Resent Developments

In Extrusion lines

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DOUBLE SPIDER DIE HEAD - RD SERIES

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 DOUBLE SPIDER DIE HEAD – RD SERIES

SALIENT FEATURES:-

• LOWER PRESSURE BUILD UP.

• SIMPLE CONTROL OF EXTRUSION PROCESS.
• EXCELLENT WALL THICKNESS CONTROL AT HIGHER
THROUGHPUT RATES.

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 DOUBLE SPIDER DIE HEAD – RD SERIES

ADVANTAGES:-

• ELIMINATION OF SPIDER LINES DUE TO STAGGERRED

DOUBLE DECKER SPIDER.
• IMPROVED MECHANICAL PROPERTIES.
• INCREASED OUTPUT RATE.
• PROCESSING OF THICK WALL PIPES WITHOUT SPIDER LINES.
• INCREASED DIE HEAD CAPACITY.
• WIDER DIAMETER RANGE PER DIE HEAD. HENCE DOWN
TIME DUE TO CHANGE OVER ELIMINATED.

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 ACCOUNTANCY
EXISTING DIE HEAD
NEW RD SERIES DIE HEAD

75 / 250 : 20D – 75D RD – 1 : 20D – 110D

110 / 250 : 63D – 110D (725Kg/Hr.)

200 / 400 : 63D – 200D RD – 2 : 63D – 280D

250 / 600 : 90D – 250D (910Kg/Hr.)

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 TWIN SCREW RPVC PIPE PLANT WITH
TWIN LINE

INCLUDES:-
vTWIN DIE HEAD 2-75/250 or 2-200/400.
vTWIN VACUUM CALIBRATOR WITH 2-VI-110
OR TWIN SPRAY BATH 2-SK-110.
vTWIN CATERPILLAR HAUL-OFF 2-R110 S.
vTWIN CUTTER 2-SPR 110.
vTWIN TRIPPING CHUTE 2-KR-110.
vPIPE RANGE OF 20-110MM.

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TWIN SCREW RPVC PIPE PLANT

7
TWIN SCREW RPVC PIPE PLANT WITH
TWIN DISTRIBUTOR

8
 Resent Developments
In
TAPE STRETCHING LINE
“Kabratec”
Tape stretching Lines

9
 WHAT IS NEED FOR DEVELOPMENT OF
“KABRATEC”
TAPE STRETCHING LINE ?

10
0
 TO OPTIMISE ENERGY CONSUMPTION
BY INCREASING LINE SPEED WITH
HELP OF ELECTRONIC WINDER AND
OVERCOMING WATER CARRYING PROBLEM.

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1
 POWER CONSUMPTION
PLANT kwh / kg
TAPE LINE WITH BLOWN FILM TECHNOLOGY
L/D RATIO 24:1 TO 26:1 > 1.2
TAPE LINE WITH SHEET DIE
L/D RATIO 28 : 1 0.9 –1.0
TAPE LINE WITH SHEET DIE
L/D RATIO 30 : 1 0.7 – 0.75
NEXT GENETATION TAPE LINE
L/D RATIO 32 : 1 < 0.6

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 ENERGY BREAKUP
IN
WOVEN SACK INDUSTRIES
OFFICE & SHED
FINISHING (0.1)
(0.1)
UTILITIES
(0.1 – 0.2)

LOOMS
(0.3 – 0.5) EXTRUSION LINES
( > 0.6 )

TOTAL CONSUMPTION = 1.1 – 1.4 kW/kg

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3
 ENERGY BREAKUP
OF
NEXT GENERATION TAPE STRETCHING LINE

0.35 52%
(0.30)
ENERGY CONSUMPTION kWH / kg

0.30

0.25

0.20 23%
(0.13-0.14)
0.15 13%
(0.07-0.08)
0.10 6% 6%
(0.035- (0.035-0.037)
0.037)
0.05

0.00
EXTD GODET OVEN * OTHER WINDER

TOTAL CONSUMPTION : < 0.6 kWH/kg

* OTHER : END TRIM, ASPIRATION, WATER SUCTION.

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4
 ENERGY BREAKUP
OF
“KABRATEC” TAPE STRETCHING LINE

0.35 56%
(0.255-0.28)
ENERGY CONSUMPTION kWH / kg

0.30

0.25

0.20

0.15 14% 15%

(0.065-0.070) (0.07-0.08)

0.10 7.5% 7.5%

(0.035- (0.035-0.037)
0.037)
0.05

0.00
EXTD GODET OVEN * OTHER WINDER

TOTAL CONSUMPTION = 0.48 – 0.52 kWH/kg

* OTHER : END TRIM, ASPIRATION, WATER SUCTION.

15
5
 ENERGY SAVING

PRODUCTION / ANNUM = 3600 MT/ANNUM

( 500 – 510 Kg/Hr )

ENERGY SAVING = 36,00,000 x 0.1

= 3,60,000 UNITS/ANNUM

COST OF POWER = Rs. 4.5 per Unit

ANNUM SAVING IN ELECT. BILL = 3,60,000 x 4.5

= Rs. 16,20,000 / ANNUM

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 KABRATEC 110/600 TAPE
LINE
EXTRUDER : 110MM 32:1
MELTING CAPACITY (PP) : 600 kg/Hr
DENIER RANGE : 500 – 2000
CONT. SCREEN CHANGER : HYADRAULIC OPERATION
T-DIE : 1750 mm
WATER QUENCH WITH : 1700 mm
INTEGRATED HOLDING UNIT
ORIENTATION OVEN : 1750 mm
COMBINED STRETCHING / : 5 GODET ROLLER SYSTEM
ANNELAING UNIT (1700 mm)
LINE SPEED : 350 m/min
CHEESE WINDER : KGS-110E
ENERGY CONSUMPTION : 0.48 – 0.52 kW/kg

 PP 2.5mm TAPE, 850 DENIER

 KGS WINDER (320 m/min) : 500 kg/Hr
 HSS WINDER (280 m/min) : 450 kg/Hr

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7
 KABRATEC 110/600 TAPE
LINE

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8
 SCREW LIFE COMPARISION

TYPE : BARRIER PROFILE – WITH

SLOTTED MIXING RING AND
HOMOGENISING MIXER.
- BI- METALLIC
(COLMONOY-56)
COATING IN HIGH
WEAR ZONE.

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9
 BARREL LIFE COMPARISION

SECTIONAL GROOVED FEED BUSH CERA.PERFORATED HEATER

BARREL :
 GROOVED FEED BARREL FITTED
WITH BI-METALLIC (XALOY-800) LINER.

 ENERGY SAVING BY MEANS OF

CERAMIC PERFORATED HEATERS
AND INSULATED COOLING JACKETS.

FEED BUSH : BI-METALLIC (XALOY-800)

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 EXTRUDER
Start Stop Procedure ( extruder with grooved feed bush )
- Temperature profile of the barrel zones ( Z1, Z2, Z3…) to be kept at minimum level
during starting.

- As the extruder screw speed is increased gradually, increase the barrel zone
temperatures gradually.

- When full speed as per requirement is achieved, temperature of barrel zones (Z1, Z2,
Z3..) are to reach to the requirement.

- Water circulation for the feed bush is to be kept on, before putting temperatures of the
barrel zones on.

- To stop the plant, close the shutter of hopper, let the material in the feed bush and
barrel flush out and then stop the drive.

- When the plant is stopped, water circulation should be kept on till the barrel zones cool
down. The water circulation should be stopped only after the barrel zones Z1, Z2, Z3
cool down.

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 EXTRUDER
Purging of Extruder ( Disco Purge method by Dupont )

100
90
80
70
% Max RPM

60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Minutes

22
AUTO-SCREEN CHANGER
µ
µ

ADVANTAGES :
NON STOP RUNNING OPERATION SINCE AUTOMATIC &
NO WASTAGE OF MATERIALS.
NO OPERATOR ATTENTION.
UNIFORM QUALITY IF TAPE THROUGHOUT OPERATION
& HENCE NO BREAKAGE OF TAPE
NO MOVING PARTS & HENCE LONGER LIFE 23
 CONTINUOUS SCREEN CHANGER

 CONSISTANT DENIER THROUGHOUT OPERATION.

 MINIMISE START-UP WASTAGE.
 HYDRAULIC OPERATION.
 PRE-FILL ARRANGEMENT FOR CONTINUOUS OPERATION.
 THERMALLY BALANCED.

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4
 CONTINUOUS SCREEN CHANGER

 CANDLE TYPE EASY MANUAL OPERATION.

 CONSISTANT DENIER THROUGHOUT OPERATION.
 MINIMISE STARTUP WASTAGE.
 INCREASE IN PRODUCTIVITY DUE TO CONTINUOUS OPERATION.

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5
 WATER QUENCH WITH
INTEGRATED HOLDING UNIT

26
6
 WATER QUENCH SECTION

 2 SETS OF HARD CHROME

PLATED MIRROR FINISHED
TAKE-OFF ROLLS.

 FILM TAKE-OFF BY MEANS

OF FREQUENCY CONTROLLED
AC DRIVES.

 WATER REMOVAL SYSTEM.

 SS CYLINDER PROVIDED TO
HAVE UNIFORM CONTACT
WITH FILM TO MINIMIZE GAUGE
VARIATION.

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7
SIX STATION INDEXABLE MULTISLITTER (OSCILLATING)

28
 SLITTER SECTION

 OSCILLATING TYPE.
 LONGER BLADE LIFE.
 CONTINUOUS OPERATION.
 MINIMUM STARTUP WASTAGE.
 INCREASE PRODUCTIVITY.
 METAL EXPANDING ROLLER TO REMOVE
WRINKLES ON THE FILM.

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9
 KOLSITE GROUP OF COMPANIES

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