Efficient colour compounding

New Technologies and Possibilities for Flexible and High Efficient Production

www.roc-gmbh.com © 2015 ROC GmbH

Efficient colour compounding

Ø Efficiency

Ø Quality

Ø Monitoring

Flexible and Efficient Compounding © 2013 ROC GmbH 2

Efficiency

Ø Maximum usage of production capacity

Ø  Less downtime

Ø  Fast colour changes

Flexible and Efficient Compounding © 2013 ROC GmbH 3

Quality

Ø  Less customer complaints

Ø  Less off-spec production

Ø Operator awareness

Flexible and Efficient Compounding © 2013 ROC GmbH 4

Monitoring

Ø Continously monitoring of the production

Ø Continously monitoring of the process

Ø  Immediate reaction possible

Flexible and Efficient Compounding © 2013 ROC GmbH 5

How can we achieve this while

the production is running?

Flexible and Efficient Compounding © 2013 ROC GmbH 6

Flexible and Efficient Compounding © 2013 ROC GmbH

Fast Color Corrections with ROC-ColorControl

CIE-Lab/Spectrum

ROC-QualityReport ROC-ValueAddProgram

M

Dryer Classifier

Pelletizer Extruder

ROC-ColorDosage: 6 dosage units per line

M

ROC-ColorControl Precision color measurement on pellets in 2.5 minutes ROC-ContiSampling

Full automatic sample taking and transport

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Flexible and Efficient Compounding © 2013 ROC GmbH

ROC-ColorControl Color Measurement on Pellets

Ø  High precision color measure-ment: CIE-Lab & Spectrum.

Ø  Cutting defects and stress whitening at pellet edges do not disturb color measurement.

Ø  Spectroscopic image processing. Ø  Full automatic operation. Ø  Self calibrating. Self monitoring. Ø  Sample temperature control. Ø  Fast: 25 measurements/hour.

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Flexible and Efficient Compounding © 2013 ROC GmbH

ROC-ColorControl: Repeat Accuracy Results (25 repetitions with pellet position changes)

Sample L a b Segmentation Image Yellow PC 76.32 15.00 69.96

Standard deviation 0.017 0.029 0.042

Green ABS 41.02 -27.84 13.12

Standard deviation 0.016 0.038 0.039

Red PA GF30 45.11 43.80 23.94

Standard deviation 0.059 0.045 0.051

White PVC 91.29 -1.16 3.12

Standard deviation 0.018 0.009 0.021

Blue PC 45.78 -9.84 -36.66

Standard deviation 0.015 0.015 0.015

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Flexible and Efficient Compounding © 2013 ROC GmbH

ROC-ColorControl: Repeat Accuracy Results (25 repetitions with pellet position changes)

Sample L a b Segmentation Image Mid Grey PP 01 47.13 0.93 1.46

Standard deviation 0.028 0.005 0.008

Black PP 02 25.69 -0.18 -0.71

Standard deviation 0.045 0.005 0.010

Mid Grey PP 02 48.34 0.91 4.96

Standard deviation 0.032 0.000 0.006

Black PP 03 26.63 -0.22 -0.94

Standard deviation 0.019 0.003 0.008

Mid Grey PP 03 43.43 -2.87 -2.58

Standard deviation 0.033 0.005 0.005

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ROC-ContiSampling Full Automatic Pellet Sampling

Ø  Sampling duration 60s up to 20min

Ø  Up to 6 lines

Ø  Immediate sampling possible at any time

Ø  Flexible sampling point

Ø  Per line one carrier (no cross contamination possible)

Ø  No loss of material

Flexible and Efficient Compounding © 2013 ROC GmbH 11

© 2013 ROC GmbH

ROC ColorDosage for Shading

Single Pigment Concentrates (SPCs)

ROC-ColorDosage 6 Gravimetric

Dosage Feeders

Extruder Inlet Flexible and Efficient Compounding

Existing Feeders

Only small quantities needed for shading: 0.2 – 3 kg/h

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© 2013 ROC GmbH

ROC ColorDosage for Flexibility

Single Pigment Concentrates (SPCs)

ROC ColorDosage 6 Gravimetric

Dosage Feeders

Extruder Inlet Flexible and Efficient Compounding

Existing Feeders

Typical dosage quantity: 2 - 4% of extruder throughput

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Ø Option: flight conveying = continuous pellet transport

© 2013 ROC GmbH

ROC ColorDosage System

Flexible and Efficient Compounding

Ø 6 gravimetric dosage units

Ø Tool-free cleaning

Ø Automatic refilling

Ø For online shading and flexible production

more yellow

more red

darker

more green

more blue

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15 © 2013 ROC GmbH

Fast Color Corrections: 28 Minutes, in Spec.

1. Too blue: Add yellow shading

2. Now too green: add red shading

3. Reduce yellow

ü Off-spec In-spec

Confirmation with color laboratory plaque: o

ü

ü

Shading quantity

Extruder capacity

Flexible and Efficient Compounding © 2013 ROC GmbH 16

Fast Color Changes: 3 Grey Shades: A-B-C-A Changeover Duration: 5-8 Minutes

Online Color Changeover

Ø Color changeover from dark to light with running machine in < 15 minutes possible.

Ø No cleaning needed for modern underwater pelletising systems.

Ø Simple reworking of transition pellets.

Flexible und effiziente Compoundierung © 2013 ROC GmbH 17

Benefits

Ø Efficiency w  Increase of the production capacity w  Less downtime w  Fast Color Changes

Ø Quality w  Less customer complaints w  Less off-spec w  Operator awareness

Flexible and Efficient Compounding © 2013 ROC GmbH 18

Benefits

Ø Monitoring w  Continously monitoring of the production w  Immediate reactions possible w  Continously monitoring of the process

Ø Possibility to produce smaller lots

Flexible and Efficient Compounding © 2013 ROC GmbH 19

Flexible and Efficient Compounding © 2013 ROC GmbH

Higher Efficiency Example order: 3000 kg, 500 kg/h

0 1 2 3 4 5 6 7 8 9

0 1 2 3 4 5 6 7 8 9 10

hours

hours

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Color Plaque

Production in specification: 6h * 500kg/h = 3000kg

Pellet Color Meas. Color Plaque Dosage Correction

Premix Correction

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6,7

Standard Process

ROC Shading Correction Process

Time saving Production in specification: 6h * 500kg/h = 3000kg

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Thank you for listening! Contact:

Business & Technology Consulting Dipl.-Eng. Manfred H. Buechel

+4915256824345 ManfredBuechel@me.com

Flexible and Efficient Compounding © 2013 ROC GmbH 21