Powerful and cost-effective for all application areas Profile extrusion

Powerful and cost-effective for all
application areas
Profile extrusion solutions
Engineering Value
Profile extrusion
Requirements and tasks
Picture source: www.schueco.com
2
3
Profile extrusion lines
For your special
requirements and tasks
KraussMaffei Berstorff supplies individual machines and complete profile extrusion lines for all profile extrusion applications.
Whether profiles made of PVC, PE or other materials – and
irrespective of the profile type you want to produce - our
systems open up every available possibility to you.
Your advantages at a glance
–Energy-efficient production thanks to
innovative machine technology
–Low maintenance thanks to internally
heat-balanced screws and air-cooled
barrels
–Active wear resistance thanks to
premium quality screws and barrel
protection, e. g. molybdenum-protected
or tungsten carbide-protected screws
and/or bi-metal barrels.
–Maximum flexibility and process
reliability when processing different
formulations
–Optimum melt homogeneity thanks
to a long processing unit
–Excellent unvarying product quality
over a defined performance range
–Long service life with constantly high
output rates
–Excellent price-performance ratio
Impressive encounter:
Take a tour of a complete
extrusion line
Tip table
Haul-off-saw combination with change bars
Optionally equipped with a saw or a cutter
5
Calibration table equipped with a vacuum pump and cyclones
–Energy-efficient
– Universal molds can be clamped
KMD 114-32/P twin-screw extruder
For PVC material or PVC mixtures
Exemplary extrusion line for producing PVC window profiles
6
Profile extrusion
Twin-screw extruders
32D twin-screw extruders
High-tech profile extrusion
With their technically perfectly
matched machine components,
parallel twin-screw extruders
in the 32D Series provide you
with a cost-effective solution
for all your profile extrusion
solutions.
Optimized screw concept
The processing concept of the 32D Series
perfects material preparation, ensures
optimum melt homogeneity and permits
processing of many different PVC formulations in a very wide processing window.
KMD 90-32/P twin-screw extruder with
molybdenum-protected screws
Maximum flexibility
In process engineering terms, the 32D
Series offers maximum flexibility both in
the use of different formulations and a
wide range of molds.
Powerful gearbox
In order to safely realize the high screw
torques , a very powerful gearbox is
required. This gearbox has a compact,
robust and low-vibration design, and
is geared precisely and rigidly to the
processing unit.
Perfect wear resistance
The 32D processing units with molybdenum-protected and deep-nitrated barrels
guarantee active wear resistance for a
wide range of different formulations,
thus ensuring a long service life of the
machine.
KMD 114-32/P twin-screw extruder:
Front view
High-performance extrusion
The machine concept of KraussMaffei
Berstorff ensures maximum output
rates - and also produces constantly
perfect product quality over a defined
performance range. Compact machine
combinations, for example in twin-strand
processing, with a throughput rate of
more than 900 kg/h are a clear indication
of the solution expertise of KraussMaffei
Berstorff in high-performance extrusion.
7
Conical twin-screw extruders
Compact, flexible and robust
The conical twin-screw
extruders from KraussMaffei
Berstorff are particularly suitable for production in the lower
output range and can be used
both as mono-extruders as well
as coextruders.
Space-saving and efficient machine
concept
The simple conical series has a very
compact design, thus saving valuable
production space. The position of the
screw axes provides enough space for a
robust distribution gearbox and a strong
thrust bearing. The robust gearbox and
the ideally dimensioned drive concept
with an AC motor ensure a long service
life and low maintenance costs.
KMD 43 K/P conical twin-screw extruder with
swivel-mounted display
Perfect wear resistance
Thanks to the special molybdenum welding technique of the processing unit, the
extruders in the conical series are ideally
suited for the use of recycling material
or highly charged mixtures since they are
extremely wear-resistant.
Optimum screw concept ensures highly
flexible processing
Due to the screw design in the feed and
precompression zone, the KraussMaffei
Berstorff concept guarantees optimum
heat transfer via barrel heating.
During the design of the screw concept,
special attention was paid to high pressure
stability up to 500 bar mold back pressure.
The processing company can carry out
production in an extremely flexible way even with high mold pressures.
Different types of material, for example
Dryblend, granulate and regrind, can
also be very easily processed. The excellent price-performance ratio makes an
absolutely vital contribution towards
cost-effective production.
In addition to temperature control,
processing companies profit from
maximum melt homogeneity, thus
producing a premium quality end product.
KMD 63 K/P conical twin-screw extruder in a
mono design with the operator panel integrated
into the control cabinet
KMD 63 K/P conical twin-screw extruder mounted
as a stand-alone model on a column
(Presentation without switching cabinet and
operator panel)
8
Profile extrusion
Coextrusion
Innovative product range of coextrusion models
For different applications
Coextrusion is the current trend in profile extrusion. For example, window main profiles made of
recyclates or cost-effective formulations are produced in the core or in the invisible area of the
profile; the visible surfaces are made from colorfast new products.
KraussMaffei Berstorff supplies a wide range of coextruder products and space-saving coextrusion
concepts such as column or piggyback combinations. The type of application or the available
space determines the extruder arrangement.
9
Coextrusion solutions in detail
Coextrusion with parallel basic extruders
Frequent use is made of combinations
comprising basic extruders featuring
parallel twin screws with one or two piggyback extruders from the conical series.
The basic extruder prepares the recycling
material while the coextruder processes
the new material.
Conical extruders can easily be mounted
above the main extruder – movable on
two axes.
Coextrusion with the conical series
The extruders in the conical series are
also used, for example, as stand-alone
models. These models can be quickly
moved and permit flexible injection into
the coextrusion mold from many different
positions. Coextruders can also be quickly
added to different coextrusion lines without any modification and can be moved
in all directions. The coextruders can be
supplied with their own C5 control system
and with a control unit integrated in the
main extruder. In this case both extruders
can be controlled from a central operator
panel.
The C5 control system is extremely efficient, especially when integrating several extruders in a coextrusion system.
Several extruders can be regulated here
using a single control system. On the
other hand, several autarchic extruders
can also be synchronously regulated in a
network using the C5 control system.
KMD 43 K/P conical twin-screw extruder as
a column version on a KMD 63 K/P conical
twin-screw extruder with a lifting and swivel
mechanism
KMD 63 K/P twin-screw extruder as a piggyback
version on a parallel KMD 114-32/P twin-screw
extruder
KMD 63 K/P conical twin-screw extruder on a
column as a stand-alone model fixed on a base
plate (presentation without switching cabinet or
operator panel)
KMD 63 K/P conical twin-screw extruder as a
column version on a parallel KMD 90-32/P
twin-screw extruder mounted with complete
electric integration
10
Profile extrusion
Extrusion systems
Efficient extrusion systems
Processing of natural fiber
composites
Active wear resistance in
extrusion of natural fiberreinforced plastics. Innovative
and energy-efficiency machine
technology for a wide range of
applications.
Thanks to their durability, natural fiber
composites are increasingly replacing
pure natural products in many application
areas, for example decking products,
fence components or screening walls.
KraussMaffei Berstorff supplies all kinds
of complete system solutions for special
applications.
Counter-rotating twin-screw extruders
for processing compounds
Counter-rotating twin-screw extruders
are used throughout the world to process
natural fiber-reinforced plastics, for
example wood plastic composites
(WPCs). The KraussMaffei Berstorff
Counter-rotating parallel twin-screw extruder
for processing natural fiber-reinforced plastics
extruders are characterized by a large
number of advantages, for example
constant material feed, careful material
preparation and high pressure stability of the screws when manufacturing
semifinished products. They are also ideally suited for processing of a prepared
compound. High screw torque – coupled
with a long processing unit – produces
the highest possible output rates. In
addition to careful material preparation,
the special screw geometry produces
a homogeneous melt with an optimum
mass temperature even with high melt
pressures.
Co-rotating twin-screw extruder for
cost-effective compounding
Thanks to the concept of the co-rotating
twin-screw extruder, the components
can be directly metered on the extruder
in an energetic and economically efficient
way through direct extrusion. The use of
patented multi-processor screw elements
ensures careful material preparation
and homogeneous mixing of the natural
fibers. Other advantages include the long
service life of the inductively hardened
housings and extremely flexible adaptation to different processing requirements
due to the modular design of the processing element.
Active wear resistance for a long
service life
KraussMaffei Berstorff ensures maximum wear resistance through a special
process concept, tungsten carbide protection of the screws and bi-metal lining
of the barrel bores; the machines therefore have a long service life and require
very little maintenance.
Co-rotating twin-screw extruder for direct
extrusion during processing of natural fiberreinforced plastics
Partial view of a tungsten carbide-protected
screw
11
XS models for standard profile applications
Maintain your competitive production
Companies can become lucratively
involved in profile extrusion with the XS
Series, one of the world's most successful
and most widespread series. Due to the
excellent price-performance ratio, the
machines also impress well-established
processors on new markets in their
expansion intentions.
The XS twin-screw extruders are based
on the proven 26D processing unit with
molybdenum-welded screw protection.
The XS singe-screw extruders are based
on the proven 30 L/D processing unit with
a universally usable screw. All machines
have a state-of-the-art drive system, are
fitted with maintenance-free AC motors
and can be regulated and monitored via
the KraussMaffei Berstorff C5 control
system.
KME 45 XS singe-screw extruder for producing
technical profiles
KMD 90 XS/P twin-screw extruder
Powerful machines and systems
Production of technical profiles
KraussMaffei Berstorff supplies systems
and machines for producing all kinds of
technical profiles, for example profile
strips, lamp covers, lamellae, tile termination strips; the finished products are
used in the automotive, furniture, electrical and construction industries.
KME 45 XS single-screw extruder for producing technical profiles
12
Profile extrusion
C5 control system
Coextruded window profile
in core technology 1
Window main profile –
5-chamber system with
steel reinforcement 2
Cable duct
Foamed profile
for cowling
Foamed trim profile
PVC profile processed
as fence system
Gutter coextruded
Decking profiles made
of WPC compounds
Sealing profiles made
of TPE or PP
Technical profile
Window profile 3
Door module 3
Picture sources: 1) Greiner Extrusion 2) www.schueco.com 3) www.aluplast.de
Practical examples
Powerful and economical solutions
for all profile applications
13
C5 control system
State-of-the-art control, regulation
and monitoring system
C5 control system for central line control
High demands on product quality call
for high process reliability. As one of the
most modern control, regulation and
monitoring systems in the area of extrusion, the C5 control system features
reliable technology and intelligent functions for central line control. It ensures
optimized production preparation and
transparent production conditions at a
constantly high level.
Optimum visualization even for several
extruders
The individual injection units in a
machine can be visualized and operated on a row of screen pages. Thanks
to central synchronization, the complete
machine can also be safely and easily
regulated across several extruders. All
important injection units in the machine
can be directly accessed via the machine
keypad of the C5 control system. The
current operating status of the complete
machine is permanently displayed and a
freely configurable actual value column
comprising seven parameters ensures
optimum process control. Information messages and error messages are
displayed in plain text in the selected
national language. The C5 control system also features the options of extensive logging and easy connection to a
host computer.
User-friendly models
Three operating variants are available:
integrated operator panel, swivel-mounted
operator panel or mobile operator panel.
With the swivel-mounted version, the
machine can be operated entirely from
the aspect of the mold.
KraussMaffei Berstorff standard: operator
panel: integrated in the control cabinet
Swivel-mounted operator
panel (optional)
Mobile operator panel
(optional)
14
Profile extrusion
Service
Further information
This might also be of interest to you
The whole world of KraussMaffei
Berstorff profile extrusion
– Window main and secondary profiles
– Multi-chamber profiles
– Coextruded window profiles
–Window profiles in core technology,
with regrind, extruded
– Foam profiles
– Door systems
– Shutter systems
– Window sills
–Gutters
– Cable ducts
– Technical profiles
– NFC/WPC profiles
– Siding solutions
– Special customer-specific solutions
You can find detailed information on
profile extrusion solutions from
KraussMaffei Berstorff in the following
brochures:
–32D Twin-Screw Extruder Profile Series
–Conical Twin-Screw Extruders for
Profile Production
–System Solutions for Processing
Natural Fiber-Reinforced Plastics
Or visit us at:
www.kraussmaffei.com
15
KraussMaffei Berstorff
A strong brand in a unique global group
Value-proven Extrusion Technology
­solutions
Around the world, KraussMaffei Berstorff
stands for reliable and value-proven
solutions in Extrusion Technology. These
range from using individual extruders
for degassing in polymerization, compounding, pipe, profile, film and sheet
extrusion, physical foaming and the
manufacture of technical rubber articles
and intermediates for tire production up
to complete extrusion lines. All machines
and systems from KraussMaffei Berstorff
are custom-configured, for example for
the chemical, automotive, construction,
packaging or pharmaceutical industry.
There for you around the world
KraussMaffei Berstorff is your partner –
from the first planning meeting through
development of the best possible technical and business solution up through
commissioning, servicing and production
of your system. We guarantee high-quality
advice, solution expertise, reliable spare
parts logistics and fast-reacting service
during each phase. Our goal is increasing
your success.
Individualized service
Benefit from KraussMaffei Berstorff’s
reliable service. Our customer service
team and experienced fitters, technicians
and engineers are there for you as quickly
as possible and even help on location to
optimize your systems and processes and
to minimize downtime as much as possible. Rely on our highly skilled repair and
spare parts service
KraussMaffei Gruppe
Comprehensive expertise
Unique selling proposition Technology3
The KraussMaffei Group is the only provider in the world to possess the essential machine technologies for plastics and
rubber processing with its KraussMaffei, KraussMaffei Berstorff and Netstal
brands: Injection Molding Machinery,
Automation, Reaction Process Machinery
and Extrusion Technology.
The group is represented internationally
with more than 30 subsidiaries and over
ten production plants as well as about
570 commercial and service partners.
This is what makes us your highly skilled
and integrated partner. Use our comprehensive and unique expertise in the
industry.
You can find additional information at:
­www.kraussmaffei.com
The KraussMaffei Group has a global presence.
Countries ­with subsidiaries are marked in light blue.
In the white-colored regions, the Group is represented
by over 570 sales and service partners.
The product portfolio of KraussMaffei Berstorff
includes conical and parallel twin-screw extruders,
coextruders for integrated extrusion systems, and
piggyback and tandem extrusion solutions. The longproven parallel twin-screw extruders in the 32D
Series are ideally suited, in particular, for standard
applications in the medium and high output range.
We provide our customers with tailor-made solutions
for both high-performance extrusion and flexible
output requirements with core technology in the window profile sector. This also applies to the production
of small and medium-sized technical profiles, as well
as to NFC and siding processing.
We supply individual machines and complete profile
extrusion lines for all profile extrusion applications
from a single source.
www.kraussmaffei.com
1. 0 WE. 1st edition 04/12. EXT 001 BR 04/2012 EN ··· KraussMaffei reserves the right to make technical changes ··· Printed in the Federal Republic of Germany
Our response to future challenges
in profile extrusion.