Pow(d)er to the People Efficient conversion from …...Main components and working principle of a pulverizer Efficient conversion from polymer granules to powder Machine design Energy

© Maag 1 January 18, 2017

Efficient conversion from

polymer granules to powder

with Modern Pulverizing

Systems

Pow(d)er to the People

29.-31. January, Jaipur

Alexander Datzinger, Business Development Manager Pulverizer


Agenda

Agenda

Maag company overview

Main components and working principle of a pulverizer

Efficient conversion from polymer granules to powder

Machine design

Energy consumption

Machine operation

Maintenance and spare parts

Pulverizer product portfolio

Conclusion


Agenda

Agenda




Machine design

Energy consumption

Machine operation



Conclusion


Plastic Processing Solutions from Maag

Pump & Filtration Systems.pptx

Strand Pelletizing.pptx

Underwater Pelletizing.pptx

Pulverizer.pptx


Maag Pump Systems founded in 1913

Headquartered in Oberglatt, Switzerland

Specialists in Plastics Processing

More than 1,000 employees worldwide

Global footprint with facilities

in USA, Europe and Asia Pacific

Annual turnover ~ US$ 300 Mio.

Part of the Dover Corporation

since 2012

Inside Maag


Maag today is formed by four successful and well experienced companies with an

impressive heritage. Each of them brings a wealth of knowledge and years of

experience. All four have achieved much in the past and will achieve even more

together in the future.

Maag is

incorporated

as a Dover

Company

Historical Timeline


Maag Group – 16 Locations:

We’re Close to Our Customers

Kent, OH - USA

Charlotte, NC - USA

Roanoke, VA - USA

Eagle Rock, VA - USA

Sao Paulo - Brazil

Villeurbanne - France

Xanten - Germany

Grossostheim - Germany

Oberglatt - Switzerland

Rozanno- Italy

India - Vadodara

Shanghai - China

Taipei- Taiwan

Chonburi - Thailand

Singapore

Kuala Lumpur - Malaysia

Location

Manufacturing Sales Customer Service Grinding Center Test Center

Everywhere You Are …


Agenda

Agenda




Machine design

Energy consumption

Machine operation



Conclusion


Cyclone

Material transfer piping

Control cabinet with PLC

Mill housing

Sifter

Blower

Feeder

Main Components


Working Principle


Agenda

Agenda




Machine design

Energy consumption

Machine operation



Conclusion


Machine Design

Horizontal orientation of mill chamber

360° distribution of pellets by centrifugal force

Even load distribution on Pulverizing Discs

Easy maintenance and gap-setting

Small unit(s) with compact footprint

e.g. RE 85XLP 2.400 x 1.562 x 4.486 mm

Main components already pre-assembled and

connected

Mill with drive(s),

Feeder(s)

Sifter unit

Electrical panel and controls


Machine Design

Fast and simple installation and connection of

Blower

Cyclone

Airlock

Material piping

Metric bolts and fasteners

Control panel mainly Siemens components

PLC Siemens S-7


Energy Consumption

Efficient utilization of its entire available power makes Reduction Pulverizing

Systems the most economical machine with relation to kilograms produced over

power consumed (approx. 0,13 – 0,18 kW/kg)

Highest output per installed kW

High efficiency drives

Large air volume with small blower motors

due to optimized air flow in the system

Total conversion cost € 0,04 – 0,05/kg


Energy Consumption

Identical mill assemblies for all production scale

pulverizers. Drive power and number of mill heads is

increasing with capacity/machine size.

Reduced moving masses

Smaller total installed capacity

Lower energy consumption

Mill 1 Mill 2 Blower Capacity

RE 85XLP 22 kW N/A 5,0 kW 150 - 200 kg/h

RE 85XLP 55 kW N/A 7,5 kW 270 - 450 kg/h

REX duo 55 KW 22 kW 11,0 kW 500 - 700 kg/h

REX duoPLUS 55 kW 55 kW 18,0 kW 900 - 1.360 kg/h


Machine Operation

Integrated PLC controls (from RE 85XLP and up), assures fully automatic

operation with minimal manpower.

The touch-screen panel shows all

necessary process parameters and

operating conditions and is more or

less self explanatory. The feed rate

is automatically adjusted according

to the actual process conditions

(mill temperature, motor load,…).

All process parameters are

password protected.

Multiple installed safety features will stop the feed of material and/or will turn off

the machine in case of any malfunction.


Mill temperature

sensor

Hopper low

level switch

System

vacuum

sensor

Motor load

control

Mill vacuum

sensor

Sifter out of

balance switch

Cyclone high

level switch

In-feed bar

magnet

Machine Operation


Machine Operation

PLC with interlock system

Mill(s)

Blower

Airlock

Sifter

Feeder(s)

All interlocks and process parameters /

conditions which allow or prevent start of

certain system components are shown on a

maintenance page. This allows fast and easy

trouble shooting.


Fast access to mill internals for

disc replacement and/or

maintenance work

Balanced flywheel on shaft with

massive bearings for long

lasting performance

Easy adjustment of milling gap

from the outside by push- and

pull rods

30 min. for replacement of discs

including gap setting

Maintenance and Spare Parts


Disposable Discs are 75% lighter (less than 7kg instead of 27kg) and 75% thinner

than standard discs. A larger cutting diameter improves the throughput and a 40%

larger inlet area allows for more efficient mill cooling and heat transfer.

No need for re-sharpening

High alloy tool steel for non-abrasive

applications

D2 tool steel for abrasive applications

(PE + pigments, PVC,..)

Multiple designs for special applications

Disposable Disc retrofit kits are available for all RE pulverizers built to date

It also provides much easier handling for

operators and faster turnaround times for

replacement.

Maintenance and Spare Parts


Agenda

Agenda




Machine design

Energy consumption

Machine operation



Conclusion


REX tech

Lab scale pulverizing system for sampling, R&D or small

scale production.

The unit is manufactured for both ambient and cryogenic

operation with use of the proper attachments.


REX basic

The REX basic Pulverizer was designed for users

that do not require tight particle distribution

specification and can be used to pulverize a wide

variety of materials. This includes compounding,

extrusion, molding and recycling markets.


RE 85XLP

The Reduction Pulverizing System RE 85XLP, with

its compact design, is the perfect fit for the medium

throughput range or the ideal solution for starting with

In-House production.

Integrated PLC controls assures the highest quality

performance with minimal manpower.


REX duo

The REX duo is serving end-users with demands for

quantities of high quality powder and production

rates.

Efficient utilization of its entire available power makes

this machine the most economical pulverizer with

relation to kilograms produced over power

consumed.


Agenda

Agenda




Machine design

Energy consumption

Machine operation



Conclusion


Conclusion

Thought-out machine concept, proper process control, easy

maintenance and Disposable Disc Technology allow:

Processing PE for Rotmolding applications at highest possible

temperatures

Flow properties of the powder

Particle size distribution

Bulk density

High output rates on small footprint

Low cost of operation

Manpower

Energy

Parts


Thank you for your attention!

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Pow(d)er to the People Efficient conversion from …...Main components and working principle of a pulverizer Efficient conversion from polymer granules to powder Machine design Energy