COMPOUNDING Extruders and extrusion lines
1
↗ Overview
↗ Overview
COMPOUNDING – HIGH THROUGHPUTS
TYPICAL COMPOUNDING TASKS INCLUDE:
IN THE BEST QUALITY
↗ reinorcing polymers, e.g. by incorporating glass, carbon or natural fibers ↗ improving the dimensional stability and breaking strength o polymers, e.g. by incorporating inorganic fillers, glass beads
Focus on material characteristics
↗ improving the flow behavior and flame resistance o polymers, e.g. by incorporating low-viscosity substances or flame retardants Compounding is a process in which the polymer is melted and mixed with e.g. additives, fillers or reinorcing materials. This process changes the physical, thermal, electrical or aesthetic properties (conductivity, flame resistance, wear resistance, color etc.) o the polymer. The final product is called a compound.
Compounding, in other words the processing o plastics, is one o the prime disciplines o Leistritz twin screw extruders. Diverse incorporation options or filler and reinorcement materials into the polymer matrix are possible and lead to new material properties, which are used in a multitude o applications.
↗ the manuacture o polymer blends, e.g. by mixing compatible or incompatible polymers (impact-resistant modification o thermoplastic materials) ↗ enhancing the chemical/physical durability o polymers, e.g. by incorporating stabilizers, anti-static agents
Examples of final products e.g. computer case
Compounding Filling (e.g. CaCO₃, wood compounds, talcum) Basis: raw polymer
Reinforcing (e.g. glass or carbon fibers)
e.g. car front-end
Additivation (e.g. flame retardants, UV stabilizers) e.g. garden furniture
Cross-linking of elastomers (e.g. TPE-V) Reactive extrusion Blending (e.g. PC + ABS)
e.g. tool handles
e.g. shoe soles, ski boots
Compounding means satisfying the requirements
specification of the end product in an ideal way . « e.g. headlight housing for cars
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Leistritz
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Extrusion Technology
↗ Applications
↗ Applications
INCORPORATING FILLERS It’s all about good dispersion Fillers are added to polymers to improve their properties and/or reduce the price o the compound. The good incorporation options or fillers in the polymer matrix are used in a wide variety o applications, such as the manuacture o computer cases. Another example: drain pipes. The filler is used here as sound insulation so that flushing noises cannot be heard in apartment buildings, or example. Leistritz extruders are able to incorporate a very high share o fillers, or example in the filler masterbatch.
The polymer can be mixed with up to ��% o fillers such as chalk or talcum. Side eeders are used to incorporate fillers (see p. ₁₄). Two or more may be used or larger shares o fillers. The modular extruder is simply extended in such cases. The volume flow o the added materials is distributed amongst the existing eed options - depending on the ormulation - to minimize abrasion and to wet thesystem filler Example of a customized as well as possible.
Example of a formulation: ₇� - ₈�% CaCO ₃ + �₈ - ��% polyolefins + � - ₂% additives
Line layout:
gravimetric eeder: filler
gravimetric eeder: filler
gravimetric eeder: raw polymer (+ possibly filler)
The main demand on the extruder is to incorporate large quantities o the filler. The primary task is to disperse the filler optimally and distribute it in the polymer matrix. The dispersion process can be split into the ollowing steps: ↗ melting o the polymer matrix ↗ wetting the filler with the melt ↗ dispersion o agglomerates and aggregates (dispersive mixing) ↗ homogeneous distribution in the matrix (distributive mixing) ↗ homogenization and degassing o the melt FILLER CRITERIA
Fillers are incorporated in plastics to improve the material characteristics o the compound and/or to save costs. There are three important criteria that affect the interaction between the filler and the polymer matrix:
FREQUENTLY USED INORGANIC FILLERS
↗ Talcum is flaky; is preerably added to the melt via a side eeder; gives the final product special surace properties
↗ Particle shape o the filler Particles with a small aspect ratio (e.g. glass beads, CaCO3 or BaSO4) do not significantly improve the tensile strength and tear resistance, but do normally improve the modulus o elasticity. Particles with a large aspect ratio (e.g. talcum or wollastonite) help improve the tensile strength and tear resistance as well as the modulus o elasticity.
↗ Calcium carbonate (CaCO₃) is cubic; avail able in three states: chalk, limestone and marble; cost -effi cient
↗ Particle size distribution o the filler The behavior o filler particles during processing depends on both the Van-der-Wals orces acting between the particles (with particle sizes > 1 µm) and the dispersive shearing orces in the extruder (with particle sizes < 10 µm).
↗ Barium sulfate (BaSO₄) are rhombic crystals (cuboid); added via a side eeder, has a high specific weight and density
↗ Surface o the filler The specific surace (m²/g) indicates the number o adhesion points between the filler and polymer chains: large surace > numerous adhesion points > better mechanical properties (higher stiffness and surace gloss o the polymer, better tensile strength and tear resistance as well as impact strength). The surace coating is also important because it changes the surace energy: a hydrophilic surace becomes hydrophobic. This hydrophobing means that ewer agglomerates orm and the ree-flowing property is improved. The wetting is essentially affected by how ar apart the surace energies o the particles and the polymer matrix are. The closer together they are, the better the wetting.
↗ Wollastonite is fibrous: added via the side eeder
Example of a compounding plant to incorporate calcium carbonate (further details on p. �⁰/��)
↗ Applications
↗ Applications
INCORPORATING FILLERS It’s all about good dispersion Fillers are added to polymers to improve their properties and/or reduce the price o the compound. The good incorporation options or fillers in the polymer matrix are used in a wide variety o applications, such as the manuacture o computer cases. Another example: drain pipes. The filler is used here as sound insulation so that flushing noises cannot be heard in apartment buildings, or example. Leistritz extruders are able to incorporate a very high share o fillers, or example in the filler masterbatch.
Example of a formulation: ₇� - ₈�% CaCO ₃ + �₈ - ��% polyolefins + � - ₂% additives
The polymer can be mixed with up to ��% o fillers such as chalk or talcum. Side eeders are used to incorporate fillers (see p. ₁₄). Two or more may be used or larger shares o fillers. The modular extruder is simply extended in such cases. The volume flow o the added materials is distributed amongst the existing eed options - depending on the ormulation - to minimize abrasion and to wet thesystem filler Example of a customized as well as possible.
gravimetric eeder: filler
Line layout:
gravimetric eeder: filler
gravimetric eeder: raw polymer (+ possibly filler)
The main demand on the extruder is to incorporate large quantities o the filler. The primary task is to disperse the filler optimally and distribute it in the polymer matrix. The dispersion process can be split into the ollowing steps: ↗ melting o the polymer matrix ↗ wetting the filler with the melt ↗ dispersion o agglomerates and aggregates (dispersive mixing) ↗ homogeneous distribution in the matrix (distributive mixing) ↗ homogenization and degassing o the melt FILLER CRITERIA
Fillers are incorporated in plastics to improve the material characteristics o the compound and/or to save costs. There are three important criteria that affect the interaction between the filler and the polymer matrix:
FREQUENTLY USED INORGANIC FILLERS
↗ Talcum is flaky; is preerably added to the melt via a side eeder; gives the final product special surace properties
↗ Particle shape o the filler Particles with a small aspect ratio (e.g. glass beads, CaCO3 or BaSO4) do not significantly improve the tensile strength and tear resistance, but do normally improve the modulus o elasticity. Particles with a large aspect ratio (e.g. talcum or wollastonite) help improve the tensile strength and tear resistance as well as the modulus o elasticity.
↗ Calcium carbonate (CaCO₃) is cubic; avail able in three states: chalk, limestone and marble; cost -effi cient
↗ Particle size distribution o the filler The behavior o filler particles during processing depends on both the Van-der-Wals orces acting between the particles (with particle sizes > 1 µm) and the dispersive shearing orces in the extruder (with particle sizes < 10 µm).
↗ Barium sulfate (BaSO₄) are rhombic crystals (cuboid); added via a side eeder, has a high specific weight and density
↗ Surface o the filler The specific surace (m²/g) indicates the number o adhesion points between the filler and polymer chains: large surace > numerous adhesion points > better mechanical properties (higher stiffness and surace gloss o the polymer, better tensile strength and tear resistance as well as impact strength). The surace coating is also important because it changes the surace energy: a hydrophilic surace becomes hydrophobic. This hydrophobing means that ewer agglomerates orm and the ree-flowing property is improved. The wetting is essentially affected by how ar apart the surace energies o the particles and the polymer matrix are. The closer together they are, the better the wetting.
↗ Wollastonite is fibrous: added via the side eeder
Example of a compounding plant to incorporate calcium carbonate (further details on p. �⁰/��)
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Leistritz
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Extrusion Technology
↗ Applications
↗ Applications
REINFORCING COMPOUNDS Break resistant and stiff Particularly or applications requiring properties such as strength and stiffness, the polymer (e.g. PP or PA) is reinorced with materials such as glass fibers, carbon fibers, and also natural fibers. The filler content o PP with glass fibers, or example, can be up to ��% depending on the application.
The addition and combination o the polymer chains to and with the fiber structures creates a very strong bond that matches, and sometimes even exceeds the properties o metallic materials. Their low weight make reinorced thermoplastic materials a very popular material, particularly in automobile manuacturing.
Application example: incorporation of glass fibers (��%) into polycarbonate (��%)
gravimetric eeder: raw polymer (+ possibly filler)
gravimetric eeder: glass fibers
Line layout:
Example: glass fibers The goal o processing glass fibers in a twin screw extruder is to distribute the fibers homogeneously in the polymer matrix and achieve an optimum length distribution in the final product with the lowest possible destruction o the fibers. The size on the fibers makes them smoother and more resistant to mechanical loads. However, the size has to be compatible with the polymer matrix. Chopped or short glass fibers with initial fiber lengths o approx. � mm are usually used. Alternatively, rovings (filaments) may also be added.
long fiber lengths → better mechanical product properties, poorer flow behavior in the melt (e.g. during urther processing in injection molding) short fiber lengths → poorer mechanical product properties, better mold-filling behavior during injection molding
Processing in a twin screw extruder
Test: ZSE MAXX (D a /Di = �.��) v. ZSE HP (Da /Di = �.�� PC + ��% GF
Fibers are usually ed into the polymer matrix afer the plasticizing step during compounding. I the fibers are added through the main eed port, they will be ragmented too heavily in the plasticizing unit and cause too much abrasion in the melting zone.
ZSE �� HP
→ A ZSE MAXX extruder is the right choice or running shear-sensitive applications.
ZSE �� MAXX
→ Up to ��% more throughput can be realized here. ) h / g k (
→ When working with higher filling degrees energy savings o up to ��% are possible due to a higher volume and high torque.
t u p h g u o r h t
REM image: glass fibers well embedded in a PC matrix Source: Technische Hochschule Nürnberg Georg Simon Ohm
Results:
screw speed (rpm)
↗ Applications
↗ Applications
REINFORCING COMPOUNDS Break resistant and stiff Particularly or applications requiring properties such as strength and stiffness, the polymer (e.g. PP or PA) is reinorced with materials such as glass fibers, carbon fibers, and also natural fibers. The filler content o PP with glass fibers, or example, can be up to ��% depending on the application.
Application example: incorporation of glass fibers (��%) into polycarbonate (��%)
The addition and combination o the polymer chains to and with the fiber structures creates a very strong bond that matches, and sometimes even exceeds the properties o metallic materials. Their low weight make reinorced thermoplastic materials a very popular material, particularly in automobile manuacturing.
gravimetric eeder: raw polymer (+ possibly filler)
gravimetric eeder: glass fibers
Line layout:
Example: glass fibers The goal o processing glass fibers in a twin screw extruder is to distribute the fibers homogeneously in the polymer matrix and achieve an optimum length distribution in the final product with the lowest possible destruction o the fibers. The size on the fibers makes them smoother and more resistant to mechanical loads. However, the size has to be compatible with the polymer matrix. Chopped or short glass fibers with initial fiber lengths o approx. � mm are usually used. Alternatively, rovings (filaments) may also be added.
long fiber lengths → better mechanical product properties, poorer flow behavior in the melt (e.g. during urther processing in injection molding) short fiber lengths → poorer mechanical product properties, better mold-filling behavior during injection molding
Test: ZSE MAXX (D a /Di = �.��) v. ZSE HP (Da /Di = �.��
Processing in a twin screw extruder
PC + ��% GF
Fibers are usually ed into the polymer matrix afer the plasticizing step during compounding. I the fibers are added through the main eed port, they will be ragmented too heavily in the plasticizing unit and cause too much abrasion in the melting zone.
ZSE �� HP
Results: → A ZSE MAXX extruder is the right choice or running shear-sensitive applications.
ZSE �� MAXX
→ Up to ��% more throughput can be realized here. ) h / g k (
→ When working with higher filling degrees energy savings o up to ��% are possible due to a higher volume and high torque.
t u p h g u o r h t
REM image: glass fibers well embedded in a PC matrix Source: Technische Hochschule Nürnberg Georg Simon Ohm
screw speed (rpm)
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Leistritz
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Extrusion Technology
↗ Applications
↗ Applications
THERMOPLASTIC ELASTOMERS
POLYMER BLENDS
Elastic, pliable, flexible
Cost efficient and performance-optimized
Thermoplastic elastomers (TPE) are materials in which elastic polymer chains are incorporated in a thermoplastic material. They can be processed in a purely physical process through the use o high shearing orces, exposure to heat and subsequent cooling. They can be melted and shaped by heating again. A number o TPEs exist that differ greatly in both their polymer structure and their properties. Their common eature is the basic structure in the orm o block polymers in which the elastomer segments copolymerize with the basic polymer. The share o elastomer chains in the overall polymer can be varied broadly or a number o TPE classes. This means that settings rom very stiff to almost gel-like are possible.
TPEs are used in a wide variety o industries: in the automotive sector, or example, they are used as window surrounds or control elements. They are also used in industry or tool handles or sealing rings, or example. Or in the consumer sector or toothbrushes or packaging. The production o numerous different thermoplastic elastomers calls or a proound knowledge o machines and process engineering. Depending on the type o elastomer (rom a standard SEBS through to dynamically cross-linked TPE-V systems) various machines concepts are applied. What is important is the necessary process engineering know-how and flexible extruders. The process lengths o the twin screw extruders used here range rom ₄� L/D up to ₆ � L/D. The addition o oil, fillers or various cross-linking agents varies depending on the application.
Blends offer the possibility o creating a whole series o new, more effi cient and less expensive polymers with customized properties rom the available potential o basic polymers. Their main field o use is in the automotive and electrical industry. They are ound here in shock absorbers or hub caps as well as the casing material or telephones and computers. The compatibility o the basic polymer is crucial and plays an important role or the compounding. There are three groups: ↗ blends with ull compatibility between the basic polymers (e.g. SMA + SAN, PPO + HIPS) ↗ partially compatible blends: basic polymers orm a two-phase matrix, but with good physical interaction (e.g. PC + ABS, PC + PBT) ↗ blends with incompatible basic polymers (e.g. PA + ABS, PPO + PA)
Application example: PC + ABS blend
� gravimetric eeders: PC + ABS possibly additives
Line layout:
Application example: TPE-V TPE-V is the name given to thermoplastic elastomers with a cross-linked rubber component. Very long process lengths o up to �� L /D are used in the production o TPE-V. This means that the necessary residence time and respective process steps (blending the EPDM with the polymer matrix, mixing in o additives, dynamic cross-linking) can be generated. The design o such a plant relies on the wealth o experience o our process engineers who set up the processing unit to match the individual process steps.
Knowing which machine concept is to be used calls for the necessary process engineering know-how . «
This polymer blend combines the advantages o polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). It is one o the ew blends that achieves a synergistic effect alongside the mere benefits o the basic polymers: the resulting material has properties that none o the basic polymers have. For example, the low-temperature impact strength o the blend is ar superior to that o either o the basic polymers. PC gives the blend a high tenacity at room temperature and heat deormation temperature, ABS a good resistance to stress cracks and processibility. However, the blend also has an exceptional impact strength, even at an ambient temperature o -�₀ °C. An important process engineering aspect that has to be taken into account here is that the two different polymers also have different viscosities in the melt. Thereore, the choice o the accurate screw geometry is crucial. A good morphology can only be achieved with an adequately designed setup.
↗ Applications
↗ Applications
THERMOPLASTIC ELASTOMERS
POLYMER BLENDS
Elastic, pliable, flexible
Cost efficient and performance-optimized
Thermoplastic elastomers (TPE) are materials in which elastic polymer chains are incorporated in a thermoplastic material. They can be processed in a purely physical process through the use o high shearing orces, exposure to heat and subsequent cooling. They can be melted and shaped by heating again. A number o TPEs exist that differ greatly in both their polymer structure and their properties. Their common eature is the basic structure in the orm o block polymers in which the elastomer segments copolymerize with the basic polymer. The share o elastomer chains in the overall polymer can be varied broadly or a number o TPE classes. This means that settings rom very stiff to almost gel-like are possible.
TPEs are used in a wide variety o industries: in the automotive sector, or example, they are used as window surrounds or control elements. They are also used in industry or tool handles or sealing rings, or example. Or in the consumer sector or toothbrushes or packaging. The production o numerous different thermoplastic elastomers calls or a proound knowledge o machines and process engineering. Depending on the type o elastomer (rom a standard SEBS through to dynamically cross-linked TPE-V systems) various machines concepts are applied. What is important is the necessary process engineering know-how and flexible extruders. The process lengths o the twin screw extruders used here range rom ₄� L/D up to ₆ � L/D. The addition o oil, fillers or various cross-linking agents varies depending on the application.
Blends offer the possibility o creating a whole series o new, more effi cient and less expensive polymers with customized properties rom the available potential o basic polymers. Their main field o use is in the automotive and electrical industry. They are ound here in shock absorbers or hub caps as well as the casing material or telephones and computers. The compatibility o the basic polymer is crucial and plays an important role or the compounding. There are three groups: ↗ blends with ull compatibility between the basic polymers (e.g. SMA + SAN, PPO + HIPS) ↗ partially compatible blends: basic polymers orm a two-phase matrix, but with good physical interaction (e.g. PC + ABS, PC + PBT) ↗ blends with incompatible basic polymers (e.g. PA + ABS, PPO + PA)
Application example: PC + ABS blend
� gravimetric eeders: PC + ABS possibly additives
Line layout:
Application example: TPE-V TPE-V is the name given to thermoplastic elastomers with a cross-linked rubber component. Very long process lengths o up to �� L /D are used in the production o TPE-V. This means that the necessary residence time and respective process steps (blending the EPDM with the polymer matrix, mixing in o additives, dynamic cross-linking) can be generated. The design o such a plant relies on the wealth o experience o our process engineers who set up the processing unit to match the individual process steps.
Knowing which machine concept is to be used calls for the necessary process engineering know-how . «
This polymer blend combines the advantages o polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). It is one o the ew blends that achieves a synergistic effect alongside the mere benefits o the basic polymers: the resulting material has properties that none o the basic polymers have. For example, the low-temperature impact strength o the blend is ar superior to that o either o the basic polymers. PC gives the blend a high tenacity at room temperature and heat deormation temperature, ABS a good resistance to stress cracks and processibility. However, the blend also has an exceptional impact strength, even at an ambient temperature o -�₀ °C. An important process engineering aspect that has to be taken into account here is that the two different polymers also have different viscosities in the melt. Thereore, the choice o the accurate screw geometry is crucial. A good morphology can only be achieved with an adequately designed setup.
₈
Leistritz
₉
Extrusion Technology
↗ Plant example
↗ Plant example
EXTRUSION LINE FOR HIGHLY FILLED COMPOUNDS High engineering competence
High-tech compounding plant for highly filled compounds
Task: design and construction o a plant or the stable and largely automated production o highly filled compounds o a constant product quality
Plant concept: ↗ material supply rom sacks, big bags and silos ↗ ormulation-controlled suction system or premixes ↗ gravimetric eeding system ↗ twin screw extruder ZSE ₇� MAXX ↗ gear pump and screen changer ↗ underwater pelletizing ↗ filling station ↗ control system + control panel
Process engineering concept: The art o producing highly filled compounds lies in the optimum distribution o the material streams. Great process engineering expertise is required to incorporate large quantities o fillers in the most homogeneous way in a polymer matrix. The air streams brought in with the material eeding in particular have to be controlled. A urther challenge is posed by the material moisture, which may complicate the process. Accordingly, the processing unit and screw geometry must have an optimum configuration or this task. This plant example convinces through state-o-the-art technology. The high volume (OD/ID = �.₆₆) and the high specific torque o up to �₅ Nm/cm³ o the ZSE ₇₅ MAXX twin screw extruder means that not only can maximum throughputs be run, but an energy-efficient production can also be realized. The topic o flexibility is also taken seriously: whereas the plant was built to produce highly filled compounds with up to �₅% calcium carbonate, various other processes can also be run on it with minimum adjustments, or instance talcum, titanium dioxide or barium sulate. Aluminum or magnesium hydroxide can also be processed or the field o flame retardancy.
↗ Plant example
↗ Plant example
EXTRUSION LINE FOR HIGHLY FILLED COMPOUNDS High engineering competence
High-tech compounding plant for highly filled compounds
Process engineering concept:
Task:
The art o producing highly filled compounds lies in the optimum distribution o the material streams. Great process engineering expertise is required to incorporate large quantities o fillers in the most homogeneous way in a polymer matrix. The air streams brought in with the material eeding in particular have to be controlled. A urther challenge is posed by the material moisture, which may complicate the process. Accordingly, the processing unit and screw geometry must have an optimum configuration or this task.
design and construction o a plant or the stable and largely automated production o highly filled compounds o a constant product quality
Plant concept:
This plant example convinces through state-o-the-art technology. The high volume (OD/ID = �.₆₆) and the high specific torque o up to �₅ Nm/cm³ o the ZSE ₇₅ MAXX twin screw extruder means that not only can maximum throughputs be run, but an energy-efficient production can also be realized. The topic o flexibility is also taken seriously: whereas the plant was built to produce highly filled compounds with up to �₅% calcium carbonate, various other processes can also be run on it with minimum adjustments, or instance talcum, titanium dioxide or barium sulate. Aluminum or magnesium hydroxide can also be processed or the field o flame retardancy.
↗ material supply rom sacks, big bags and silos ↗ ormulation-controlled suction system or premixes ↗ gravimetric eeding system ↗ twin screw extruder ZSE ₇� MAXX ↗ gear pump and screen changer ↗ underwater pelletizing ↗ filling station ↗ control system + control panel
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Leistritz
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Extrusion Technology
↗ Plant example
↗ Plant example
LARGE-SCALE COMPOUNDING FOR PP STABILIZATION Competent system supplier Task: Panorama view of the overall plant
design, planning and construction o a large-scale compounding plant (climate zone rom -�� – +�� °C).
Plant concept: ↗ material supply in a nitrogen atmosphere rom a reactor ↗ mixing and supply silos ↗ dosing units ↗ extrusion line with a ZSE ��� MAXX twin screw extruder ↗ gear pump and screen changer ↗ underwater pelletizing ↗ homogenizing silos ↗ bagging station with subsequent palletless palletizing ↗ control with integrated online rheometer
Process engineering concept: PP is produced in the upstream polymerization plant. The raw polymer powder rom the reactor is transported in a nitrogen atmosphere over a distance o approx. ��� m to the co-rotating twin screw extruder ZSE ��� MAXX where it is stabilized against auto-oxidation (throughput �� t/h). The specific adjustability and uniorm viscosity o the stabilized polypropylene during the extrusion process plays a crucial role in terms o process engineering. This viscosity is measured during the process with an online rheometer. By using a special controller integrated in the Leistritz control unit, metering o the peroxide masterbatch and thus the viscosity (MFR/MFI) is adjusted to the specifications and any fluctuations in the raw polymer can be compensated.
Self-controlled adjustment of the MFI value
Plant overview
↗ Plant example
↗ Plant example
LARGE-SCALE COMPOUNDING FOR PP STABILIZATION Competent system supplier Task: Panorama view of the overall plant
design, planning and construction o a large-scale compounding plant (climate zone rom -�� – +�� °C).
Plant concept: ↗ material supply in a nitrogen atmosphere rom a reactor ↗ mixing and supply silos ↗ dosing units ↗ extrusion line with a ZSE ��� MAXX twin screw extruder ↗ gear pump and screen changer ↗ underwater pelletizing ↗ homogenizing silos ↗ bagging station with subsequent palletless palletizing ↗ control with integrated online rheometer
Process engineering concept: PP is produced in the upstream polymerization plant. The raw polymer powder rom the reactor is transported in a nitrogen atmosphere over a distance o approx. ��� m to the co-rotating twin screw extruder ZSE ��� MAXX where it is stabilized against auto-oxidation (throughput �� t/h). The specific adjustability and uniorm viscosity o the stabilized polypropylene during the extrusion process plays a crucial role in terms o process engineering. This viscosity is measured during the process with an online rheometer. By using a special controller integrated in the Leistritz control unit, metering o the peroxide masterbatch and thus the viscosity (MFR/MFI) is adjusted to the specifications and any fluctuations in the raw polymer can be compensated.
Self-controlled adjustment of the MFI value
Plant overview
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Leistritz
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Extrusion Technology
↗ Optional extras
↗ Optional extras
SIDE FEEDING
SIDE DEGASSING
Easy material feed - modular adjustment
Reliable degassing of volatile substances
The side eeder is mostly used to add powders. Leistritz can offer the right side eeder or every application and all extruder sizes. The LSB XX series convinces through the high OD/ID ratio (2.0) o the screws and can also convey materials with very low bulk densities.
Apart rom the generally known process tasks such as melting, mixing or homogenizing, the degassing o volatile substances is a key part o plastics processing. Leistritz can offer the perect side degasser or every application and all extruder sizes. As an alternative to conventional passive degassing systems, there are the Leistritz side degassing LSE XX and the Leistritz vertical degassing LVE XX. They allow a sae degassing o the extrusion process, even in unavorable process conditions such as during start-up or heavily oaming products. In connection with the largest possible ree volume in the screw flight o the extruder and the constant renewal o the product surace, it creates optimum conditions or degassing the polymer molten mass. The two screws that rotate in the same direction that are fitted in the side degassing orce any melt that tries to escape back into the process chamber but allow all gases to pass. This avoids any blockages or deposits in the degassing barrel. The productivity and saety o extrusion plants are increased in this way.
SPECIAL FEATURES OF THE LSB XX:
↗ segmented screws can be used (configuration according to the needs o the raw material) ↗ adaption o the LSB XX to the extruder with tie rods (LSB XX can be astened to the extruder barrel in the cold, easily accessible area o the gear box with no risk o injuries ↗ use o various types o steel (allows eeding both highly abrasive (e.g. TiO₂) and highly corrosive products)
LSE XX / LVE XX
Extruder size Screw diameter
(mm)
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₆�
₇₅
₈₇
₁₁�
₁�₅
ZSE
ZSE
ZSE
ZSE
ZSE
ZSE
ZSE
ZSE
�₀ MAXX
�₅ MAXX
₈� MAXX
��₀ MAXX
��₅ MAXX
₃₅ iMAXX
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�₀ MAXX ₅₀ MAXX
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↗ option: internal cooling o the screw (possible through special gear box design) SPECIAL FEATURES:
↗ OD/ID =� (higher ree volume) ↗ LSE barrel heated by heating cartridges
LSB XX
Extruder size Screw diameter (mm)
�₅
��
₅�
Base frame
₇₅
ZSE ZSE ZSE ZSE ZSE �₅ iMAXX �₀ MAXX ₅₀ MAXX �₀ MAXX �₅ MAXX ��.�
�₀.₈
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Screw speed infinitely variable (rpm) Drive power (kW)
₆�
�₀.�
₈₇
₁₁�
↗ cooled gear box lantern (prevents overheating o the gear box)
₁�₅
↗ horizontal (lateral) attachment on the base rame or vertical via special adapter (barrel insert)
ZSE ZSE ZSE ₈� MAXX ��₀ MAXX ��₅ MAXX
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LSE XX (lateral attachment)
LVE XX (vertical attachment)
₀��₀₀ �.₅ without
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₅.� with
A retrofit of LVE XX is easily possible with minimum effort . «
↗ Optional extras
↗ Optional extras
SIDE FEEDING
SIDE DEGASSING
Easy material feed - modular adjustment
Reliable degassing of volatile substances
The side eeder is mostly used to add powders. Leistritz can offer the right side eeder or every application and all extruder sizes. The LSB XX series convinces through the high OD/ID ratio (2.0) o the screws and can also convey materials with very low bulk densities.
Apart rom the generally known process tasks such as melting, mixing or homogenizing, the degassing o volatile substances is a key part o plastics processing. Leistritz can offer the perect side degasser or every application and all extruder sizes. As an alternative to conventional passive degassing systems, there are the Leistritz side degassing LSE XX and the Leistritz vertical degassing LVE XX. They allow a sae degassing o the extrusion process, even in unavorable process conditions such as during start-up or heavily oaming products. In connection with the largest possible ree volume in the screw flight o the extruder and the constant renewal o the product surace, it creates optimum conditions or degassing the polymer molten mass. The two screws that rotate in the same direction that are fitted in the side degassing orce any melt that tries to escape back into the process chamber but allow all gases to pass. This avoids any blockages or deposits in the degassing barrel. The productivity and saety o extrusion plants are increased in this way.
SPECIAL FEATURES OF THE LSB XX:
↗ segmented screws can be used (configuration according to the needs o the raw material)
LSE XX / LVE XX
↗ adaption o the LSB XX to the extruder with tie rods (LSB XX can be astened to the extruder barrel in the cold, easily accessible area o the gear box with no risk o injuries
Extruder size
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Screw diameter
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(mm)
↗ use o various types o steel (allows eeding both highly abrasive (e.g. TiO₂) and highly corrosive products)
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↗ option: internal cooling o the screw (possible through special gear box design) SPECIAL FEATURES:
↗ OD/ID =� (higher ree volume) ↗ LSE barrel heated by heating cartridges
LSB XX
Extruder size Screw diameter (mm)
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Screw speed infinitely variable (rpm) Drive power (kW) Base frame
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↗ cooled gear box lantern (prevents overheating o the gear box)
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↗ horizontal (lateral) attachment on the base rame or vertical via special adapter (barrel insert)
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LSE XX (lateral attachment)
LVE XX (vertical attachment)
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A retrofit of LVE XX is easily possible with minimum effort . «
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Leistritz
Extrusion Technology
EXTRUSION TECHNOLOGY Available for you all over the world
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EXTRUSION TECHNOLOGY Available for you all over the world
USA
GERMANY
CHINA
Leistritz Advanced Technologies Corp., Somerville, NJ
Headquarters Leistritz Extrusionstechnik GmbH, Nuremberg
Leistritz Machinery (Taicang) Co., Ltd., Taicang
ITALY
FRANCE
SINGAPORE
Leistritz Italia Estrusione, Castellanza
Leistritz France Extrusion, Ceyzeriat
Leistritz SEA Pte Ltd, Singapore
Leistritz Extrusionstechnik GmbH | Markgraenstraße ����₉ | ₉���₉ Nuremberg | Germany Tel.: +�₉ ₉�� �� �� � � |
[email protected]
www.leistritz.com
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