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Introduction
Due to its excellent material characteristics and its outstanding price / performance ratio, until today PVC is the most used material worldwide for pipes or profiles made from plastics. As the market is very competitive manufacturers of RPVC/UPVC pipes or profiles have been exposed to increasing pressure on prices and costs for years. At the same time higher and higher demands are made on the product quality.
So, lets have a look at HOW Neoplasts Conical Twin Screw Extruders are helpful in producing better quality PVC Pipes or Profiles !!!
1. Feed Zone 2. Plasticizing Zone 3. Compression Zone 4. Vent Zone 5. Metering Zone
Importance of Each Zone Feed Zone: Feeding and pre-heating of the material. Plasticizing zone: Heating and agglomeration. Compression Zone:
Sealing-off of vent zone in support of the plasticizing process.
Vent zone: Degassing & venting of the melt. Metering Zone Completion of melting, homogenizing & outputting of melt.
In other words,
A Conical 45mm extruder can match the output of a 65 mm parallel model, the intake section has the surface area and gentle plasticizing of a 100 mm parallel, while only the metering section has the excess friction and shear of a 45 mm parallel. The small screw front face results in a low axial force on the screws. The wide screw shaft center distance at the rear allows space for large thrust bearings and a simple, sturdy, distribution gearbox.
F=1250 cm2
F=490 cm2
From above graph, if is evident that the meshing surface area is higher for conical twin screws compare to the same diameter parallel twin screws hence homogeneous and better melt quality.
Continuity of Compression
From the graph, it can be derived that by using conical twin screws, compression continuity can be maintained throughout the length of the screw and hence better quality of the end product.
Compression
venting
Life of Gears
The pinion gears of conical twin screws last much longer than those of parallel twin screws. The reason is the center distance is much larger, the gear pinions are much larger in diameter. The life of gear pinions increases with approximately the cube of the diameter ; which enhance reliability.
Specific Throughput : A high specific output means a high material throughput at low screw RPM means low Power consumption. Moreover, low screw speeds required to achieve specific output results in low shear stresses, gentle plasticizing and low screw wear.
Ease of maintenance
The conical twin screws are taken out from the backward direction. The barrel is simply moved to the side. When active screw core thermoregulation is used, the coupling elements for the heat transfer oil lines remain attached to the screw tappets & oil spillages cannot occur. Higher productivity by time saving.
The conical idea Brilliant when it was born, and still brilliant today
So, Lets have a look at the key features of NCMT series Extruders.
Material feed
Hopper Feeding
For easy flowing dry-blends with constant quality & apparent density, a sliding hopper is used which allows for three positions Production, Shut-off & Emptying
Metering Unit
Metering units enable accurate adjustment of the screw filling factor and plasticizing capacity. They are ideal for materials with the possibility of density variations & particularly suitable for the processing of regrind and pellets.
The design of the barrel heating and cooling elements (air power cooling), and optimal locations for the barrel thermocouples, ensure accurate temperature control. The large surface area cooling elements combine the advantages of high efficiency and minimal maintenance.
Venting Unit
The venting port on the barrel is coupled to specially designed efficient venting pump for effective removal of air and gases generated during the plastification process
Cimitherm is a self-regulating system which adjusts to changing heat transfer requirements & doesnt require any kind of adjustment.
Die Head
Optimized for PVC formulations of tomorrow. Production flexibility by a modular system of basic heads, adapters and die sets Large head volume for a smooth inner surface of the pipe / profile
High compression ratio to prevent spider lines & streamlined spider legs
Automatic thermal centering for very tight wall thickness tolerances Corrosion-resistant hard chrome plated surface
For Pipe Extrusion Various models to suit outputs from 50 to 500 kg/hr. Vacuum calibration chamber length 3 to 6 meter, fully or partially under vacuum as per requirement. Individual headers for water & vacuum connections Uniform water spray with specially designed nozzles and inline water filters. Single or dual strand. After spray cooling, back or front seal supporting disk, guide rollers can be provided.
Haul Off
Various models to suit various pipe or profile size or shapes with different throughput capacity. Precision clamping for to avoid distortion of product, slip less pulling of extrudate, stronger driving mechanism, step less or synchronized adjustable speed Two belts, three belts or multi belts Depends on product size, shape or output; belts or chains with customized pad shape
Cutting Saw
Various models to suit various pipe or profile size or shapes with different throughput capacity. Different cutting system available like chopping cutter, saw cutter, Planetary saw cutter with optional chamfering provision. Specially designed cutter for profile cutting All cutters are with safety guards Optional saw dust collection unit
Pellet Cooler
Suitable to cool soft & Rigid PVC pellets Adjustable vibration, easy cleaning & low noise Dust separator for dust free pellets Completely cooled pellets with reverse air cooling Compact, space saving & versatile system
Applications