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Feedingsystems
Rotors
Twin screw extruder sensor
Single screwextruder sensors
Rheocord 300p
Rheocord 300p + Mixer/Extruder Rheocord 300p + Mixer/Extruder SSensorensor
= = PolyLab PolyLab SystemSystem
Mixer sensors
Screws Dies Postex
2
PolyLab SystemPolyLab System
3
4
PolyLab PolyLab SystemSystem
• Laboratory Mixers :
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Laboratory MixersLaboratory Mixersmeasuring principle measuring principle
3 2
Shearing of a test sample
in a heated mixing chamber
with counter rotating rotors
Test results:
Torque
Melt temperature
6
Mixer -Mixer - Rheogram Rheogram
Temperature
Energy
Torque
7
Rotors for Rheomix mixersRotors for Rheomix mixers
Banbury rotors
Roller rotors
Cam rotors
Sigma rotors
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Mixer TestMixer Test
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Influence of the mixer load on PVC fusionInfluence of the mixer load on PVC fusion
m: 60 g
ApplicationApplication
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m: 66 g
Influence of the mixer load on PVC fusionInfluence of the mixer load on PVC fusion
ApplicationApplication
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Change from Mixer to ExtruderChange from Mixer to Extruder
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PolyLab PolyLab SystemSystem
• Single Screw Extruders :
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Rheomex single screw extruderRheomex single screw extruder
Feeding coolingSensor ports
(2 standard, others optional)Screw back-pressuresensor (optional)
collars for heating and cooling
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Rheomex ApplicationRheomex Application
Extruders are generally used to:
• transport material
• plasticize
• compress
• homogenize
• compound
• vent
• chemical reaction
• building up pressure
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Rheomex ApplicationRheomex Application
Measuring of process variables:
• torque
• melt temperature
• melt pressure
• mass flow
Optimizing of process parameters:
• extruder speed
• temperature profile
• pressure
• screw design
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Screws for single screw extrudersScrews for single screw extruders
Conical Core Screw
Standard MeteringScrew
Short MeteringScrew
Venting Screw
Mixing Screw
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Pressure built-up in a single screw extruderPressure built-up in a single screw extruder
barrel - length [L/D]
pressureP2
P3P4
P1
P5
11 14,5 20,5 24,50
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PolyLab PolyLab SystemSystem
• Twin Screw Extruders :
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Twin-screw extruders CTW100 and PTW25Twin-screw extruders CTW100 and PTW25
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Feeding of material into Feeding of material into twin-screw extruderstwin-screw extruders
Co-rotatingCo-rotating Counter-rotatingCounter-rotating
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Rheomex CTW100pRheomex CTW100p
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Rheomex CTW100pRheomex CTW100p
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Screw geometries for CTW100p extruderScrew geometries for CTW100p extruder
Venting screw
Intensive mixing screw
Standard screw
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Rheomex CTW100pRheomex CTW100p
25
Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 11
• Plasticising
• Mixing
• Homogenising
• Cooking
• Gelling
• Degassing of momomers, oligomers, solvents etc.
• Concentrating of polymer solutions
• Modifying by incorporation of plasticizers, cross-linking agents, flame retardants, UV-stabilisers, etc.
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• Incorporation of fillers and reinforcing agents such as: wood flour, talc, glass fibres etc.
• Alloying of polymers
• Polycondensation, Polyaddition and Polymerization of polymers
• Chemical reactions
• Dispersing of pigments and additives
• Breaking down of high molecular particles
Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 2 2
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Rheomex PTW16pRheomex PTW16p
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Rheomex PTW16pRheomex PTW16p
Hinged barrel for easy handlingHinged barrel for easy handling
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flexible screw configurationflexible screw configuration
Rheomex PTW16pRheomex PTW16p
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Compounding + RheologyDegassing of i.e. solvents etc.Modifying by incorporation of plasticizers, cross-linking agents, flame retardants, UV-stabilisers, etc.Incorporation of fillers and reinforcing agents such as:
wood flour, talc, glass fibres etc.Breaking down of high molecular particles
Applications:Applications:
Rheomex PTW16pRheomex PTW16p
31
Screws:
• Segmented, with slip-on elements, allowing variable configuration
• Screw diameter: 16 mm• Corotating, intermeshing
screws• Screw shafts:
– Design: hexagonal– Material: Heat treated,
abrasion resistant
Technical SpecificationsTechnical Specifications
Rheomex PTW16pRheomex PTW16p
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Rheomex PTW16pRheomex PTW16p
Screw elements:Screw elements:
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Rheomex PTWRheomex PTW2424pp
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Rheomex PTW24pRheomex PTW24p
35
SidefeedingSidefeeding
Segmented screwSegmented screw
Extruder barrel: segmented and hingedExtruder barrel: segmented and hinged
Rheomex PTW24p – Advantages:Rheomex PTW24p – Advantages:
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Rheomex PTW25Rheomex PTW25
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Rheomex PTW25 withRheomex PTW25 with PolyLab PolyLab SystemSystem
MasterSlaveHeat-exchanger
PolyLab System
Rheomex PTW25
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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTW25PTW25Screw segments 1/3Screw segments 1/3
Conveying elementsConveying elements::
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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTW25PTW25
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557- 5001 Rheomex PTW 25 x 20D557- 5001 Rheomex PTW 25 x 20D
Barrel segments:
Feeding barrel 4DClosed barrel 6DOpen barrel 6DMeasuring barrel 4D
Application:
Melting of polymersVenting
FeedingVenting
41
Barrel segments:
Feeding barrel 4DClosed barrel 6DCombi barrel 4DClosed barrel 4DOpen barrel 6DOpen barrel 4DMeasuring barrel 4D
557- 5031 Rheomex PTW 25 x 32D557- 5031 Rheomex PTW 25 x 32DPProduction of roduction of MMasterbatchasterbatch
M a t e r i a l S h a p e Q u a n t i t y i n%
P P , P E , P E T ,P C , P A , e t c .
p o w d e r o rg r a n u l a t e s
6 0 - 8 0
p i g m e n t s p o w d e r 2 0 - 4 0
Side-feeding (pigments)
Venting(vacuum)
Venting(atmosphere)
Venting(atmosphere)
Feeding(polymer)
42
Screw configuration Rheomex PTW25/38Screw configuration Rheomex PTW25/38
FFor typical food extrusionor typical food extrusion
25/1/2
37.5/1/2
37.5/1/2
37.5/1/2
37.5/1/2
37.5/1/2
25/1/2
25/1/2
25/1/2
ZB
-37.5
25/1/2
25/1/2
E-K
B-25/L
I
25/1/2
25/1/2
E-K
B-25/L
I
25/1/2
25/1/2
E-K
B-37.5/L
I
25/1/2
25/1/2
E-K
B-37.5/L
I
E-K
B-37.5/L
I
37.5/1/2
37.5/1/2
37.5/1/2
37.5/1/2
37.5/1/2
25/1/2
25/1/2
25/1/2
Screw
tip
Dry-BlendLiquidsSteam
FeedingMixing/HydrationCookingVentingCooling
43
Masterbatch productionMasterbatch production
Vac
uu
m
Pre
mix
Atm
osp
her
e
Parallel twin-screwWater bath Pelletizer
44
• Feeding systems :
PolyLab PolyLab SystemSystem
45
Metering FeederMetering Feeder
Motor with gearbox
StandardHopper
Closure for Cleaning
glass window
interchangeablefeeding tube
Metering screw
Extruder
PPrinciple sketchrinciple sketch::
46
Metering FeederMetering Feeder
47
• Accurate dosing of powder
• Accurate dosing of pellets
• Starved feeding to enable venting
• Starved feeding to reduce torque
• Production of masterbatches
• Feeding of parallel twinscrew extruders
ApplicationApplication::
Metering FeederMetering Feeder
48
• Extruder Application :
PolyLab PolyLab SystemSystem
49
Cast film applicationCast film application
• Instruments:
• Rheocord 300p
• Extruder (single- or twin-screw extruder)
• Screws
• Sheet & ribbon die
• Sheet & ribbon take-off
• Pressure sensor
• (Screen package)
• (OQT 512)
• Application:
• Small production of films
• Testing the processabillity
• Testing of additives• Testing and optimisation of
processing conditions
• Results:
• Fish-eye testing
• Pigment distribution
• Surface quality
• Tensile testing
• Weathering
50
Sheet and Ribbon DieSheet and Ribbon Die
Die width:
25/50/100/150 mm
Die gap:
adjustable(standard: 0.2-1.2 mm)
fixed die gap on request
Max. temperature: 360°C
1 measuring port
51
Sheet and Ribbon Take OffSheet and Ribbon Take Off
polished and temperablesteel rollers
rubber rollers
circulator
waterbathMotor
adjusting the gap
take-uproller
52
PVC sheets: good & bad
Cast film applicationCast film application
53
Cast film applicationCast film application
54
Blown film applicationBlown film application
• Instruments:Rheocord 300pExtruder (single- or twin-screw extruder)ScrewsBlown film dieCooling ringBlown film take-offPressure sensor(Screen package)(OQT 512)
• Application:small production of filmsTesting the processability of compoundsTesting of additivesTesting and optimisation of processing conditions
• Results:Fish-eye testingPigment distributionsurface quality
55
557- 3175 Blown 557- 3175 Blown FFilm ilm DDieie
• Ring diameter 25mm (35mm)
• Pin diameter 24mm (34mm)
• Gap width 0-0.8 mm
• Measuring ports 2
• Max. temperature 480°C
Air
adjustable die gap
56
PolyLab System with extruder
Blown film take-off
PolyLabPolyLab blown-film combination blown-film combination
57
PolyLabPolyLab blown-film combination blown-film combination
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PolyLabPolyLab blown film combination blown film combination
PolyLab System with extruder
Lightning Device
CCD-CameraBlown film take off
WWith optical testing unit OQTith optical testing unit OQT
59
Blown film take-off with built in camera systemBlown film take-off with built in camera system
60
OQT- Graphical display of OQT- Graphical display of defectsdefects
61
OQT- Graphical display of the dataOQT- Graphical display of the data and defects and defects
62
OQT- Graphical display of the dataOQT- Graphical display of the data
63
CompoundingCompounding
• Instruments:• PolyLab RC300p• Rheomex twin-screw
extruder• extruder Screw(s)• Pressure sensor(s)• (Screen package)• Rod die (horizontal or
vertical) or Multistrand die• Waterbath• Pelletizer
Test results:
• Testing of the processability of polymer compounds
• Testing of additives
• Testing and optimisation of processing conditions
• small production of masterbatches
64
557- 3235 557- 3235 Horizontal rod dieHorizontal rod die
• Application:Universal die for extrusion tests
• manufacturing of polymer strands for the production of pellets.
• Nozzles available from: 1mm - 6mm
• Two sensor ports for pressure- and temperature-measurement
65
557- 3150 557- 3150 Vertical rod dieVertical rod die
• Application:Universal die for extrusion tests
• manufacturing of polymer strands for the production of pellets.
• Nozzles available from: 1mm - 6mm
• Two sensor ports for pressure- and temperature-measurement
66
557- 3180 557- 3180 Multistrand dieMultistrand die
Application:Universal die for extrusion tests with higher output
manufacturing of polymer strands for the production of pellets.
Strand diameter: 3 mm (others on request)
67
CompoundingCompounding