1

Optimize Strand PelletizingOptimize Strand PelletizingOptimize Strand PelletizingOptimize Strand Pelletizing

BKS in a NutshellBKS in a NutshellBKS in a NutshellBKS in a Nutshell

� For more than 25 years BKS is a leading [knife] service supplier in various

businesses such as Plastics, Recycling, Textile, Packing, Food etc.

� BKS pelletizing and pulverizing technology is a relatively new developed business

with the headquarter in Belgium [Lambermont], re-sharpening service centers

in Malaysia and Indonesia.

� Our team of experts and the use of state of the art machinery offers manufacturing,

maintenance, modification, revision and [re-] sharpening of all wear parts for

pelletizing and pulverizing equipment.

� With know-how and experience of pelletizing and pulverizing technology BKS offers

customers added value.

� Our permanent search for optimal solutions, innovation and top quality guarantee

that our products and services comply above your expectation.

BKS, Beyond Expectation

1. Kind of polymer, additives, fillers, quality and homogeneity.

2. Temperature and distribution in the strands.

3. Strand speed, number of strands and cross cut surface.

4. Corrosion and wear.

5. Cutting tool material choices and combinations.

6. Cutting gap adjustment.

7. Cutting geometry and helix of the rotor knife.

8. Re-sharpening quality.

Influencing ParametersInfluencing ParametersInfluencing ParametersInfluencing Parameters

BKS, Beyond Expectation

To be able to make a quick and reliable check on the optimization potential

BKS developed a model, where we distinguish the influencing parameters:

A)A)A)A) FixedFixedFixedFixed

- The given situation [i.e. master batch]

B) Customer influencedB) Customer influencedB) Customer influencedB) Customer influenced

- Parameters the user can influence [i.e. cooling bath]

C) Service Supplier influencedC) Service Supplier influencedC) Service Supplier influencedC) Service Supplier influenced

- Parameters the service partner can influence [i.e. re-sharpening]

ModelModelModelModel

BKS, Beyond Expectation

1 1 1 1 ---- Polymer CharacteristicsPolymer CharacteristicsPolymer CharacteristicsPolymer Characteristics

FixedFixedFixedFixed

The to be processed polymer is a given The to be processed polymer is a given The to be processed polymer is a given The to be processed polymer is a given

Assuming we cannot simply change the material composition as most materials

are developed and engineered for their application.

BKS, Beyond Expectation

2 2 2 2 –––– Strand TemperatureStrand TemperatureStrand TemperatureStrand Temperature

Customer influencedCustomer influencedCustomer influencedCustomer influenced

Temperature and distribution of temperature in the strandTemperature and distribution of temperature in the strandTemperature and distribution of temperature in the strandTemperature and distribution of temperature in the strand

The higher the temperature of the strand, the less risk there is to break the material instead

of cutting it. On the other side pellets should not stick together after cutting. The temperature

is also determined by type of polymer, filler, additives and the handling of the strand before

cutting.

An important parameter of influence is the temperature homogeneity in the cross cut of the

strand. If the strand is cool on the outside but still hot [or even liquid] on the inside, negative

side effects like creation of dust, fines and shorter life time of the cutting tools will occur.

It is important to set up the granulation process in such a way that the strand temperature

is evenly divided over the cross-cut of the strand and as high as possible given the

circumstances.

BKS, Beyond Expectation

3 3 3 3 –––– StrandsStrandsStrandsStrands

Customer influencedCustomer influencedCustomer influencedCustomer influenced

Speed, number and dimensionSpeed, number and dimensionSpeed, number and dimensionSpeed, number and dimension

The number of strands and their speed have a direct influence on the number of cuts.

The number of cuts per unit of time directly influences the life time performance of the

cutting tools.

Also the diameter of the strands influences wear generated on the cutting tools.

ImprovementImprovementImprovementImprovement

Cutting material choice strongly effects cutting tool life time.

Optimal distribution of the strands along the cutting width extend cutting tool lifetime.

BKS, Beyond Expectation

4 4 4 4 –––– Corrosion and WearCorrosion and WearCorrosion and WearCorrosion and Wear

FixedFixedFixedFixed

Customer influencedCustomer influencedCustomer influencedCustomer influenced

CorrosionCorrosionCorrosionCorrosion

Has an negative influence on the cutting tool materials and can be caused by polymer,

ingredients or contaminated cooling water. The cooling water quality can be influenced.

WearWearWearWear

Has an negative influence on the cutting tool materials and can be caused by corrosion

and/or abrasive polymer or ingredients.

BKS, Beyond Expectation

5 5 5 5 ---- Cutting Gap AdjustmentCutting Gap AdjustmentCutting Gap AdjustmentCutting Gap Adjustment

Customer influencedCustomer influencedCustomer influencedCustomer influenced

Adjustment of the rotorAdjustment of the rotorAdjustment of the rotorAdjustment of the rotor---- and bed knifeand bed knifeand bed knifeand bed knife

The smaller the gap between the rotor and

bed knife, the better the cutting quality and

life time performance of the cutting tools.

The feasible adjustment depends on type

and accuracy of the pelletizer.

The optimal adjustment needs to be as precise [narrow gap] as possible

within the pelletizers limitation.

BKS, Beyond Expectation

Customer influencedCustomer influencedCustomer influencedCustomer influenced

Service Supplier influencedService Supplier influencedService Supplier influencedService Supplier influenced

Material choice for of cutting tools:Material choice for of cutting tools:Material choice for of cutting tools:Material choice for of cutting tools:

Different cutting materials and combinations for bed- and rotor knives are available.

The polymer to be cut, corrosion and wear are critical factors to be taken into consideration.

Bed knife materials: Tungsten Carbide, Ceramics, Stellite or Diamond.

Rotor knife materials: Tool- and Stainless steels, Tungsten Carbides, Stellite

and Powder Metallurgical Materials.

The choice of cutting materials should be based on the circumstances and have an major

influence on the cutting- and life time performance.

6 6 6 6 –––– Cutting MaterialsCutting MaterialsCutting MaterialsCutting Materials

BKS, Beyond Expectation

7 7 7 7 ---- GeometryGeometryGeometryGeometry

Service Supplier influencedService Supplier influencedService Supplier influencedService Supplier influenced

Geometry and helix of the rotor knife:Geometry and helix of the rotor knife:Geometry and helix of the rotor knife:Geometry and helix of the rotor knife:

The geometry [shape] and the helix of the rotor knife teeth influences the cuttingbehavior of the pelletizer.

Especially helix, rake- and relief angle have a strong influence on the cutting performance. [quality of the pellets & life time cutting tools]

Last but not least the final circular re-grindingneeds to be adjusted to the to be cut polymerfor optimal performance.

The best solution can only be found if user and service supplier work closely together.

BKS, Beyond Expectation

8 8 8 8 –––– ReReReRe----Sharpening QualitySharpening QualitySharpening QualitySharpening Quality

Service Supplier influencedService Supplier influencedService Supplier influencedService Supplier influenced

ReReReRe----Sharpening ServiceSharpening ServiceSharpening ServiceSharpening Service

Not only the geometry and the wear resistance of the cutting materials are crucial for

the quality and lifetime performance. The execution of the re-sharpening has minimal

similar influence and requires know-how.

The pelletizers construction, design/type of the bearing seat[s] and the quality level

of the maintenance have a direct influence on the concentricity of the cutting rotor.

This concentricity has a direct influence on the cutting gap, effecting the pelletizers

overall performance. Optimal bearing maintenance therefore is crucial.

BKS, Beyond Expectation

SummarySummarySummarySummary

ConclusionConclusionConclusionConclusion

By influencing parameters - strand temperature and distribution

- cutting gap adjustment

- cutting materials

- geometry and re-sharpening quality

we directly influence the pelletizers performance and can

control Maintenance, Repair and Overhaul costs.

RecommendationRecommendationRecommendationRecommendation

Execution of this model is easily applicable in every strand pelletizing production facility.

Gained information should be shared with your service partner which will result in cutting

costs for MRO and improving overall quality.

BKS, Beyond Expectation

14

Questions ?Questions ?Questions ?Questions ?

How can BKS help to control your costs for MRO?How can BKS help to control your costs for MRO?How can BKS help to control your costs for MRO?How can BKS help to control your costs for MRO?

15

Thank you for your attentionThank you for your attentionThank you for your attentionThank you for your attentionEadse de JongEadse de JongEadse de JongEadse de Jong

Technical Sales ManagerTechnical Sales ManagerTechnical Sales ManagerTechnical Sales Manager

BKS BKS BKS BKS Pelletizing & Pulverizing TechnologyPelletizing & Pulverizing TechnologyPelletizing & Pulverizing TechnologyPelletizing & Pulverizing TechnologyRUE JEAN KOCH 4RUE JEAN KOCH 4RUE JEAN KOCH 4RUE JEAN KOCH 4

4800 LAMBERMONT4800 LAMBERMONT4800 LAMBERMONT4800 LAMBERMONT

BELGIUMBELGIUMBELGIUMBELGIUM

EDEJONG@BKS.BEEDEJONG@BKS.BEEDEJONG@BKS.BEEDEJONG@BKS.BE

WWW.BKS.BEWWW.BKS.BEWWW.BKS.BEWWW.BKS.BE