD PRO-CON

TYPE Model Die l mm/inches

PRO-CON C-200/32 80-200 3-8PRO-CON C-400/48 200-400 8-16PRO-CON C-750/64 400-750 16-30PRO-CON K-1100/80 750-1100 30-44PRO-CON K-1650/106 1100-1650 44-65PRO-CON K-2200/128 1650-2200 65-86


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You can find more information about this productin our PRO-CON flyer.

Advantages:

y High bubble stability – fast return of investmenty Perfect basic tolerancesy Significant higher output, up to 40 % more

than comparable cooling systemsy Better mechanical film properties possible

BETTER COOLING WITHMAGIC-FLOW & PRO-CON DUO II

MAGIC-FLOW is the result of extensive researchin the increase of cooling capacity for blown filmlines.

This has been achieved by improving the aero-dynamic flow path between the blower, mani-fold and cooling ring. Additionally, extensive developments in the internal geometries of thecooling ring and the complete redesigned lipshape allows higher air speeds and air volumes atthe cooling interface. The net effect is that bub-ble stability is increased, transverse tolerances im-proved and higher machine outputs are achieved.

MAGIC-FLOW really does surpass all expectations:output increases of up to 40% are possible com-pared to standard double lip air rings.

An additional output increase becomes possibleby using PLAST-CONTROL’s double air ring tech-nology, PRO-CON DUO II. Mechanical propertieswill also be improved by using the DUO II. Theelectrical controlled upper air ring elevator allowsfor easy adjustment and accessibility.

The combination of “improved output – bettermechanical properties” ensures a fast return oninvestment.

DOWNGAUGINGwith PLAST-CONTROL

-6%

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A PRO-CON DUO IIS DowngaugingD IBC stack F Section view through the PRO-CON C-400

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The PRO-JET profile control is achieved throughthe mounting of a segmented plate, underneathan existing air ring. Adjustable air valves locatedbelow the air ring, control the volume of airflowin each segment.

The PRO-JET is suitable for stationary and movingdies and have diameters from 100 mm -2500 mm(4”-100”).

The basic tolerances are improved with up to 50%.PRO-JET does not affect output rates.

A PRO-JET layoutS PRO-JET installationD PRO-JET cut-out picture

Advantages:

y Economic solution for retrofitsy Immediate responsey Low additional energy inputy Auto profile shift compensation

PROFILE CONTROLPRO-JET

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profile control


Also included is a comprehensive technical andlegal counseling during the installation and thesecurity check in the working environment of theinstalled system.

Advantages:

y Modulary Safety functiony Retrofit/exchange of the old componentsy Long term availability of spare partsy Operation through Touch Screeny Implementation of clients’ individual wishesy Safety assurance of E-Stop circuitry

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STATE OF THE ART LINE CONTROL WITHNAVIGATOR

The NAVIGATOR operator allows a simple graphi-cal touch screen control of your entire extrusionprocess, including extruder drives, temperatures,blower controls, calibration cage, collapsing frame,haul-off and treater. The NAVIGATOR can be easi-ly adapted to new lines, upgraded or retrofitted,irrespective of the Original Equipment Manufac-turer.

PLAST-CONTROL produces many electronic com-ponents and the software package in-house, whichsets us apart from on-going technology obsoles-cence in the ever evolving computer world.

This enables us to provide our customers completeservice and spare parts for all our products formany years along with a migration to the futureproduct.

This flexible solution for existing extrusion linesas well as for new lines enables you to implementan identical operation philosophy throughout yourentire company. NAVIGATOR is available in manylanguages.

The configuration, implementation and documen-tation of all work steps are part of our service.

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A NAVIGATOR-screenS Power distribution and drive controlD Cabinets for CoEx-line

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PRO-SONIC can be integrated into all PLAST-CONTROL systems or can be supplied as a stand-alone system. For accurate control of the bubblediameter, speed is everything. PRO-SONIC incor-porates non-contact high quality ultra-sonic sen-sors processed by ultra-fast signal processing hard-ware and software. Bubble diameter calculatedwithin 100 ms per update.

Upgrading to PRO-SONIC offers full non-contacthigh resolution sensors and ultra-fast acting STVcontrol valve, reducing edge trim width (de-creased scrap) and reduction in order change time.

Stepper motor driven air Throttle Valve (STV)supplies instantaneous response to the controlrequired by the system. Layflat width variationsare reduced to a minimum. Startup requires mini-mal operator interaction.

Ultra-sonic sensors

We have achieved width tolerances of less than +/-2mm (0,08 inches) on existing lines using thelatest generation of ultra-sonic sensors combinedwith the newly developed air control valve.

You can find more information about this productin our PRO-SONIC flyer.

Advantages:

y Fully integratedy Cost effective solutiony Contact-free measurement

IBC BUBBLE CONTROLPRO-SONIC

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A Ultra-sonic sensors 1-3S IBC System controlD Frequency converterF Signal converterG Blower IBC in/outH STV air valve

(Stepper Throttle Valve)J Ultra-sonic sensor

on calibration basket

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sensors on frostline level

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frequencyconverter

air valvecontrol

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sensor 2

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pivot self centering, easily exchangeable rollersor the L series with single pivot operation.

Both devices feature a choice of roller surfaces fordifferent applications.

Advantages:

y Precise width controly Various roller surfacesy Rigid constructiony Compact design with wide adjustment range

BUBBLE CONTROLPRO-WIDE & PRO-CAGE

Width Control PRO-WIDE

A width measurement bar is installed between thecollapsing frame and the winder. The measuringsleds precisely detects the edges of the film bymeans of infrared sensors. For film with gussets,the width measurement can optionally be madewith ultra-sonic sensors on the calibration cage.

Width adjustments are made by automaticallyopening or closing the calibration cage on IBCsystems or with a digital air valve on non-IBC lines.

Calibration Cages PRO-CAGE

The calibration cage is possibly one of the mostoverlooked items in regard to the influence it hason film quality and profile tolerance.

The PRO-CAGE range of cages offers an innovativedesign with a rigid construction and precise con-trol of the cage position throughout the opera-tional range. You can choose between two typesof cages: the M series with high precision double

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FA Width measurementS MotorD Ultra-sonic sensorF PRO-CAGE Type L


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The PRO-LAB II has a touching sensor for the ab-solute, real thickness measurement of film profilesaccording to the norms DIN 533370/ ISO 4593/ASTM-D 6988-08.

In addition to the touching sensor the system isavailable with a capacitive sensor for a contin-uous measurement mode or with a combinationof both sensors.

To analyze the thickness distribution, a film stripis put into the holding device of the PRO-LAB IIsystem. The measuringvalue is taken with themechanical detectionhead at selectabledistances or continuouswith the capacitive sensor.The maintenance freestepper motor moves thefilm strip step by step bythe mechanical detectionsensor.

The PRO-LAB II basicsystem is equipped witha serial interface, so thatthe system can be con-nected to a customer PC.The software package isWindows based and has auser friendly environmentallowing a professionalprofile analysis. Based onmeaningful profilegraphics, average values,min. and max. values,the tolerance of the pre-selected set pointswill be easily detected.

With the help of Windows, these measuringresults can be documented withproduct or order numbers,archived or recorded.

You can find more information about this productin our PRO-LAB flyer.

Advantages:

y Measurement according to the norms DIN/ISO/ASTM

y Easy handlingy Automatic modey Easy calibration

GAUGE MEASUREMENTPRO-LAB II

A PRO-LAB II (standard version)S PRO-LAB II the mechanical detection with film guiding

device and tablet PC (optional)D Tablet PC with PRO-LAB II software (optional)

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PLAST-CONTROL GMBH WALTER-FREITAG-STR. 15 · 42899 REMSCHEID · GERMANYTEL. +49 2191 9480 0 · FAX +49 2191 9480 49

PLAST-CONTROL LTD. UNIT 17, LEEWARD ROAD · ASHTON-PRESTON · LANCASHIRE PR2 2TE · GREAT BRITAINTEL. +44 1772 769963 · FAX +44 1772 736357

PLAST-CONTROL INC. 65 PARKER STREET, UNIT 10 · NEWBURYPORT, MA 01950 · USATEL. +1 978 462 0306 · FAX +1 978 462 1425

PLAST-CONTROL ASIA LTD. 7F, NO. 155, KEELUNG ROAD · SEC. 1, XINYI DISTRICT · TAIPEI CITY, 110 · TAIWANTEL +886 2 3765 1808 · FAX +886 2 2767 2538

PLAST-CONTROL CHINA CO. LTD. UNIT 53 · FLOOR 11 · NO. 6088 HUMIN ROAD · SHANGHAITEL +86 21 5413 3383 · FAX +86 21 5413 3323

PLAST-CONTROL INDIA PVT. LTD. REDBRICKS · HDIL KALEDONIA 1ST FLOOR · SAHAR ROAD ANDHERI EASTMUMBAI 400 069 · MAHARASHTRA · INDIA · TEL +91 9594 033 303

WEB SITE: WWW.PLASTCONTROL.COM

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