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1 Optimize Strand Pelletizing

Optimize strand pelletizing

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Page 1: Optimize strand pelletizing

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Optimize Strand Pelletizing

Page 2: Optimize strand pelletizing

BKS 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] and a re-sharpening service center in Malaysia.

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

Page 3: Optimize strand pelletizing

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 Parameters

BKS, Beyond Expectation

Page 4: Optimize strand pelletizing

To be able to make a quick and reliable check on the optimization potentialBKS developed a model, where we distinguish the influencing parameters:

A) Fixed - The given situation [i.e. master batch]

B) Customer influenced - Parameters the user can influence [i.e. cooling bath]

C) Service Supplier influenced - Parameters the service partner can influence [i.e. re-sharpening]

Model

BKS, Beyond Expectation

Page 5: Optimize strand pelletizing

1 - Polymer CharacteristicsFixed

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

Page 6: Optimize strand pelletizing

2 – Strand Temperature

Customer influenced

Temperature 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

Page 7: Optimize strand pelletizing

3 – Strands

Customer influenced

Speed, 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.

Improvement

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

Page 8: Optimize strand pelletizing

4 – Corrosion and Wear

Fixed Customer influenced

Corrosion

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.

Wear

Has an negative influence on the cutting tool materials and can be caused by corrosionand/or abrasive polymer or ingredients.

BKS, Beyond Expectation

Page 9: Optimize strand pelletizing

5 - Cutting Gap Adjustment

Customer influenced

Adjustment of the rotor- and 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

Page 10: Optimize strand pelletizing

Customer influencedService Supplier influenced

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 majorinfluence on the cutting- and life time performance.

6 – Cutting Materials

BKS, Beyond Expectation

Page 11: Optimize strand pelletizing

7 - GeometryService Supplier influenced

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

Page 12: Optimize strand pelletizing

8 – Re-Sharpening Quality

Service Supplier influenced

Re-Sharpening Service

Not only the geometry and the wear resistance of the cutting materials are crucial forthe quality and lifetime performance. The execution of the re-sharpening has minimalsimilar 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 pelletizersoverall performance. Optimal bearing maintenance therefore is crucial.BKS, Beyond Expectation

Page 13: Optimize strand pelletizing

Summary

Conclusion

By influencing parameters - strand temperature and distribution- cutting gap adjustment- cutting materials- geometry and re-sharpening quality

we directly influence the pelletizers performance and cancontrol Maintenance, Repair and Overhaul costs.

Recommendation

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 cuttingcosts for MRO and improving overall quality.

BKS, Beyond Expectation

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Questions ?How can BKS help to control your costs

for MRO?

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Thank you for your attentionEadse de Jong

Technical Sales Manager

BKS Pelletizing & Pulverizing Technology

RUE JEAN KOCH 44800 LAMBERMONT

BELGIUM

[email protected]