single screw extruders

alpha

Index

� Extruder models

� Applications

� Basic and optional equipment

� Technical data

� Processing unit

� Screw designs / output list

� SecuRe functionality

� Interfaces and synchronization

� Highlights

� Customer benefits

� Summary

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Extruder models

alpha

� alpha 45-25B alpha 45-28G

� alpha 60-25B alpha 60-28G

� alpha 75-25B alpha 75-30G

ProtonA

� proton.A 45-25B proton.A 45-28G

� proton.A 60-25B proton.A 60-28G

� proton.A 75-25B proton.A 75-30G

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Application I

Technical profiles

� Automotive profiles (car seat), PP, HDPE, LDPE, PC, PS, ABS

� Support profiles for concrete application, PVC-regrind

Co-extruded profiles

� Price tag boarder, transparent/rigid PVC

� Roller shutter, rigid/soft PVC

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Application II

Technical profiles

� Light applications, PC, transp. PVC

Small tubes and pipes

� coextruded (Hula Hoop) PE

� corrugated PA, PP, PE, PVC

� roughened (perforated) pipe (PVC regrind, micronized)

� Medical grade pipes

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Basic and Optional equipment

� Smooth or grooved intake part

� Direct flanged AC drive

� 2-stage gear box

� Rupture disc (safety device)

� Sliding hopper

� Hour meter

� BC- SecuRe control (relay)

� 3x 400V/230V+PE+N/50 Hz

� Drive display “remote control” with 15m cable

� 3-colour LED warning light

� Synchronization interface(discrete or CanBus)

� Mass pressure & temperature sensor

� UPS

(uninterruptible power supply

for controls)

� Gravimetric interface

(screw speed)

� Leveling pads or height adjustable rolls

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Basic Optional

Technical data

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Technical data unit alpha 45 alpha 60 alpha 75

motor power kW 18 33 75

screw speed (nom./max) U/min 97/148 81/124 100/120

screw diameter Unit 45 60 75

L/D (smooth/grooved) - 25/28 25/28 25/30

heating/cooling zones - 4/4 4/4 4/4

Adapter zone kW 5,5 5,5 5,5

Tooling zones kW 4 x 5,5 4 x 5,5 8 x 5,5

installed heating capacity kW 8,8 16 20

Installed back pressure 1) bar 360 360 360

1) back pressure defined through rupture disc; higher pressures on request

Processing unit

Advantages smooth(B) feed zone:

� Highest processing flexibility

� For almost each polymer granulate

� Simple operation

Advantages grooved (G) feed zone:

� Constant specific output performance

� High output per screw revolution

� Back pressure independent – PFT-system

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0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0 50 100 150

spec

ific

ou

tpu

tkg

/rp

mh

screw speed rpm

Output comparison between smooth and grooved processing unit based on:

alpha 45 and 150 bar tool back pressure

25 L/D smooth intake

28 L/D grooved intake

Processing unit

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Rupture disc

Rupture disc - mechanical safety device

Rupture disc

� Bursting pressure 380 bar

� Tolerance: +/- 5% (360 to 400bar)

� Melt pressure alarm limit 330 bar

� Optional: rupture disc for higher pressure available on request

Screw design

� 3 zone screw (for multitude technical polymers)

� 5 zone screw with mixing elements PE, PS, PET, ABS

� 3 zone screw with shear section soft-PVC, TPE, PP

� 5 zone screw with short mixing elements PVC-pellets

� Barriere & Maddock screw for grooved version PE, PP

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25 L/D screws

28 or 30 L/D screw

Output rates

Notes:� (-) on demand: output rates to be defined

� Minimum output rates are appr. 80% below the warranty values

� Polymers based on battenfeld-cincinnati material reference list

� Output rates for 25 L/D depend on: tool back pressure, pellet size, screw design

� Output rates at 300 bar are appr. 20 % less than at 100 bar

� PA1: recommendation: bimetallic barrel + stainless steel screw � special proton.a version

� alpha B and G is not recommended for PUR= TPU=TPE-U

� pre-drying is necessary for nearly all technical polymers

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Material alpha 45-25 60-25 75-25 45-28 60-28 75-30

HDPE kg/h 60 90 130 70 100 300

LDPE kg/h 45 60 110 40 70 250

PP-R kg/h 45 60 80 50 80 250

ABS kg/h 60 85 140 60 90 -

PS kg/h 50 80 140 - - -

PC/ABS kg/h 60 90 180 - - -

PC kg/h 40 60 120 no no no

ASA; POM kg/h 40 60 120 - -

TPE-S,TPE-V kg/h 40 60 100 50 80 -

PA61, 111, 121; PET kg/h 30 50 100 no no no

PPO kg/h 40 70 140 - - -

soft-PVC kg/h 65 110 140 65 110 200

Rigid-PVC kg/h 50 80 150 no no no

SecuRe functionality

battenfeld-cincinnati controller:

� High precision PID temperature controller

� Self-tuning capability

� Integrated on/off function

3- color LED light - is active if:

� green if extruder is in operation

� yellow if there are some problems with control voltage or barrel cooling

� red if barrel or tooling zone are too cold, emergency stop is pressed, melt pressure is too high, control reports internal fault

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Operator panel functionality

Remote control

� Motor display status:

� „stop“ „run“ „ready“

� Motor load in %

� Set screw speed in rpm

� Actual screw speed in rpm

� Display back light

� Display language „English“

� Motor speed control; 0.1 rpm steps

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alpha Interfaces

Standard analogue (X6) interfaces for:

� Emergency stop

� Set value, actual screw speed value (0…10VDC = 0-100%)

� Start/stop (only in slave mode)

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(option) E27-CANBus in/out(only in slave mode)

hour meter

power receptacles with switch (3x400VAC)

alpha synchronization

Possible synchronization

� Coex application

Via 0-10V � if both alpha (master & slave) are based on relays control (SecuRe)

Via Euromap � if master has a computer control; slave can be a SecuRe

� Extruder screw speed

alpha screw speed (+/-) synchronization via gravimetric signal

� Haul off speed

Haul off synchronization via extruder screw speed only ifthe downstream can convert the 0-10V DC extruder speed signal

Impossible synchronization

� alpha (SecuRe control) can not operate as CANBUS Master

� alpha does not support Euromap 27 communication with downstream equipment

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HighlightsCostumer benefit

Customer benefits

5 clear and precise arguments!

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2. Performance

1. Quality

3. Flexibility

4. Reliability

5. Price

Customer benefits

Manufactured with best European materials

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1. Quality

Mechanical transmission

� No belts, no slip, exact speed control – A.C. Motor

� Maintenance free

� Two-stage gear

� Integrated gear-coupling- motor arrangement

� Minimum space requirements

Thermoregulation unit

� Ceramic heater bands

� Even temperature distribution

� Air cooling distributor

� Stainless steel execution

Temperature control

� 4 barrel heating/cooling zones

� 4+1 tool heating zones (8+1 for alpha 75)

� High precision PID

� Temperature controller with self-tuning capability

Control panel A.C. motor

� Remote control panel for key functions

New sliding hopper with 3 positions

� Stainless steel

� Control material level

� Simple and fast to use

Customer benefits

Best performance with alpha family

� Maximum productivity; wide range of polymers & applications

� Each alpha can operate with perfect quality at high output

� Examples for alpha 60-25B performing above output table

� uPVC profiles: some customers are running up to 100 kg/h

� soft PVC: up to 140 Kg/h

� Corrugated pipes: up to 114 Kg/h – 47,5 m/min with DN 16

� LDPE pipes: up to 80 Kg/h

� It is possible to process from 10 up to 300 kg/h with different materials for various extrusion applications:

� profile, pipes, hoses, coextrusion, rods, medical tubes, seals, cables etc…

� Plug and produce:� immediate start-up

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2. Performance

Customer benefits

alpha flexibility = highest modularity on the market !!!

20 different basic configurations + options & different screws

to meet customer needs

� alpha 45

25B or 28G � proton.A 25B / proton.A28G – Bimetallic – PA.version - (* special 30G )

� alpha 60

25B or 28G � proton.A 25B / ProtonA 28G – Bimetallic – PA.version - (* special 30G )

� alpha 75

25B or 30G � proton.A 25B / proton.A 30G – Bimetallic – PA.version

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3. Flexibility

Customer benefits

customer asks for an extruder

� able to produce with almost any material, for all kinds of products atmaximum production capacity, performing also at low speed and withexcellent plastification performance…

the answer is

“alpha”

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3. Flexibility

customer asks for an extruder

� as complete machine with all the necessary components, thermoregulation, safety andalarms, with melt temperature and pressure sensors. A machine which also offers thepossibility to be used as a co-extruder, which can be mounted on wheels and whichoffers the possibility of having a remote control panel in one hand while optimizing theprocess…

the answer is

“alpha”

Important for you

� fast on time delivery, constant production quality, without interruptions and without loss in production

���� alpha provides the reliability customers are looking for!

Reliability for many years in production!!!

� Quality

� Strong construction

� Simple to use

� Large range of processed products

� Minimum maintenance

� Spares parts easy to find and always available

� Wide range of materials and applications

� Many accessories to complete an extrusion line

Over 700 alpha produce worldwide

The best evidence for customers confidence

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Customer benefits

4. Reliability

Fixed and equal price all over the world

� Maximum correctness for all customers

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alpha 45-25 60-25 75-25* 45-28 60-28 75-30*

Price € 29.900 34.900 58.870 37.900 45.900 70.870

Basic extruder prices incl. screwNot included options: Melt temperature- & pressure measuring,

UPS (controls voltage drop protection), UL execution * “alpha75” with 8+1 tooling zones and frequency converter

At first competing products may look interesting,but it is important to compare the offers and the real production agility!

Customer benefits

5. Price

Summary

alpha Extruder:

� the right choice for technical profiles and small pipes

� 3 extruder sizes with smooth or grooved intake zone

� Multiple screw designs for your materials

Extruder on stock / shortest delivery time

Cash & carry – plug & produce

Best price/performance ratio

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Successful through successful customers.

Long-term profitable growth.

leading solutions.