polymer processing cost saving workshop - 05 screw design and smart heat
TRANSCRIPT
NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14
What costs should we reduce ?
Cost per Kg of output.
Cost per part produced.
Factors Include:
Kg or parts per hour
But good parts – minimize scrap.
Energy costs.
Output vs Screw Wear
.10 .20 .30 .40 .50 .60 .70 .80 .90 1.000
20
40
60
80
100
120
140
160
180
200
Screw Diameter = 120 mm. 130 RPM.
CLEARANCE PER SIDE in mm
GR
AM
/SE
C
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31118.20
118.40
118.60
118.80
119.00
119.20
119.40
119.60
119.80
120.00
Plot of Screw Diameter:
Measured
Max OD
Min OD
SC
RE
W D
IAM
ET
ER
mm
Special Coatings:X830 Hardfacing
Base Material
X8000TM Carbide CoatingStandard Surface Finish: (60 Ra)
Polished Surface Finish: Ra = 0.2 (16-32 Ra)
RATE OVER TIME
00
20
40
60
80
100
120
140
160
180
200
Screw 120 mm
TIME
RA
TE
GR
AM
/SE
C
____ = 4140/C56/Cr
____ =4140/X830/X-8000
Most Machines have ‘GP’ Screws
(‘General Purpose’)
(Or ‘Generally Poor’ ?)
(Or ‘No Purpose’)
Mixing Screw Illustration (Pulsar Mixer)
POLYCARBONATE LENS PROJECT
RESIN: PC (TYP 740-4) CLEAR 100% CHECK ON BLACK SPECS PROBLEM: SCRAP RATE ~ 20%
DEMAG 200-840 SCREW DIAMETER 45 MM L/D RATIO 22:1 SHOTWEIGHT: 50 Grams CYCLE TIME: 23 Sec.
TARGET:
IMPROVE PRODUCT QUALITY REDUCE SCRAP RATE
44,8044,85 39,60
39,58
43,0 39
,7
44,4
-0,0
5-0
,1
258
240
159
100
DIA 38,0
12,010,2
59,0-0,1-0,2
± 0,5
STAMP:“ SN-XXXXX” “17-4PH+ST12-L1
2 x 30°
SPLINESOD= 44,4 -0,05/-0,1CD= 40,0 -0,05/-0,1NUMBER OF TOOTH = 21
1020
1278
45 MM SCREW
Drawn by: almh Date:
Drawingnr.: SCHR_291NOTES:REVISIONS:
5. 4.
3. MATERIAL: 17-4PH-ST12-L1
1. CUSTOMER:
2. I.M.M. DEMAG 200-560/840This drawing is the property of NordsonXaloy-Europe GmbH. Reproduction or disclosure of any part of this drawingor information therein and the usethereof for making other drawings or for making apparatus therefrom are prohibetedwithout priar written consent of NordsonXaloy-Europe GmbH.
• DISTRIBUTIVE MIXER• LOW SHEAR • LOW MELT TEMPERATURE• SUITABLE FOR SHEAR SENSITIVE
RESINS
POLYCARBONATE LENS PROJECT
RESULTS:
CYCLE TIME REDUCTION: 3 seconds
SCRAP RATE REDUCED FROM 20 % to 1.5%
BASED UPON 6000 hrs: productivity improvement 625000 pcs = 41%
TOTAL INVESTMENT € 5000 (screw only)
ROI: 21 days
POLYCARBONATE LENS PROJECT
NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14
AUTOMOTIVE PROJECT
I.M.M. BATTENFELD HM 19000 - 2700
SCREW DIAMETER 130 MM
L/D RATIO 26:1
SCREWSPEED MAX: 120 RPM
GOAL:
PROCESS PP + 40% LGF
SHOTWEIGHT: 4400 Grams
OVERALL CYCLE TIME: 70 Sec.
IMPROVE PRODUCT QUALITY
SN-#
4765 O.A.L.
395
1285
119,8119,7
STAMP -
NOTE: STAMP NUMBERS SO THEY CAN
SPLINES ACC. DIN 5480
BE SEEN BY OPERATOR
130 MM SCREW FOR LGF
Drawn by: almh Date:
Drawingnr.: SCHR_458NOTES:REVISIONS:
5. 4.
3. MATERIAL:
1. CUSTOMER:
2. I.M.M.:BATTENFELD HM 19000This drawing is the property of NordsonXaloy-Europe GmbH. Reproduction or disclosure of any part of this drawingor information therein and the usethereof for making other drawings or for making apparatus therefrom are prohibetedwithout priar written consent of NordsonXaloy-Europe GmbH.
• DISTRIBUTIVE MIXER• LOW SHEAR • LOW MELT TEMPERATURE• SUITABLE FOR SHEAR
SENSITIVE RESINS
AUTOMOTIVE PROJECT
RESULTS:
CYCLE TIME DEDUCTION: 4 sec = 5.7%
BASED UPON 6000 hrs: productivity improvement 18702 pcs = 6%
INCREASE IMPACT STRENGTH 10%
TOTAL INVESTMENT USD 88500 (screw,barrel,valve)
ROI: 270 days
AUTOMOTIVE PROJECT
Product: Bucket: 10 Ltr.Resin: PP MFI: 8Shot-weight: 584 GRScrew diameter: 98mm with LD = 25
OE solution 32,9 gr/revXALOY solution 35,5 gr/rev
Our design: MeltPro Barrier + Z-MixerInvestment: 7500 EUR
Benefit:• Cycle time reduction by 7.5%• ROI: 40 days
PACKAGING
TWINSHOT
The TWINSHOT® Co-Injection Technology enables a conventional machine with a single barrel and screw to inject two materials in a single shot with one material totally enclosing the other.
Twinshot loop-c.exe
SKIN RESIN: PP+20%CaCO2
CORE RESIN: Regrind PP+CaCo2+blowing agent
SHOTWEIGHT: 3800 Gr.
INVESTMENT: 117500
ROI: 160 days
TWINSHOT EXAMPLE
Nordson XALOY
PRESENTATION
Integrated BarrelHeating Technology
Sustainability requires True Innovation
nXheat®Induction heating
Mica band-heaters
Ceramic band-heaters
Infrared heater systems
Insulating blankets
SmartHeatTM
IntegratedMelt-Stream Heating
1950
1960
1970
20032006
2011
Melt-Stream Heating Evolutionary Timeline
Introducing
, a heating coating for barrelsA barrel heating technology that offers the:
Best process control
Most energy efficient
Most reliable
Most compact
Safest …barrel heating system on the market today
What is ? Plasma sprayed metallized-ceramic heater
coating
Pure resistive heating
Simple retrofit of existing heater bands
Eliminates exposed wires for maximum safety
Supplied with thermal insulation
Plasma heater layer
Integrated heating technology
Easy to thoroughly insulate
Benefits
• Improved Process Control Less Scrap – Higher Yield
• Superior Energy Savings Reduces your costs & saves money
• Safer Operation Less operator injury risk or fire potential
Improved Process Control
Non-uniform temperature distribution Uniform temperature---Fully insulated
What benefits could apply to your processes if you could rely on a 55% improvement in temperature consistency shot to shot?
Temperature Response with Band-Heaters
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Te
mp
era
ture
(oC
)
32
96
160
224
288
352
416
480
544
608
672
736
Temperature Response with SmartHeatTM
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Tem
pera
ture
(oC
)
32
96
160
224
288
352
416
480
544
608
672
736
Improved Process Control
Uniform heat profile leads to a more stable process and consistent part
Part Weight Variability
-0.5
-0.4
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
0.4
0.5
0 5 10 15 20 25 30
Cycle Number
De
via
ito
n f
rom
Me
an
(g
ram
s)
Conventional Barrel
New Barrel Band Heaters SmartHeat Barrel
Improved Process Control
Ramps to target 30% faster using 23% less energy
Response time to maintain temperature is quicker
Superior Energy Savings
30%-60% more energy efficient than band heaters
Design watt density is 60% of band heaters
(1000 watt band heater = 600 watt SmartHeat™)
Virtually eliminates heat losses to the environment
Save on A/C expense
For process temperatures up to 750oF (400oC)
Superior Energy SavingsLab Machine Trials -- Power Distribution Profile
(36 mm screw, PP, 28 sec cycle, 38 gram shot, 249oC/480oF melt)
0
200
400
600
800
1000
1200
1400
1600
Nozzle power Discharge Middle Feed
Po
wer
(w
atts
)
A) Band-heaters -- not insulated
B) SmartHeat -- not insulated
C) SmartHeat -- insulated50% Less Energy
over Heater Bands
Safer Operation
SmartHeat™ barrels are supplied with a thermal insulation wrap and straps.
The complete system provides “Cool to the Touch” operator safety and the covered
electrical connections provide for significant fire hazard safety improvements.
Safer Operation
Eliminate fire hazard from numerous wires from multiple heater bands
All wiring run under thermal insulation for safety
Elimination of all the loose wiring
Melt Pipes
SmartHeat Melt Pipe• Uniform heat end to end• No loose wiring (buried under the
insulation)
Conventional Heater Bands• Non-uniform heat• Loose wiring
Maintenance Free
Eliminates heater band maintenance
Simple retrofit to existing heater band wires and control
Plastic resin easily chips off
Hardened resin just pops right off
Typical ROI Southern US Southern U.S. (FL, TX, GA, AL, MS)
about 12 months air conditioning
ExampleCustomer: processor in Texas Machine: 60 mm Engel machine Utility Cost: $0.12/kWh. ROI: about 12 months
Typical ROI Midwestern US (OH, MO, IN, CA) about 8 months air conditioning
Typical ROI Northern US (MI, MN, WI, MA)
no air conditioning
Customer Testimonial Siemon Company
55 Ton Milacron Roboshot Machine8 cavity mold running Makrolon PCElectrical Connectors
• ROI of less than 1 year
• Cut start up time by 50%
• 80% Improvement in shot to shot consistency
Customer Testimonial Piolax Corporation
50 Nissei FN4000 Machine32 cavity mold – 24 sec cycleAutomotive Interior Parts
• Energy savings of 59%
• Multiple SmartHeat being ordered
on Melt Pipes
Features
• Uniform heater coating around the melt pipe
• Integrated heating system with SmartHeat™ as part of the melt pipe
• 25% energy savings or more
• Eliminate band heaters and their maintenance
• Resin will not stick to SmartHeat™ coating
Benefits
• Consistent and uniform heating of polymer providing a stable process and fewer rejects
• Considerably less wiring creating a safer, cleaner work environment
• Improved ROI using SmartHeat™
• Less downtime when SmartHeat™ is an integrated part of the melt pipe
• Less downtime from cleaning
on Melt Pipes
Application photos
on Melt Pipes
Application photos / Paragon Films
on Nozzles
Feature
• Eliminate nozzle band heaters and all their maintenance
• Uniform heater coating around the entire nozzle
• Resin will not stick to SmartHeat coating
Benefits
• Less downtime when SmartHeat™ is an integrated part of the nozzle
• Consistent and uniform heating of polymer providing a stable process and fewer rejects
• Less downtime from cleaning
Superior Process Control
Better Shot Consistency
Stable, Uniform Heat Profile
Maximum Energy Savings
Maintenance Free
Extremely Durable & Safe
Summary