Flat Dies and Feedblocks for the Extrusion Industry

Flat Dies and Feedblocks for the Extrusion Industry
The world leader for proven processing solutions.
1
What We Offer
Maag has been providing high
quality extrusion line
equipment and systems for
more than 25 years.
Now we can provide sheet
and film processors a
complete package from the
extruder outlet that includes
the screen changer, melt
pump, mixer, and die. With all
that we have to offer,
partnering with Maag has
never made more sense.
Maag offers a full line of film, sheet,
foam sheet, and double wall dies,
and associated feedblocks. Our
TruFlowTM products are engineered
and constructed to world class standards, typical of what you’ve come to
expect from Maag.
Whether provided individually, or as
part of a complete package with melt
pump, screen changer, and/or static
mixer, you get the quality and lasting value that has made Maag one of
the most trusted names in extrusion
today.
Dies are available for producing
single and multiple layer output,
including foam and corrugated layers.
Capacities include:
Typical Products Handled
• Up to 6,600 lb/hr
• Up to 315 in. wide
• Up to 1.18 in. thick
• Up to 9 layers
A variety of manual and automatic
lip adjustments are available, including adjustments without production
interruption, as well as internal and
external deckling arrangements.
• PC
• PMMA
• PA
• PP
• PE, HDPE, LDPE, LLDPE
• PS, HIPS
• PVC
• PET
• PVB
• ABS
• TPU
• EVOH
• Cellulosic plastic
A TruFlowTM model C2-1 quick adjusting
die with automatic fine gauge control and
feedblock incorporated into a system with
melt pump and screen changer.
2
TruFlowTM Product Overview
Maag offers dies to suit most applications, such as:
• Film and sheet
• Coating and laminating
• Coextrusion
• Specials, including dies for foam
sheet and double wall products
Standard construction features
include:
• Premium steel construction with
hardness of RC 33-35 for bodies
and RC 38-42 for lips
• Surface finish for flow channels is
4-6 RMS and 2-3 RMS for lips
• Chrome plated internal (0.0080.015 in.) and external (0.006-0.008
in.) surfaces
• One inch center distance for thickness adjustment screws
All dies and feedblocks have computer optimized flow channels for consistent residence time and residence
time distribution. State of the art
3- and 5-axis machining centers are
used to produce the complex channel designs. Thorough lab testing
ensures performance objectives are
met. More than 8,000 die installations
worldwide attest to their superior
design and craftsmanship.
Maag TruFlowTM dies are available in 18 standard designs
for a wide variety of extruded products.
Computer modeling is used to
optimize flow channels in TruFlowTM
dies and feedblocks.
3
TruFlowTM Film and Sheet Dies
Models A1 & A3 Cast Film Dies
Thicknesses to 0.012 in.
Models A2 & A2-1 Film / Sheet Dies
Thicknesses to 0.118 in.
Model C2-1 Quick Adjusting Die
Thicknesses to 0.158 in.
The A1 is equipped with manual push
thickness control and fixed lower lip
for close contact with the casting
rolls.
For film and light gauge sheet. The
upper lip is adjustable by manual
push and the lower lip is adjustable
or exchangeable, for a wide range of
thickness adjustment.
This innovative die allows lower
lip adjustment without process
interruption.
The A3 adds automatic gauge control. Upper lip adjustment is provided
by thermal expansion bolts, which
are heated via closed-loop control
using data collected from a gauging
system immediately downstream of
the die. The bolts are insulated to
eliminate thermal influence between
the bolts and die lips.
Standard Specifications
• Outputs to 2,200 lb/hr ( 3,950 lb/hr
for A3)
• Widths 8 – 180 in. (217 in. for A3)
• Thicknesses 0.0004 – 0.012 in.
• Melt indexes 1 – 5
• Upper lip adjustment: 45° manual
push
• Upper bonding bolt
• Installation: vertical
Standard Specifications
• Outputs to 3,950 lb/hr
• Widths 8 – 217 in.
• Thicknesses 0.006 – 0.118 in.
• Melt indexes 1 – 5
• Upper lip adjustment: 45° manual
push (push and pull for A2-1 model)
• Lower lip : adjustable or
exchangeable
• Upper bonding bolt
• Installation: horizontal, vertical, or
45°
Options
Standard Specifications
• Outputs to 3,300 lb/hr
• Widths 8 – 80 in.
• Thicknesses 0.012 – 0.158 in.
• Melt indexes 1 – 5
• Upper lip adjustment: 45° manual
push
• Lower lip: quick adjustable
• Lower bonding bolt
• Installation: horizontal or 45°
Options
• Choke bar
• Custom die cart
• External deckling system
• TruFlowTM coextrusion feedblock
• Custom die cart
• Internal or external deckling system
(20 in. max adjustment each side)
• TruFlowTM coextrusion feedblock
Options
• Custom die cart
• Internal or external deckling system
(20 in. max adjustment each side)
• TruFlowTM coextrusion feedblock
Our automatic cast film die
maintains precise gauge control
without operator intervention.
The C2-1’s quick adjustment feature
allows changing gauge thickness online in
under 2 minutes.
4
Models C1 & C2 Sheet Dies
Thicknesses to 0.59 in.
Model B Sheet Die
Thicknesses to 1.18 in.
Model C2-2 Sheet Die
Thicknesses to 1.18 in.
C1 and C2 dies are for light to heavy
gauge sheet production and include
a choke bar to promote uniform melt
flow across the die width.
For heavy gauge sheet.
For extra heavy gauge sheet.
Standard Specifications
Standard Specifications
• Outputs to 4,400 lb/hr
• Widths 8 – 315 in.
• Thicknesses 0.008 – 1.18 in.
• Melt indexes 1 – 5
• Upper lip adjustment: push, 45°
push and pull fine adjustment, 90°
adjustment for >0.6 in. thickness
• Lower lip: adjustable up to 0.08 in.
thickness, exchangeable up to 0.24
in.
• Choke bar: 45° for 0.08 – 0.24 in.
thickness, 90° for thicker material
• Lower bonding bolt
• Installation: horizontal or 45°
• Outputs to 6,600 lb/hr
• Widths 8 – 217 in.
• Thicknesses 0.118 – 1.18 inches
• Melt indexes 1 – 5
• Upper lip adjustment: 90° push and
pull, changeable
• Lower lip: exchangeable
• Choke bar 90°
• Upper bonding bolt
• Installation: horizontal or 45°
The C2 further offers higher precision
output.
Standard Specifications
• Outputs to 1,320 lb/hr
• Widths 8 – 217 in.
• Thicknesses 0.118 – 0.59 inches
• Melt indexes 1 – 5
• Upper lip adjustment: 45° push
• Lower lip: fixed or adjustable
• Choke bar: 45°
• Lower bonding bolt
• Installation: horizontal or 45°
Options
• Custom die cart
• External deckling system
• TruFlowTM coextrusion feedblock
TruFlowTM dies are precision
built from high quality steel
with all surfaces hard chrome
plated and polished.
Options
• Custom die cart
• External deckling system
• TruFlowTM coextrusion feedblock
Options
• Custom die cart
• External deckling system
• TruFlowTM coextrusion feedblock
5
TruFlowTM Coating and Laminating Dies
Models A1-1 & A1-2 Coating, Laminating, and Oriented Film Dies
The A1-1 is equipped with internal
deckling with thick edge reduction.
The A1-2 model adds automatic
gauge control. Upper lip adjustment
is provided by thermal expansion
bolts which are heated via closedloop control using data collected
from a gauging system immediately
downstream of the die. The bolts are
insulated to eliminate thermal influence between the bolts and die lips.
Standard Specifications
• Outputs to 1,100 lb/hr (2,200 lb/hr
for A1-2)
• Widths 8 – 158 in. (217 in. for A1-2)
• Thicknesses 0.0002 – 0.004 in.
• Melt indexes <8
• Upper lip adjustment: push
• Lower lip: fixed
• Installation: horizontal, vertical, or
45°
TruFlowTM coating and laminating dies
include internal deckling as standard.
Options
• Custom die cart
• TruFlowTM coextrusion feedblock
This external deckling system allows
width adjustment without production
interruption.
6
TruFlowTM Specialty Dies
Model C2-3 Polystyrene Foam
Sheet Die
Models D1-1 & D1-2 PVC Foam
Sheet Dies
Model I Double Wall Die
Specially designed for polystyrene
foam applications. Each lip features
independent oil temperature control.
The D1-1 model is for free foam and
the D1-2 model is for Celuka foam.
Each lip features independent oil
temperature control. The D1-2 model
has two independent channels,
each with choke bar, which provide
minimum polymer residence time and
precision flow control. This model
also has separate oil temperature
control for the die body.
This dual channel design produces
double wall PP and PC sheet for a
hollow material that is rigid, yet lightweight. A special version is available
for applying a UV resistant layer with
the addition of a feedblock.
Standard Specifications
• Outputs to 1,100 lb/hr
• Widths 7.9 – 78.7 in.
• Thicknesses 0.039 – 0.78 in.
• Melt indexes 1 – 5
• Upper lip adjustment: push, 45°
push and pull fine adjustment
• Lower lip: adjustable or exchangeable, depending on thickness
• Choke bar: 45°
• Installation: horizontal, vertical, or
45°
Options
• Custom die cart
• External deckling system
Standard Specifications
• Outputs to 1,750 lb/hr
• Widths 7.9 – 118 in.
• Thicknesses (free foam) 0.039
– 0.787 in.; (Celuka foam) 0.118 –
1.181 in.
• Upper lip adjustment: 45°, 90°, fine
adjustment (exchangeable on the
D1-2 model)
• Lower lip: adjustable or exchangeable, depending on thickness
• Choke bar: 45° or 90°, depending
on application
• Upper or lower bonding bolt
• Installation: horizontal
Standard Specifications
• Outputs to 1,100 lb/hr
• Widths to 138 in.
• Thicknesses (PP) 0.079 – 0.787 in.,
(PC) 0.158 – 1.181 in.
• Upper lip adjustment: 90° fine
adjustment
• Lower lip: 90° fine adjustment
• Choke bar: (PP) 90° in both
channels
• Installation: horizontal
Options
• Custom die cart
Options
• Custom die cart
Examples of internal structure patterns used in double wall sheets.
The round holes are compressed air
outlets.
A typical TruFlowTM foam die
7
TruFlowTM Coextrusion Dies and Feedblocks
Model D Dual Manifold Sheet Die
Model DF-1 Triple Manifold Film /
Sheet Die
Model E Triple Manifold Sheet Die
For handling two different polymers.
It features two independent channels, each with temperature control
system, to provide minimum polymer
residence time and precision flow
control.
For film and light gauge sheet using
three or more different polymers. It
features three independent channels, each with temperature control
system, to provide minimum polymer
residence time and precision flow
control.
For medium to heavy gauge sheet
using three or more different polymers. It features three independent
channels, each with temperature
control system, to provide minimum
polymer residence time and precision
flow control.
Standard Specifications
Standard Specifications
• Outputs to 3,300 lb/hr
• Widths 11.8 – 315 in.
• Thicknesses 0.0008 – 0.008 in.
• Upper lip adjustment: 45° fine
adjustment
• Lower lip: adjustable or exchangeable, depending on thickness
• Choke bar: 45° on upper channel,
other channels if needed
• Lower bonding bolt
• Installation: horizontal, vertical, or
45°
• Outputs to 3,300 lb/hr
• Widths 11.8 – 315 in.
• Thicknesses 0.008 – 0.787 in.
• Upper lip adjustment: 45° fine adjustment, 90° available
• Lower lip: adjustable or exchangeable, depending on thickness
• Choke bar: 45° or 90° on upper
channel, other channels if needed
• Lower bonding bolt
• Installation: horizontal, vertical, or
45°
Options
Options
Options
• Custom die cart
• Internal or external deckling system
• TruFlowTM coextrusion feedblock
• Custom die cart
• Internal or external deckling system
• TruFlowTM coextrusion feedblock
• Custom die cart
• External deckling system
• TruFlowTM coextrusion feedblock
Standard Specifications
• Outputs to 3,300 lb/hr
• Widths 11.8 – 315 in.
• Thicknesses 0.0008 to 0.008 in.
• Melt indexes 1 – 5
• Upper lip adjustment: 45° fine
adjustment
• Lower lip: adjustable or exchangeable, depending on thickness
• Choke bar: 45° on upper channel,
lower channel if needed
• Lower bonding bolt
• Installation: horizontal, vertical, or
45°
A TruFlowTM coextrusion die with
external deckling.
8
Model F Integral Die and Feedblock
Combination
Model G Fixed Geometry
Feedblock
Model H Variable Geometry
Feedblock
Our coextrusion dies can be integrally
combined with one of our feedblocks
for easier installation.
• Dependent upon the die chosen
Designed for 2, 3, or 4-layer sheet
production, the layer configuration
can be changed via use of different
flow selection cartridges. Layer percentages can be adjusted by adding
or removing flow channel modules.
Options
Options
Designed for 5- to 9-layer sheet production, this type of feedblock allows
layer percentage control externally,
using flow control pins or adjustable
vanes for each layer. The layer configuration can be changed via use of
different flow selection cartridges.
• Custom die cart
• Internal or external deckling system
• Maag TruFlowTM die
Standard Specifications
Options
• Maag TruFlowTM die
A seven channel variable geometry
feedblock with control pin type layer
adjustment. The flow selection cartridge
(attached to the top of the inlet section)
allows flexibility in layer configuration.
A three channel variable geometry feedblock with vane type layer adjustment.
9
Package Systems
In addition to dies and feedblocks,
Maag offers the following extrusion
optimization products:
Maag can provide a complete engineered package that combines the
die and/or feedblock with:
• Melt pumps: for higher line
throughputs with better gauge
control and lower overall energy
consumption.
• Screen changer
• Melt pump
• Static mixer
• Hydraulic power units
• Sensors, instrumentation, and
controls
• Adapters and connectors
• Motors, gear reducers, and drives
• Shafts, couplings, and guards
• Base plates, support frames, and
carts
• Screen Changers: in a variety of
continuous, semi-continuous, and
non-continuous configurations for
increased product quality and protection of downstream equipment.
• Static mixers: for uniform mixing
and temperature distribution with
low pressure losses in a compact
inline design.
Benefits
When you buy a packaged system
from Maag, you realize the benefits
of:
• Single source responsibility
• An integrated system where all
components are designed to work
together
• Simpler procurement
Melt Pump
Screen Changer
Static Mixer
Inlet Pressure
Pump
Drive
Die
RPM
Current
Speed control
Drive
Control
Master
Discharge Pressure
Melt Temperature
Drive
Control
Typical schematic of Maag
extrusion optimization
equipment.
10
Standard Die Selection
Die Type
Heating Zones in Body
3-5
Heating Power (KW)
9-25
9-25
15-45
21-55
33-75
39-85
45-125
Die width (in.)
< 25
25-50
50-80
80-100
100-120
120-140
140-220
Thickness
(in.)
3-5
Output
(lb/hr)
100-200
11-15
13-17
A1/A3
A1/A3
650-1,500
A1/A3
900-2.200
A3
1,100-3,300
A3
1,500-4,000
0.006-0.08
Film /
Light Gauge
Sheet
0.008-0.08
100-200
0.012-0.12
A3
A2/A2-1
200-650
A2/A2-1
450-1,100
A2/A2-1
650-1,500
900-2, 200
15-25
A1
450-1,100
Cast Film
7-11
Model Number
200-650
0.004-0.012
5-9
A2/A2-1
C2-1
1,100-3,300
C2-1
1,500-4,000
A2/A2-1
175-350
0.12-0.6
200-900
C1/C2
450-1,300
Sheet
650-1,750
0.12-1.18
900-3,300
C2-2
1,100-4,400
1,300-6,600
70-175
175-450
Coating /
Laminating
350-900
0.0002-0.004
450-1,100
650-1,550
900-1,750
1,100-2,200
A1-1
A1-1
A1-1
A1-2
A1-2
A1-2
A1-2
The selection guide and all other representations presented in this brochure are for standard dies only. We can also
supply custom dies built to specific customer requirements. Consult Maag for more information.
USA
Switzerland
Germany
Italy
Maag Pump Systems Inc.
1500 Continental Blvd.
Charlotte, NC 28273
USA
Tel +1 704-716-9000
Fax +1 704-716-9001
[email protected]
Maag Pump Systems AG
Aspstrasse 12
8154 Oberglatt
Schweiz
Tel +41 44 278 82 00
Fax +41 44 278 82 01
[email protected]
Maag Pump Systems GmbH
August-Kümpers-Strasse 9
48493 Wettringen
Deutschland
Tel +49 2557 92 80 0
Fax +49 2557 92 80 20
[email protected]
Maag Pump Systems S.r.l.
Viale Romagna 7
20089 Rozzano (M)
Italia
Tel +39 02 575 932 1
Fax +39 02 575 932 32
[email protected]
Singapore
France
China
Maag Pump Systems Pte. Ltd.
25 International Business Park
04-73 German Center
609916 Singapore
Tel +65 6562 8720
Fax +65 6562 8729
[email protected]
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111, Rue du 1er Mars 1943
69100 Villeurbanne
France
Tel +33 4 72 68 67 30
Fax +33 4 72 68 67 31
[email protected]
Maag Pump Systems Shanghai
Room 1204A, Silver Tower
218 South Xi Zang Road
200021 Shanghai, China
Tel +86 21 5396 6555
Fax +86 21 5396 6 913
[email protected]
www.maag.com