Windsor Machines Ltd,

New developments in Blown Film Co-Extrusion

Windsor Manufactures Blown film Co-Extrusion lines

under license from Kuhne GmbH, Germany

By Manoj Prakash/ Windsor Machines Ltd

Conventionally,

Die lip 300mm , Outputs 300Kg/hr +/- Die lip 400mm , Outputs 400Kg/hr +/- Die lip 600mm , Outputs 600Kg/hr +/-

Hence, Ratio of 1:1

Maximiser Technology from Germany,

Die lip 180mm , Outputs 360Kg/hr +/- Die lip 250mm , Outputs 500Kg/hr +/- Die lip 350mm , Outputs 700Kg/hr +/-

Hence, Ratio of 1:2

MAXIMISER Design leads to :– • MORE capacity utilization on small sizes,

• MORE Blow up Ratios (BUR) upto 4 & 5,

• MORE (Enhanced) film properties,

• MORE Savings in cost per unit production,

• and MORE….

Low Neck / High Neck Operation

Elevation upto 500mm / 1200mm

Imparts Ultra High Punchure resistance

Downgauging possible with enhanced properties in Films

Wide range of films without compromise on BUR

MORE capacity utilization on small sizes,

High Neck / Low Neck Operation

Film Outputs 500+/- 50 Kg/hr On LFW 1600mm , 250mm Die lip

Film Outputs 325 +/- 25 Kg/hr On LFW 600mm, 180mm Die lip

MORE capacity utilization on small sizes,

Folienbreiten bei SmartLip DL und Maximizer

200300400500600700800900

10001100120013001400150016001700180019002000

150 160 170 180 190 200 210 220 230 240 250

Werkzeugdurchmesser (mm)

Folie

nbre

ite (m

m)

MaximizergeregeltmaximaleBreite

MaximizergeregeltminimaleBreite

Film

Wid

ths

mm

Film widths in relation to Die diameters

MORE Blow Up Ratios, (BUR)

Die Lip Diameter mm

BUR-5.0

BUR-3.4

BUR-5.0

BUR-3

Maximizer

150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600

150 160 170 180 190 200 210 220 230 240 250

Thro

ughp

ut (

kg/h

)

max

min.

Throughput In relation to Die Lip Diameters

MORE capacity utilization,

Die Lip Diameter mm

MORE Savings in use of expensive polymers

Extensive Studies reveals at least 10-15% reduction in use of expensive Polymers like metallocene when same film is produced with maximiser concept based

Hybrid Lines while still enhancing the desirable film properties,

Details can be discussed on interest,

1. Output increase + 30% in comparison to a normal dual lip air ring.

2. Faster change over because of the lip geometry.

3. Better cooling (transparent, glossy films)

4. Can be retrofitted to each machine (bottle necks need to be checked)

5. Better Tolerances due to the elongation of the films

6. Controlled shrinkage of the product

7. Faster cleaning of the die gap

8. Height adjustment can be stored in the formulations

9. Faster thread up in comparison to systems using two air rings

10. Easy to handle and to understand, no new thinking necessary

MORE merits of Maximiser concept over Double air ring Designs

MORE Savings with filler layer

• Lamination Films with 1:5:1 Layer Ratio • Possibility of upto 1:8:1 with thicker films

• Unique German sprial die design guarantees good control on layers

WINDSOR has successfully demonstrated during extensive inhouse trials to a reputed industry processor (and our customer) substantial cost savings in polymer by reducing skin layers to only 5-Microns each and with a filler layer of 25 Microns, without effecting the end-application requirement. Encouraged by a pay back of merely

less than a year this processor converted all eight numbers of 3-Layer IBC lines to 1:5:1 layer ratios at once.

LAYER RATIO Inner Layer Middle Layer Outer Layer

1 1 1

Film Output [ kgs / hr ]

600

Extruder Output [ kgs/hr ] Inner Middle Outer

200 200 200

CASE-1 Lamination Film 36 Micron, Layer ratio 1:1:1

36 Microns

Layer ratio Microns Kg per layer Cost per layer

Outer LL-C4 LD 1 12 0.33 23.5990 10

Middle LL-C4 HD 1 12 0.33 22.4840 60

Inner mLL LD 1 12 0.33 29.3290 10

Cost per kg 36 1.00 75.38INR

Polymer Price/KgLL-C4 69.755 As per Indian market conditions.mLL 88.83LDPE 80HDPE 65.875

Lamination Film

LAYER RATIO Inner Layer Middle Layer Outer Layer

1 5 1

Film Output [ kgs / hr ]

600

Extruder Output [ kgs/hr ] Inner Middle Outer

86 429 86

CASE-2 Same Lamination Film 36 Micron, Layer ratio 1:5:1

Layer ratio Microns Kg per layer Cost per layer

Outer LL-C4 LD 1 5 0.14 10.1190 10

Middle LL-C4 HD 5 26 0.71 48.1640 60

Inner mLL LD 1 5 0.14 12.5690 10

Cost per kg 36 1 70.84INR

Polymer Price/Kg

LL-C4 69.755 Savings from 1:1:1 to 1:5:1mLL 88.83 = 75.38-70.84LDPE 80 = 4.54HDPE 65.875 In %age 6%

On 1000 Tons /month Savings of whooping 4 Mill ion INR ( $80,000)

Receipe

Windsor - Kuhne Hybrid Lines

Offers

Maximiser Technology.

Following Scope 100% Imported from Principals Kuhne GmbH, Germany.

•Maximiser IBC Die Head, •Air Ring Smart Lip Maximizer,

• Cooling Blowers, •Ultrasonic Sensors/IBC Control,

Following Scope sourced from Plast Control/

Octagon, Germany. •Auto Thickness Profiling,

•Gravimetric batch blenders,

REX-1700 Hybrid

Automatic Surface Winders

Kuhne’s German Design for safety and Reliability in Operation

Combination Gap winders are on its way in near future.

A Compact Multilayer Blown

Film Co-Extrusion Line

Layout. Whole line Fit in

only 7 meters width,

Of course on special request and

additional charge for extra tower &

structure

3 Numbers of 3 Layer lines of capacities 350Kg/hr , 500Kg/hr & 600Kg/hr Operating in a compact space of

only 25 x 25 Sq Mtr Space

A 5 layer line demonstrated in operation with Nylon (Polyamide) Film production at a major exhibition In India

Multiple Pipe Extrusion for high utilization of Extrusion capacity for small pipe Sizes.

• TWIN (2-Pipe) Pipe Extrusion, In common Downstream concept

• DUAL (2-Pipe) Pipe Extrusion, In Dual downstream concept.

• QUAD ( 4-Pipe) Pipe Extrusion, In Single Downstream Concept.

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PVC Pipe Extrusion

New developments

Both Pipes of same sizes simultaneously Pipe Size Range 20-50mm, under 2.5mm thick,

Same line can also produce upto 110mm but single pipe Can be configured to produce upto 200mm single pipe also.

Full Outputs - 20mm x 1.5mm @160-170Kg/hr ;

25mm x 1.5mm@ 170-200Kg/hr ;

TWIN PIPE EXTRUSION

With Common Down Stream Concept

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Different Pipe sizes possible with Kg/Mtr in close proximity

High Outouts Models as under-

16-63mm Dual Line, upto 200Kg/hr

20-110mm Dual Line, upto 400Kg/hr

20mm x Schedule-80 @ 250-280Kg/hr

63mm x 1.5mm @ 350-400Kg/hr

63-200mm Dual Line upto 900Kg/hr 63mm x 1.5mm @ 600-630Kg/hr

90mm x 2.2mm @ 870-900Kg/hr

DUAL PIPE EXTRUSION

With Double Down Stream Concept

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QUADRAPLE PIPE EXTRUSION

With Single Down Stream

Unique Innovative Concept

Same pipe size in 4 Strands possible with high capacity Extrusion.

High Output Models as under-

16-32mm Quad Line, upto 300Kg/hr 20mm x 1.2+/- mm @ 240-260 Kg/hr

25mm x 1.8+/- mm @ 280-300Kg/hr

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Single Screw Extruders for HDPE / PPR Pipes Upto 800mm OD Standard Product.

HDPE Lines for Pipe sizes upto 1000mm/1200mmm

can be offered on request.

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•45mm with 90 kw – 300 to 330 kgs/hr •60mm with 132 kw – 500 to 550 kgs/hr •75mm with 225 kw – 750 to 825 kgs/hr •90mm with 315 kw – 1000 to 1100 kgs/hr All Extruders are with L/D as 37:1, Energy Consumption around 0.29 Units per kg, Designs Inline with Global players….

Next Generation SPEED series

Green Extruders

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Next Generation SPEED series High Capacity Single Screw Extruders

Green Extruders

Extruder SPEED 45-90

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• Inbuilt Electrical Panel with PLC, • Directly coupled Motor with Gearbox, • Compact design, • Long L/D 37:1 for good homogenization, • Optimized energy consumption,

CONPRO / INOEX make Scanner

• Measuring through ultrasonic sensors.

• Measuring parameters are Wall Thickness, Eccentricity, Inner Diameter, Outer Diameter & Ovality

• Flange mounted to the back side of tank

• Easy assembly, Short change over time

• Excellent cost / performance ratio

HDPE LARGE PIPE EXTRUSION LINES

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Thank You