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Case Study

Industry: Plastic Reprocessing

Systems Training - Make sure your speaker is on -

16/12/2013jkhkjhkj';,';Customer IntroductionSystems TrainingJune 2013George Cuneo

Started Business in 1952Offers a full line of PE and PVC products26/12/2013jkhkjhkj';,';Customer IntroductionSystems TrainingJune 2013George Cuneo

The polyethylene blown film division operates 21 blown film lines and 3 reprocessing lines36/12/2013jkhkjhkj';,';Process DescriptionSystems TrainingJune 2013George Cuneo

2010: K-Tron was called on to design and provide the material handling system for 3 new reprocessing lines to produce 10,000 lbs./hr. of plastic pellets. The reprocessing lines required several conveying and feeding systems for a wide variety of materials.K-Trons design included 10 systems and incorporated Series 2400 equipment, continuous conveying equipment, storage silos, Problend Zone Blenders, volumetric and gravimetric feeders and weigh belts.

46/12/2013jkhkjhkj';,';Process DescriptionSystems TrainingJune 2013George Cuneo

56/12/2013jkhkjhkj';,';Raw Material Handling Systems Systems TrainingJune 2013George Cuneo

SourcesGaylords

DestinationsFeeders

Conveying Rates 3 * 4,000 lbs. per hourThree vacuum sequencing systems, each conveying to:- 2 receivers for pellets/regrind- 2 receivers for fine powders(Talc & Calcium Carbonate)66/12/2013jkhkjhkj';,';Special Designs for ReceiversSystems TrainingJune 2013George Cuneo

Large Capacityallows the receiver to be used as the refill hopper/saves on headroom

Extended Cartridge additional filter area handles conveying/separating fine minerals

Vent Assembly eliminates the need for external dust collection during feeder refilldisplaced air is ducted back to the receiver via a vent valvethe receiver is used as the filter for the displaced air during feeder refill76/12/2013jkhkjhkj';,';Line Recipe Control Systems TrainingJune 2013George Cuneo

K-Visionsimple operator interface and line recipe controleach line has 2 gravimetric & 2 volumetric feeders as well as a weigh belt feederthroughput of the extruder is measured by the SWB300 which provides the master signal for the rest of the feeders on the line.main ingredients and additives are fed in preset ratios based on the master signal from the SWB30086/12/2013jkhkjhkj';,';Transfer & RecirculationSystems TrainingJune 2013George Cuneo

Silos on Load Cellsthe plastic pellets are conveyed from the extruder to one of three indoor storage silos on load cellsthis provides an accurate inventory of material in each silo & set points for the recirculation processonce the storage silo reaches set point the materials can be transferred to the blending silos or to the outdoor storage silos;Automation/PLC/HMIallows the operators to select recirculation times & destinations96/12/2013jkhkjhkj';,';Indoor Storage and Blending SilosSystems TrainingJune 2013George Cuneo

Designed and manufactured by K-Tron; 8 ft. diameter X 24 ft. tall; 25,000 pound capacity; carbon steel construction with interior epoxy coating and exterior enamel coating; silos equipped with modular bin vents106/12/2013jkhkjhkj';,';Homogenized Blend Systems TrainingJune 2013George Cuneo

ProBlendTM

Zone BlenderZone Blenderproducts were made from various off spec materialsthis caused inconsistencies in the composition of the finished pelletsthree of the silos were supplied with K-Trons ProBlend Zone Blenders20,000 lb. batches were blended before transferring homogenized finished pellets to the outdoor silos116/12/2013jkhkjhkj';,';ChallengesSystems TrainingJune 2013George Cuneo

Recycled Materialsthe source of the raw materials was recycled or off spec materials, ranging from pellets to regrind to fine powdersthis required the system to be designed to handle a wide variety of materialsthe customers tight budget and determination to maintain the scope of the project, required an innovative cost effective system design126/12/2013jkhkjhkj';,';K-Tron BenefitsSystems TrainingJune 2013George CuneoGlobal name recognition; this helped when the customer was discussing the process with extruder manufacturer headquartered in Austria. A broad range of equipment, and extensive knowledge and experience with material handling. Designing and providing a complete system; the customer only had to deal with one supplier.Providing controls for the complete material handling system, including some equipment not manufactured by K-Tron; system integration.

136/12/2013jkhkjhkj';,';Why Were We Successful?Systems TrainingJune 2013George CuneoSince the majority of the equipment could be provided from the K-Tron Process Group with very little buyout, we could offer an affordable solution.

The customers favorable history with K-Tron and the local representative provided us a clear advantage over the competition.

146/12/2013jkhkjhkj';,';What did we learn?Systems TrainingJune 2013George CuneoNot all recycling operations are outfitted with recycled equipment.

There is potential for K-Tron to provide equipment for this type of recycling/reprocessing industry.

The customer indicated satisfaction and we have received significant additional pneumatic and feeding equipment orders since the original system order.

156/12/2013jkhkjhkj';,';The EndSystems TrainingJune 2013George CuneoThank you for your time and attention.

Any questions should be directed to:George CuneoSenior Systems EngineerK-Tron, Routes 55 & 553Pitman, NJ 08071, USAwww.ktron.comgcuneo@ktron.com

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