1 Feeding systems Rotors Twin screw extruder sensor Single screw extruder sensors Rheocord 300p Rheocord 300p + Mixer/Extruder Sensor = PolyLab System

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Feedingsystems

Rotors

Twin screw extruder sensor

Single screwextruder sensors

Rheocord 300p

Rheocord 300p + Mixer/Extruder Rheocord 300p + Mixer/Extruder SSensorensor

= = PolyLab PolyLab SystemSystem

Mixer sensors

Screws Dies Postex

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PolyLab SystemPolyLab System

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PolyLab PolyLab SystemSystem

• Laboratory Mixers :

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Laboratory MixersLaboratory Mixersmeasuring principle measuring principle

3 2

Shearing of a test sample

in a heated mixing chamber

with counter rotating rotors

Test results:

Torque

Melt temperature

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Mixer -Mixer - Rheogram Rheogram

Temperature

Energy

Torque

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Rotors for Rheomix mixersRotors for Rheomix mixers

Banbury rotors

Roller rotors

Cam rotors

Sigma rotors

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Mixer TestMixer Test

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Influence of the mixer load on PVC fusionInfluence of the mixer load on PVC fusion

m: 60 g

ApplicationApplication

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m: 66 g

Influence of the mixer load on PVC fusionInfluence of the mixer load on PVC fusion

ApplicationApplication

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Change from Mixer to ExtruderChange from Mixer to Extruder

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• Single Screw Extruders :

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Rheomex single screw extruderRheomex single screw extruder

Feeding coolingSensor ports

(2 standard, others optional)Screw back-pressuresensor (optional)

collars for heating and cooling

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Rheomex ApplicationRheomex Application

Extruders are generally used to:

• transport material

• plasticize

• compress

• homogenize

• compound

• vent

• chemical reaction

• building up pressure

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Rheomex ApplicationRheomex Application

Measuring of process variables:

• torque

• melt temperature

• melt pressure

• mass flow

Optimizing of process parameters:

• extruder speed

• temperature profile

• pressure

• screw design

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Screws for single screw extrudersScrews for single screw extruders

Conical Core Screw

Standard MeteringScrew

Short MeteringScrew

Venting Screw

Mixing Screw

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Pressure built-up in a single screw extruderPressure built-up in a single screw extruder

barrel - length [L/D]

pressureP2

P3P4

P1

P5

11 14,5 20,5 24,50

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• Twin Screw Extruders :

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Twin-screw extruders CTW100 and PTW25Twin-screw extruders CTW100 and PTW25

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Feeding of material into Feeding of material into twin-screw extruderstwin-screw extruders

Co-rotatingCo-rotating Counter-rotatingCounter-rotating

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Rheomex CTW100pRheomex CTW100p

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Screw geometries for CTW100p extruderScrew geometries for CTW100p extruder

Venting screw

Intensive mixing screw

Standard screw

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Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 11

• Plasticising

• Mixing

• Homogenising

• Cooking

• Gelling

• Degassing of momomers, oligomers, solvents etc.

• Concentrating of polymer solutions

• Modifying by incorporation of plasticizers, cross-linking agents, flame retardants, UV-stabilisers, etc.

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• Incorporation of fillers and reinforcing agents such as: wood flour, talc, glass fibres etc.

• Alloying of polymers

• Polycondensation, Polyaddition and Polymerization of polymers

• Chemical reactions

• Dispersing of pigments and additives

• Breaking down of high molecular particles

Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 2 2

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Rheomex PTW16pRheomex PTW16p

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Hinged barrel for easy handlingHinged barrel for easy handling

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flexible screw configurationflexible screw configuration


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Compounding + RheologyDegassing of i.e. solvents etc.Modifying by incorporation of plasticizers, cross-linking agents, flame retardants, UV-stabilisers, etc.Incorporation of fillers and reinforcing agents such as:

wood flour, talc, glass fibres etc.Breaking down of high molecular particles

Applications:Applications:


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Screws:

• Segmented, with slip-on elements, allowing variable configuration

• Screw diameter: 16 mm• Corotating, intermeshing

screws• Screw shafts:

– Design: hexagonal– Material: Heat treated,

abrasion resistant

Technical SpecificationsTechnical Specifications


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Screw elements:Screw elements:

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Rheomex PTWRheomex PTW2424pp

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SidefeedingSidefeeding

Segmented screwSegmented screw

Extruder barrel: segmented and hingedExtruder barrel: segmented and hinged

Rheomex PTW24p – Advantages:Rheomex PTW24p – Advantages:

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Rheomex PTW25Rheomex PTW25

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Rheomex PTW25 withRheomex PTW25 with PolyLab PolyLab SystemSystem

MasterSlaveHeat-exchanger

PolyLab System

Rheomex PTW25

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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTW25PTW25Screw segments 1/3Screw segments 1/3

Conveying elementsConveying elements::

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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTW25PTW25

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557- 5001 Rheomex PTW 25 x 20D557- 5001 Rheomex PTW 25 x 20D

Barrel segments:

Feeding barrel 4DClosed barrel 6DOpen barrel 6DMeasuring barrel 4D

Application:

Melting of polymersVenting

FeedingVenting

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Barrel segments:

Feeding barrel 4DClosed barrel 6DCombi barrel 4DClosed barrel 4DOpen barrel 6DOpen barrel 4DMeasuring barrel 4D

557- 5031 Rheomex PTW 25 x 32D557- 5031 Rheomex PTW 25 x 32DPProduction of roduction of MMasterbatchasterbatch

M a t e r i a l S h a p e Q u a n t i t y i n%

P P , P E , P E T ,P C , P A , e t c .

p o w d e r o rg r a n u l a t e s

6 0 - 8 0

p i g m e n t s p o w d e r 2 0 - 4 0

Side-feeding (pigments)

Venting(vacuum)

Venting(atmosphere)

Venting(atmosphere)

Feeding(polymer)

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Screw configuration Rheomex PTW25/38Screw configuration Rheomex PTW25/38

FFor typical food extrusionor typical food extrusion

25/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

25/1/2

25/1/2

25/1/2

ZB

-37.5

25/1/2

25/1/2

E-K

B-25/L

I

25/1/2

25/1/2

E-K

B-25/L

I

25/1/2

25/1/2

E-K

B-37.5/L

I

25/1/2

25/1/2

E-K

B-37.5/L

I

E-K

B-37.5/L

I

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

25/1/2

25/1/2

25/1/2

Screw

tip

Dry-BlendLiquidsSteam

FeedingMixing/HydrationCookingVentingCooling

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Masterbatch productionMasterbatch production

Vac

uu

m

Pre

mix

Atm

osp

her

e

Parallel twin-screwWater bath Pelletizer

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• Feeding systems :


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Metering FeederMetering Feeder

Motor with gearbox

StandardHopper

Closure for Cleaning

glass window

interchangeablefeeding tube

Metering screw

Extruder

PPrinciple sketchrinciple sketch::

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• Accurate dosing of powder

• Accurate dosing of pellets

• Starved feeding to enable venting

• Starved feeding to reduce torque

• Production of masterbatches

• Feeding of parallel twinscrew extruders

ApplicationApplication::


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• Extruder Application :


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Cast film applicationCast film application

• Instruments:

• Rheocord 300p

• Extruder (single- or twin-screw extruder)

• Screws

• Sheet & ribbon die

• Sheet & ribbon take-off

• Pressure sensor

• (Screen package)

• (OQT 512)

• Application:

• Small production of films

• Testing the processabillity

• Testing of additives• Testing and optimisation of

processing conditions

• Results:

• Fish-eye testing

• Pigment distribution

• Surface quality

• Tensile testing

• Weathering

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Sheet and Ribbon DieSheet and Ribbon Die

Die width:

25/50/100/150 mm

Die gap:

adjustable(standard: 0.2-1.2 mm)

fixed die gap on request

Max. temperature: 360°C

1 measuring port

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Sheet and Ribbon Take OffSheet and Ribbon Take Off

polished and temperablesteel rollers

rubber rollers

circulator

waterbathMotor

adjusting the gap

take-uproller

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PVC sheets: good & bad


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Blown film applicationBlown film application

• Instruments:Rheocord 300pExtruder (single- or twin-screw extruder)ScrewsBlown film dieCooling ringBlown film take-offPressure sensor(Screen package)(OQT 512)

• Application:small production of filmsTesting the processability of compoundsTesting of additivesTesting and optimisation of processing conditions

• Results:Fish-eye testingPigment distributionsurface quality

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557- 3175 Blown 557- 3175 Blown FFilm ilm DDieie

• Ring diameter 25mm (35mm)

• Pin diameter 24mm (34mm)

• Gap width 0-0.8 mm

• Measuring ports 2

• Max. temperature 480°C

Air

adjustable die gap

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PolyLab System with extruder

Blown film take-off

PolyLabPolyLab blown-film combination blown-film combination

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PolyLabPolyLab blown-film combination blown-film combination

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PolyLabPolyLab blown film combination blown film combination

PolyLab System with extruder

Lightning Device

CCD-CameraBlown film take off

WWith optical testing unit OQTith optical testing unit OQT

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Blown film take-off with built in camera systemBlown film take-off with built in camera system

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OQT- Graphical display of OQT- Graphical display of defectsdefects

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OQT- Graphical display of the dataOQT- Graphical display of the data and defects and defects

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OQT- Graphical display of the dataOQT- Graphical display of the data

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CompoundingCompounding

• Instruments:• PolyLab RC300p• Rheomex twin-screw

extruder• extruder Screw(s)• Pressure sensor(s)• (Screen package)• Rod die (horizontal or

vertical) or Multistrand die• Waterbath• Pelletizer

Test results:

• Testing of the processability of polymer compounds

• Testing of additives

• Testing and optimisation of processing conditions

• small production of masterbatches

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557- 3235 557- 3235 Horizontal rod dieHorizontal rod die

• Application:Universal die for extrusion tests

• manufacturing of polymer strands for the production of pellets.

• Nozzles available from: 1mm - 6mm

• Two sensor ports for pressure- and temperature-measurement

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557- 3150 557- 3150 Vertical rod dieVertical rod die

• Application:Universal die for extrusion tests

• manufacturing of polymer strands for the production of pellets.

• Nozzles available from: 1mm - 6mm

• Two sensor ports for pressure- and temperature-measurement

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557- 3180 557- 3180 Multistrand dieMultistrand die

Application:Universal die for extrusion tests with higher output

manufacturing of polymer strands for the production of pellets.

Strand diameter: 3 mm (others on request)

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CompoundingCompounding

Documents

1 Feeding systems Rotors Twin screw extruder sensor Single screw extruder sensors Rheocord 300p Rheocord 300p + Mixer/Extruder Sensor = PolyLab System