reliable automation and optimization of extrusion … · 2014-04-10 · all of our automation...

YEARS

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34EXTRUSION CONTROL SOLUTIONS

RELIABLEAUTOMATIONAND OPTIMIZATIONOF EXTRUSIONPROCESSES

Prospekt (GB/US) 2013-RZ1 30.09.2013 16:57 Uhr Seite 3

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Main Products

➊ Central Operator Station

➋ Material conveying (vacuum loading) with intelligent control

➌ Gravimetric extrusion control systems, up to 7 dosing units per extruder or six batch feeders

➍ Thickness profile control, patented air ring technology

➎ PRO-SONIC internal bubble cooling control

➏ PRO-CAGE sizing cage

➐ IBC, internal bubble cooling hardware

➑ On-line profile measurement

➒ Haul-off measurement, haul-off control

➓ Width measurement

ACSFor more than 30 years PLAST-CONTROL has beenautomating extrusion processes. From the onsetwe focused on the supply of equipment for blownfilm extrusion lines expanding into other extrusionprocesses. Today we are the leading manufacturerin this worldwide market.

PLAST-CONTROL is the only company in our marketwhich produces all critical components in-house.This indepth knowledge of the principles and

hardware gives you the customer the chance touse your process knowledge to the greatest effect.

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

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

Advantages:• Waste reduction and material savings• Fast product changes• Higher outputs• Reproducible products• Reduction of operator faults

EXTRUSIONAUTOMATION &QUALITY CONTROL


GDCn

3

ACS

GT3

A FAMILY OF SYSTEMS ...GT3, GDCn, ACS

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 use with thelarge 19”color TFT touch screen display.

And there are more benefits. In addition, all PLAST-CONTROL systems can handle these functions:

• Capacitive online gauge measurement• Width measurement and control• IBC control• Material flow control MFC (vacuum loading)• Connection to data collection• Modem connection for online service

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 process data is displayed with a 5.5“ LCD dis-play

The GDCn 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 GDCn is the economic solution. Product-ion data is displayed on an easy to read 10.4“ color TFT display with optional touch screen controlfor specific functions.

The powerful computer grants a fast and efficientcontrol. GDCn is the right choice for simple gravi-metric batch-blending systems or continuous gravimetric dosing systems up to 15 components.Additional functions as IBC and width measure-ment and control can be integrated.

➊ System GT3

➋ System GDC-N

➌ System ACS

➌ System ACS


All of our automation principles over the last 30years have been based on gravimetric extrusioncontrol. The “loss in weight” principle guaranteesprecise measurement of throughput and controldesigned for all types of extrusion processes. Thisapproach of control is suitable for all mono- andco-extrusion applications.

Extrusion control has proven to be an essential firststep for establishing a stable extrusion process.

Fully modular construction allows up to 6 dosingunits plus main material to be fitted to each ex-truder (including co-extruders). Precise dosing ofcostly additives and master batches takes placedirectly above the extruder throat – eliminatingthe problems of de-mixing and inconsistent ho-mogenization associated with batch blenders.

All dosing units outputs are synchronized withthe main hopper output to guarantee an accurateproduct recipe.

GRAVIMETRICEXTRUSION CONTROL &CONTINUOUS DOSING

➊ Continuous gravimetric dosing

➋ Process status display

➌ Servo drive motor (RCM)

➍ Removable weighing hoppers

➎ Transparent tubes

➏ Micro-dosing unit

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The latest generation of dosing unit now incorpo-rates a high torque motor delivering a wide speedrange. This minimizes the need for dosing screw changes. Advanced software control guarantees accurate control fromvery low to high output rates.

The new MICRO-DOSING unitsfollow the trend to more components and smaller dosing amounts. The new units can cover a range from 100 g/h up to 8 kg/h.

Advantages:• Independent from bulk density• Fast product change• Rigid construction• Precise dosing of small volumes• Easy operation and simple target entry• Customer tailored solutions• Up to 7 components per extruder• No dosing screw changes necessary• Easy cleaning due to removable hoppers


GRAVIMETRICEXTRUSION CONTROL &BATCH BLENDING

The NANO-BATCH blender is an economic alter-native to the PRO-BATCH series. This blender usesone weighing chamber instead of two.

Additionally, only one slide gate is used per component.

The combination of both dosing principles(batch & continuous) isunique on the market and enables us to supply a tailormade solution for each application.

All blenders are supplied with clever features for maintenance and handling.

Advantages:• Higher throughput

with double chamber technology• Improved precision for critical additives• Unique economic combination• Excellent possible safety features

The PLAST-CONTROL batch blenders can be usedoff-line as a general purpose blender, online or on-line with extrusion control.

PRO-BATCH units including PB 422 and PB 624are an enhanced development of the basic batchblending principles for mixing and blending plastic pellets. Double slide gates for each minorcomponent provide high precision in each batch;double weighing chambers provide high outputrates in a compact unit.

Slide gates are provided in two sizes; innovativesoftware determines the correct gate to open based on needed output rate, all without operatorintervention.

A conical (PB) or horizontal (NANO) mixing hopperblends the weighed batches prior to feeding theextruder. The mixing hopper is typically fitted witha load cell for „Loss-in-Weight“ extrusion control.

➊ PRO-BATCH PB with double weighing chamber blender

➋ PRO-BATCH with optional continuous dosing unit

➌ Retrofit of older lines with PRO-BATCH PB

➍ NANO-BATCH 4 single weighing chamber blender

➎ Cleaning and local operation

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MMC

PLAST-CONTROL provides software and hardwareto deliver plastic pellets within a plant.

PLAST-CONTROL engineers can design plant-widelayout or individual system configurations. A prop-erly designed system eliminates dust and angelhair. Minimizing conveying distances and maximi-zing throughput rates while reducing energyneeds are primary considerations of the designlayout.

If your requirements are to convey small amountsof a single material over a short distance, or a production hall central vacuum system with several tons per hour demand - we have the technical solution and the appropriate equipment.

Material Minimizing Control (MMC) has been developed to reduce the amount of scrap andwaste due to changeover of products and recipes.The program makes sure that the material storagehoppers of the dosing units are empty when thechangeover is initiated and that only a smallamount of material is left in the weighing hoppers.

Advantages:• Layout for low abrasive wear• High flexibility• Centralized control• Waste reduction with MMC• Integrated bypass valve

MATERIAL-CONVEYING & CONTROL

MasterbatchA

weight

conveyorvacuum pump

with central filter

ballast hopper

material pipe

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PIPEIDENT

Dust and contamination filtrationDust and contamination of the virgin material oftencreates problems in the extrusion process. Longtransport distances and many elbows betweenthe silos and the machines produce angle dustand angle hair. These contaminates must be re-moved before entering the extruder by use of fil-tration devices.

More and more extrusion companies are chang-ing to a centralized vacuum supply. Advantageslike energy efficiency, noise reduction at the workstation and a significant higher output at lowercost for investment are only a few reasons. Theuptime is increased while the maintenance effortis decreased.

PLAST-CONTROL engineers always choose theoptimum solution according to the application.Solutions can include conventional side channel,root, or claw pumps. Customers layout needs canbe simulated in the PLAST-CONTROL test facility.Simulation tests verify conveying requirements ofpellets with 38/50/70 mm (1.5”/2/2.5”) tubesand distances of up to 130 m (425”) horizontaland 14 m (46”) vertical.

PIPE IDENT was developed to eliminate the in-correct 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 hose is connected to the wrong pipe then a visualindication is displayed on the coupling as well ason the operator display. In this case the start-upof the loading system is not allowed.

Advantages:• 360° positioning of the

vacuum and material connections• Optional application of

full or low level sensors• Optional angel hair/dust absorber• Optional controlled feeding of

repelletized trim

MATERIAL-CONVEYING& PIPE IDENT

➊ Conveying system with PCH vacuum receiver

➋ Layout of a conveying system

➌ PCP dust absorber

➍ Control layout of Material Minimizing Control (MMC)

➎ PCP-conveyors

➏ PIPE IDENT

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VPNWWW

PCC

The PLAST-CONTROL Central PCC plant-wide con-nection of your extrusion lines provides a powerfuland convenient tool for accessing and storing allproduction data – in real time.

All production data is displayed centrally andoptionally on Personal Computers integrated intoyour plant-wide network. Optionally, productionspecific data from your system network can besent to the PCC.

Precise material balance sheets, quality control,central data saving and production supervisingare possible without the need of large InformationTechnology budgets.

The basic software package includes a number of sophisticated data logging and order databaseapplications. Custom screens can be implemen-ted for a specific customer request.

A good example is the implementation of an OEE-Software. This tool enables the user to localizeproblems in the production and stop them fromreoccurring.

Advantages:• Access to production data in real time• Material balance sheet• Central data storage and retrieval• Quality control tool• Online access to all production parameters• Material database capability• Scrap accountability• Central logging of machine status and alarms• PLAST-CONTROL remote support via modem• Connection to plant network

REAL TIME PLANT-WIDEMONITORING WITH PCC

➊ PCC terminal

➋ GT3 system

➌ GDC system

➍ GDC-N system

➎ ACS system

➏ Systems from other suppliers

➐ Connect to Local Area Network

➑ Remote support

PCC

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AirCC

By using a new and patented algorithm, the systemcalculates the transverse profile in full 360° view.Barrier Films with a capacitive system can now bemeasured without restriction.

Advantages:• The right measurement solution

for all applications• Measurement of sticky (i.e.EVA)

and soft film without damage• Long service life• Several sensor surfaces available• Integrated film temperature measurement• Barrier film measurement with C-Scan• Non-contact measurement of overall thickness• Non-contact measurement

of total barrier layers

Fast-Scan versions (approx. 20 sec. for 4 m bubblecircumference) are available.

New C-SCAN solutions for Barrier and Cast film

A new technology for the effective alternative toradioactive sourced measurement: The C-Scan ismounted after the collapsing frame on blownfilm lines or after the chill rolls on cast lines andmeasures across the web.

PROFILE-MEASUREMENTPRO-FIL

➌ Profile display

➍ C-Scan

➎ Radial adjustment and round scanner

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New Non-contact AirCC sensor

PLAST-CONTROL’s experience in building and de-signing measurement sensors for the on-line gaugemeasurement of films has given rise to severalnew technologies. The new patented sensor AirCCwas developed especially for sticky and surfacesensitive films. The AirCC has two parallel wor-king sensors which creates different capacitivefields. This combination allows calculation of film thickness regardless of distance. A constant-ly changing air gap (range 100 to 350 µm) doesnot influence the result.

Capacitive Measurement sensor

Capacitive measurement sensors from PLAST-CONTROL in combination with direct drivenscanner rings in low-weight aluminum design arethe guarantee for low maintenance profile mea-surement without any slip (precise allocation).

➊ Compact C-head

➋ AirCC


As one of the pioneers in the development of au-tomatic systems for the reduction of transversedirection (TD) profile tolerances, PLAST-CON-TROL has continuously developed and refined itssystems.

Our Profile Control systems utilize the profilemeasurement devices and transmit profile data tothe computer. The software calculates and carriesout the correct positioning of the actuatorswhich, in turn, control air flow through the seg-mented air ring.

Functionally the computer opening or closing ofactuators within the PRO-CON air ring will increaseor decrease the volume of air in each segment.This influences the melt temperature and in turnthe film thickness during film blowing step.

To compensate for the displacement due to themechanical oscillation in the film line the PRO-CON software measures and calculates “shift” inthe measured profile.

This feature adapts itself depending on bubbleoscillation and profile scan speed. Accurate andconsistent reduction of profile tolerances withoutoperator adjustment is achieved irrespective ofproduct dimensions. The air rings are available insix sizes. In combination with MAGIC FLOW, improvement of at least 50 % of the basic tolerances can be expected, along with higher output rates.

More than 1100 PRO-CON have been installed to date.

PROFILE-CONTROL PRO-CON

Advantages:• 50% reduction of the basic tolerances• No additional energy input• Output increase with MAGIC FLOW• Simultaneous control of thin and

thick film areas possible• Immediate response• Easy retrofit• Retrofits of rotating/oscillating dies possible• Fast return on investment• Auto profile shift compensation

➊ PRO-CON layout

➋ PRO-CON display

➌ PRO-CON K-2200 air ring

➊ PRO-CON layout

➋ PRO-CON control display

➌ PRO-CON K-2200 air ring

Profile measurement

Profile control

PRO-CON Die ø mm

C-200/32 80-200C-400/48 200-400C-750/64 400-750K-1100/80 750-1100K-1650/106 1100-1650K-2200/128 1650-2200

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MAGIC

black MAGIC Lip

BETTER COOLING…MAGIC FLOW & PRO-CON DUO

FLOWThe Electrical controlled upper air ring elevator allo-ws foreasy adjustment and accessibility. The combi-nation of “improved output – better mechanicalproperties” ensures a fast return on investment.

BLACK MAGIC LIP and fume exhaustThe undesirable low molecular paraffin wax con-densation which may occur with higher outputscan be minimized with air ring lips made from aspecial high performance plastic in combinationwith a dedicated exhaust system.

BLACK MAGIC LIP prolongs time between thecleaning cycles. Special designed IBC towers forDUO application are available (see page 15).

Advantages:• High bubble stability -

fast product adjustment• Perfect basic tolerances• Significant higher output, up to 40 %

more than comparable cooling systems• Fast return of investment• DUO air ring for increased film strength

and higher outputs (machine permitting)• Better mechanical film properties possible

PLAST-CONTROL builds more than 80 high per-formance cooling rings per year and 90% deliv-ered with the new MAGIC-FLOW lip insert. Ourair rings are available for die sizes from 80 mm to2200 mm (3“- 86“) as a standard with larger sizesavailable on request.

MAGIC FLOW is the result of extensive researchin the increase of cooling capacity for blown filmlines. This has been achieved by improving theaerodynamic flow path between the blower,manifold 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 bubblestability is increased, transverse tolerances improvedand 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. Mechanical properties willbe improved using DUO as well.

➊ PRO-CON DUO II

➋ Downgauging

➌ Stabilisator

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The PRO-JET Profile Control is achieved with a seg-mented plate that is mounted underneath an ex-isting air ring. Adjustable air valves located belowthe air ring controls the volume of airflow in eachsegment. Suitable for stationary and moving dieswith diameters from 100 mm - 2500 mm (4”-100”)can be equipped.

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

Advantages: • Economic solution for retrofits• Immediate response• Low additional energy input• Auto profile shift compensation

PROFILE-CONTROL PRO-JET

➊ PRO-JET layout

➋ PRO-JET installation

➌ PRO-JET cut-out picture

Profile measurement

Profile control

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PRO-CON DUO

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NAVIGATOR

The Navigator operator concept allows a simplegraphical touch screen control of your entire extrusion process, including extruder drives, tem-peratures, blower controls, calibration cage,collapsing frame, haul-off and treater. The NAVI-GATOR can be adapted easily to new lines, up-grades or retrofits irrespective of the OriginalEquipment Manufacturer.

PLAST-CONTROL produces many electronic com-ponents and our software package in-house,which sets us apart from on-going technologyobsolescence in the ever evolving computerworld. This enables us to provide our customerscomplete service and spare parts for all our pro-ducts for many years along with a migration tothe future product.

NAVIGATOR is simple to use, and includes analarm handling feature which clearly shows errorsand helps the operator quickly address them.

This flexible solution for existing extrusion linesas well as for new lines enables you to implement

STATE OF THE ARTLINE CONTROL WITHNAVIGATOR

an identical operation philosophy throughoutyour entire company. NAVIGATOR is available inmany languages.

Safety functions can easily be integrated as well,and will be proven for functionality as a fundamen-tal part of any modifications we make.

Advantages:• Modular• Safety function• High dependability• Easy operation, handling• Safety assurance of E-Stop circuitry• Cost attractive retrofit and exchange of

all types of controls• Complete line control via touch screen• Implementation of customer tailored solutions

➊ Touch Screen Navigator

➋ Cabinets for CoEx-line

➌ Power distribution

➍ Drive control

➎ Winder connection

NAVIGATOR

digital I/Oanalog I/O

digital I/Oanalog I/O

Drive(s)

Auxillarydrives

NIP drive

Layflat system

Calibration basket

Data link to PLC

Blowers

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BUBBLE CONTROLPRO-SONIC

M

➌ New IBC-Control

➍ Ultrasonic sensors

➎ Signal converter

➏ Frequency converter

➐ STV Air valve

➑ Blower

➊ IBC stack

➋ STV control flap with servo drive

PRO-SONIC Control Principle

IBC air valveSTV

calibrationbasket

IBC in

sensors onfrostline level

IBC out

OPTION 1

frequencyconverter

OPTION 2

signalconverter

0-10 VDC(4-20 mA)

IBC NodePC 17

sensor 2 sensor 3

3x ultrasonicsensors

sensor 1

IBC

The IBC-control system PRO-SONIC can be inte-grated into all PLAST-CONTROL systems or canbe supplied as a stand-alone system.

For accurate control of the bubble diameter,speed is everything. PRO-SONIC incorporatesnon-contact high quality ultrasonic sensors pro-cessed by ultrafast signal processing hardwareand software. Bubble diameter calculated within100 ms per update.

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

Edge trim and start up waste can be reduced andnominal thickness is maintained.

Ultra-Sonic SensorsWe have achieved width tolerances of less than +/-2 mm on existing lines using the latest generationof Ultra Sonic sensors combined with the newly developed air control valve.

Advantages:• fully integrated• cost effective solution• high resolution ultrasonic sensors• high speed air valve


BUBBLE CONTROLPRO-SONIC & PRO-CAGE

Calibration CagesThe 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 precision con-trol of the cage position throughout the operationalrange. Two types are offered, the M series withhigh precision double pivot self centering, easilyexchangeable rollers and L series with single pivotoperation. Both devices feature a choice of rollersurfaces for different applications.

Advantages:• precise width control• various roller surfaces• ridgid construction• compact design

with wide adjustment range• easy maintenance

For non-gusseted applications the preferred solut-ion to control the final film width is by using ourabsolute width-con infrared sensor measuringsystem. Mounted after the collapsing frame thesesensors will report the physical width of the lay-flat. Width adjustments are made by automaticallyopening or closing the calibration cage on IBCsystems or with a digital air valve on non-IBC lines.

For gusseted films we offer an option of installingUltra Sonic sensors above the calibration cagewhich measure the bubble diameter; the PRO-SONIC controls the openingand closing of the cage.

Launched at "K 2010" the NANO Width measure-ment is a technically revised version of our widthscanning system, with simplyfied electronics andlower cost. Actual width is measured just beforethe winder and thus corresponds exactly to the truewidth of the film roll, with any shrinkage alreadytaking place prior to the measuring point.

➊ Width measurement

➋ PRO-CAGE Type M

➌ PRO-CAGE Type L

➍ Motor

➎ Ultra Sonic Sensor

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PROLABII

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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 continuousmeasurement mode or with a combination of bothsensors.

To analyze the thickness distribution a film strip is put into the holding device of the PRO-LAB II system. The measuring value is taken with themechanical detection head at selectable distancesor continuous with the capacitive sensor.

The maintenance free stepper motor moves the film strip step by step by the mechanicaldetection sensor.

When the capacitive sensor is supplied the film is moved in a continuous mode.

To avoid a cross movement of the film strip, if different widths of film strips are measured, a guiding frame keeps the film strip in position.

Additionally the system will be delivered witha container to put the film strip in. This container keeps the film off of the floor to help keep dust and dirtfrom contaminating the film. Small contaminantswill be eliminated by a unit at the entrance of thedevice (not usable with sticky film surfaces).

The use of commercial anti-static tissues is required.

GAUGE MEASUREMENT WITH PRO-LAB II

The PRO-LAB II basic system is equipped with aserial interface, so that the system can be con-nected to a customer PC. The software package isWindows based and has a user friendly environ-ment allowing a professional profile analysis.

Based on meaningful profile graphics, averagevalues, min. and max. values, the tolerance of thepre-selected set points will be easily detected.

With the help of Windows these measuring resultscan be documented with product or order numbers,archived or recorded.

Advantages:• Measurement acc. DIN/ISO/ASTM• Easy handling• Automatic mode• Easy calibration

➊ PRO-LAB II

➋ PRO-LAB II with film guiding device

➌ Visualization


PLAST-CONTROL GMBHWALTER-FREITAG-STR. 15

42899 REMSCHEIDGERMANY

TEL. +49 (0)2191-9480-0FAX +49 (0)2191-9480-49

[email protected]

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15:4015:3415:2815:22 15:46 15:52

PLAST-CONTROL INC.65 PARKER STREET, UNIT 10

NEWBURYPORT, MA 01950 USA

TEL. +1 978 462 0306FAX +1 978 462 1425

WWW.PLASTCONTROL.NET

PLAST-CONTROL LTD.UNIT 17, LEEWARD ROAD

ASHTON-PRESTONLANCASHIRE PR2 2TEGREAT BRITAIN

TEL. +44 1772 769963FAX +44 1772 736357

[email protected]

PLAST-CONTROL ASIA LTD. 7F, NO. 155, KEELUNG RD.

SEC. 1, XINYI DISTRICTTAIPEI CITY, 110TAIWAN

TEL +886 2 3765 1808FAX +886 2 2767 2538

WWW.PLASTCONTROL.COM

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… a History of Success.

With over 8000 systems installedworldwide, PLAST-CONTROL is theleading manufacturer of automationsystems for plastics extrusion.

Since the company’s inception in1979 we have continuously developed innovative technologiesthat have set the standards formanaging plastics extrusion.

Today, we offer our customers acomplete range of products for extrusion automation, includinggravimetric Dosing and PRO-CON,our automatic profile control systemfor blown film lines.

PLAST-CONTROL has representationthroughout the world and maintainsregional offices in the USA, GreatBritain and Taiwan.

Klappe (GB) 25.09.2013 9:41 Uhr Seite 1

reliable automation and optimization of extrusion … · 2014-04-10 · all of our automation...

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