S , BRIGHTON, MI 48116 - Plasti-coplasti-co.com/links/Typhoon-X Brochure Pages.pdf · 37 SUMMIT STREET, BRIGHTON, MI 48116 (810) 227-2266 FAX: (810) 227-5566 Temperature The second

37 SUMMIT STREET, BRIGHTON, MI 48116(810) 227-2266 FAX: (810) 227-5566

Plasti-Co’s TyPhoon X static mixing nozzles provide benefitsin quality of parts, increased production, machine flexibilityand material savings that often exceed the units cost inweeks and some cases just days of use.

Properly sized for the application, the unit can provide mixing action often better than a custom designedmixing screw, with little or no injection pressure lost through the elements. The examples belowdisplays the effectiveness of the mixing elements. We introduced two completely different color polymers(left), passed the material through the standard 8 element set of mixers cross section (middle), toshow the end result (right).

The aspect of homogenized melt temperature is often overlooked; differences in melt temperatureoften result in uneven part weight, uneven cavity distribution and flow or knit lines. Although the exampledeals with color mixing, a similar effective is seen in balancing the polymer melt temperature.

High quality molded products require a consistent, perfectly homogenized melt. Using a TyPhoonmixing nozzle can greatly impact these factors providing a larger, more forgiving processing window.

Back pressure is the most commonly used control tool employed on injection molding machines; itimparts greater energy into the process to overcome mixing and homogenizing issues with the polymer.The back pressure effects the material with higher shear, forcing it to build higher pressures forward ofthe screw tip valve. The force slows the screwís output and recovery time and in most cases impactsthe overall cycle time.

The use of back pressure is also hard on the machineís components: faster wear on the drive bearingsand pumps as well as increased barrel, feed screw and screw tip valve wear.

Back Pressure

Melt Temperature

Effectiveness of TyPhoon X Mixing Nozzles

1

input output


Temperature

The second most commonly used tool to improve polymer consistency is increased temperature settings;this can degrade the polymer reducing the quality and integrity of the molded part. Employing aTyPhoon X static mixer will not over-shear or degrade the polymer and may allow for lower overalltemperature settings which can result in shorter cooling time in the tool and improved overall cycletime.

Reductions of color additives of as much as 30%have been achieved with comparable part colordensity. The use of lower cost color additives thatwere unusable in the past often become anoption.

A common problem for molders is processingun-even regrind materials, resulting in poor meltquality. A TyPhoon X mixing nozzle can allow orincrease the level of regrind that can successfullybe processed.

Improved cycle times mean improved profitability,with reduced temperature and cooling times cycletime can be reduced. Lower screw back pressureincreases screw output and recovery time.

TyPhoon will make the process significantly morestable, allowing for less impact from factors thatare difficult to control; like ambient temperaturechanges, material inconsistency, and operatorcycle time inconsistency. A stable process willresult in less scrap and rejects.

RRRRRReturn on InvestmentReturn on Investment

RegrindColorant

Cycle Time Rejects

• Quality, Costs and Speed can provide added benefits and cost savings.• Improved Foam Cell Size and Distribution• Improved Part Quality with Regrind• Lower Part Weight Variations• Improved Color Distribution• Reduced Colorant Usage• Reduced Scrap Rates• Improved Melt Flow• Faster Cycle Times

2

The TyPhoon X mixing elements are built usinga modular design, making them flexible interms of the number of elements that canbe employed and easy to service andclean.

The elements are manufactured from highstrength 17-4PH stainless steel, providingboth high corrosion resistance and thetensile strength to withstand high pressuremolding conditions.

The elements design providessmooth polymer flow using a

double-roof peak design. Thinblade design achievable due tofully supported integral onepiece casting with multi-pointload transference, results in 30-

50% higher flow volumes andlower pressure drop than other

designs.

Mixing Elements

End view of TyPhoon X element

TyPhoon X units generally consist of 8 mixing elements; this provides the greatest mixingaction generally required for injection molding applications. The units with more or less elementsare commonly supplied for non-standard applications. The 8-element set provides 4 full L/Dratio of mixing area.

TyPhoon X elements are offered in 6 different inside diameters or flow areas; the proper size elementwill provide excellent blending action with little or no noticeable injection pressure loss through themixer.

The chart below will help determine the proper size for your machine and application. The machine itis to be used on should determine element size and its ratings, not the molded part size.

The proper size unit is based on the many factors, mainly the viscosity of the polymer(s) to be processedand the injection flow rate through the machines nozzle. Providing Plasti-Co with a completed ìTechnicalSpecifications Questionnaireî located in the back of this brochure will allow us to provide you with theproper size unit for your machine and application.

EEEEEElement Number and SizeElement Number and SizeNumber of Elements

Element Size

Model Number

Internal Flow Area mm / inches

Screw Size Range

Machine Shot Size Range

Injection Flow Rate - cm

cubed / secondAvailability

TSM 12 12mm / .472" 15 - 22mm .8 - 4 oz. < 200 Upon RequestTSM 18 18mm / .708" 22 - 60mm 5 - 28 oz. < 700 In StockTSM 22 22mm / .866" 60 - 95mm 28 - 80 oz. < 1200 In StockTSM 27 27mm / 1.063" 95 - 140mm 80 - 300 oz. < 2300 In StockTSM 33 33mm / 1.299" 140 - 180mm 300 - 600 oz. < 3700 In StockTSM 40 40mm / 1.574" 180 - 260mm 600 - 800 oz. < 7000 Upon Request

Element Sizes Process Sizes

MMMMMMixing Elements

3


NNNNNTyPhoon X nozzle housings are

manufactured from heat-treated alloy

steel or high quality stainless steel for

corrosive applications. Designed to be

installed directly into your machineís end

cap (nozzle adapter) our unique two-piece

design allows for very easy installation

and removal of the mixing elements for

cleaning or service. Durable construction with large hex areas forinstallation will provide excellent service life.

TyPhoon X nozzles are sold as complete assemblies; everything you need to operate and service theunit is supplied. The units are shipped assembled, however, the nozzle housing must be dissembled to

Assembly includes:

1) Mixing Element Set: proper size and number of yourapplication.

2) TyPhoon X Element: standard high flow X element, optionalXF filter element or XM additional mixing elements.

3) Nozzle Body Housing: 2 part assembly including mainelement housing and discharge adapter.

4) Heaters: high quality mica insulated heaters with 36î wirebraid lead wires. Designed with the specific watt density andpower distribution required for proper operation of the unit.

5) Nozzle tip: TyPhoon X units available with a standard7/8î - 14-thread nozzle tip on the TSM 18, 22, 27 and a standard1-1/4î - 12 thread nozzle tip for the TSM 27 and 33. The orificeand radius is supplied to match your mold.

6) Thermocouple: nozzle type unit with 1/4î - 28 NPT thread,with 72î of durable wire braid lead.

7) Operating and Instruction Manual: provides the informationneeded for proper usage, installation and service of your mixingnozzle.

8) Wrench & Anti-Seize: tool for installation and service of theheater bands and Plasti-Coís premium copper/graphite anti-seizecompound.

Complete Assemblies

4

Nozzle Body HousingNozzle Body HousingNozzle Body HousingNozzle Body HousingNozzle Body HousingNozzle Body Housing

CCCCCComplete AssembliesComplete Assemblies

apply anti-seize and installed on the machine in the proper stages.

TyPhoon X

TyPhoon XF

TyPhoon XM

The Typhoon-X system uses ourstandard eight piece modular mixingelements coupled with our X element.The X element provides systemflexibility and makes it possible tointerchange between standard, filter andadded mixing configurations. The Xelement also gives the added benefit ofaiding the in the safe and easy removalthe mixing elements.

The Typhoon-XF system uses a highlyefficient filter element. The filter elementuses grooves to filter the melt with eightlongitudinal channels, four inflowchannels and four outflow channels. Themelt must pass through the radialgrooves to exit the filter. These groovestrap contaminants or un-melt larger thanthe groove width. Once the melt passesthrough the filter it continues through thestandard Typhoon mixing elementassembly.

The Typhoon-XM system offersadditional mixing capability. Itreplaces the standard X elementwith a combination of a Short Xelement and two additionalTyphoon mixing elements. Thisconfiguration provides a full 5 L/Dratio of mixing area.

OOOOOOptional Configurations

X Element

XF Filter Element

5

Standard set of 8Mixing Elements


Short X Element


Element Housing

Discharge Adapter


Disturbing the laminar flow which forces material faster through the center of the nozzle than the sideor along the wall. Moving these layers from center to sides and back creates very turbulent flow, thusblending the polymer.

Plasti-Co offers limited trials on TyPhoon X mixing nozzles. The trials allow our customersto test the performance of the product for their needs and process. These trials are limited.Contact Plasti-Co for details.

The example to left showsthe extent of the mixingaction at each of thestandard eight elementstages.

This example shows thesame test results in a crosssection.

How a TyPhoon Works

Trial Testing

6


Total Wattage: Amp Draw @ 120 Volts: Amp Draw @ 240 Volts:PowerRequirement: 1090 9.08 4.54

TSM18N-D29.64”

2.75”

1.50”

2.125”

TSM18N-D3


10.64”

3.75”

1.50”

2.125”

Model Number:TSM18N-D(X)

Internal Flow Area:18mm / .708”

Screw Size Range:35 - 50mm

Machine Shot SizeRange:

8 - 16 oz.Injection Flow Ratecm - cubed/second:

<700Main Body OutsideDiameter:

2.125”Minimum LengthForward of End Cap:

7.25”Minimum Input threadSize:

1.00” / 25mmNozzle Tip Thread(standard):

7/8” - 14Discharge NozzleOutside diameter:

1.50”

TSM18N-D1


8.64”

1.50”

1.75”

2.125”

SEE PAGE 5FOR MIXING OPTIONS

7

TSM18N-D5

Total Wattage: Amp Draw @ 120 Volts: Amp Draw @ 240 Volts:

Power Requirement: 1550 12.92 6.45

12.64”

1.50”

2.125”

5.75”

TSM18N-D6



13.64”

6.75”

1.50”

2.125”

TSM18N-D4



11.64”

4.75”

1.50”

2.125”

8




Internal Flow Area:22mm / .866”









1.50”

TSM22N-D2



TSM22N-D3



TSM22N-D1



1.50”

1.50”

1.50”

9.83”

10.83”

11.83”

2.75”

2.75”

2.75”

1.75”

2.75”

3.75”

9


TSM22N-D6

TSM22N-D5

TSM22N-D4

TSM22N-D0







1.50”

1.50”

1.50”

12.83”

13.83”

14.83”

2.75”

2.75”

2.75”

4.75”

5.75”

6.75”

10Total Wattage: Amp Draw @ 120 Volts: Amp Draw @ 240 Volts:

Power Requirement: 1125 9.37 4.682.75”

8.30”

Standard Nozzle Body & Tip (Not Included)

1 3/4 - 8 Discharge thread acceptsyour standard nozzle bodies.



TSM27N-D1


TSM27N-D2


TSM27N-D3



Internal Flow Area:27mm / 1.063”









1.50”

3.00”

3.00”

12.61”

13.61”

1.50”

1.50”

2.75”

3.75”

11.61”1.75”

1.50”

3.00”

11


TSM27N-D4

TSM27N-D5

TSM27N-D0

TSM27N-D6







3.00”

3.00”

14.61”

15.61”

16.61”

1.50”

1.50”

1.50”

4.75”

6.75”

5.75”

12Total Wattage: Amp Draw @ 120 Volts: Amp Draw @ 240 Volts:




3.00”

9.78”



TSM27N-DB1


TSM27N-DB2


TSM27N-DB3


Model Number:TSM27N-DB(X)









1 1/4” - 12Discharge NozzleOutside diameter:

1.75”

3.00”

3.00”

3.00”

1.75”

1.75”

1.75”

1.75”

2.75”

3.75”

12.71”

11.71”

13.71”

13


TSM27N-DB6



1.75”

6.75”

16.71”

TSM27N-DB5



1.75”

5.75”

15.71”

TSM27N-DB4



1.75”

4.75”

14.71”

14



TSM33N-DB1


TSM33N-DB2


TSM33N-DB3


Model Number:TSM33N-DB(X)




260 - 330oz.Injection Flow Ratecm - cubed/second:





1 1/4” - 12Discharge NozzleOutside diameter:

1.75”

1.75”

1.75”

1.75”

3.50”

3.50”

3.50”

3.75”

1.75”

2.75”

13.45”

14.45”

15.45”

15


TSM33N-DB4

TSM33N-DB5

TSM33N-DB0

TSM33N-DB6







1.75”

1.75”

1.75”

3.50”

3.50”

3.50”

4.75”

5.75”

6.75”

16.45”

17.45”

18.45”

163.50”

12.45”






Most customers install a TyPhoon X to address one processing issue; the most commonbeing color streaks or clouds of color in the part. Once this problem is fixed, many overlookthe other benefits that the unit may provide, to improve quality, productivity and reduce materialexpense.

Many molded parts that are being processed satisfactory could benefit from the use of aTyPhoon and recover the cost of the unit in weeks and sometimes just days. There are threemain categories of benefit, exploring all will provide the quickest payback and most addedprofitability for your company.

Once your main concern for ordering a TyPhoon X has been addressed, testing for otherareas of improvement in Quality, Costs and Speed can provide added benefits and cost savings.

Getting The Most Benefits From Your TyPhoon Mixing Nozzle

17

BENEFIT PAYBACK

Benefits of Optimum Melt QualityDESCRIPTION

QualityImproved Distribution of Additives ProvidingA) Reduced color spotsB) Reduced color streaks and clouds

Greater Temperature Homogenization ProvidingA) Less part distortionB) Less part weight variationC) More uniform filling of multi-cavity moldsD) Improved part size tolerancesE) Improved surface finish

A) Lower scrap ratesB) Material savingsC) No re-grinding costs

Improved Distribution of Additives ProvidingA) Reduced colorant usage; 10% - 40% in many casesB) Increased levels of regrindC) Larger window of acceptable regrind sizesD) Use of lower quality raw materials

Optimum Melt Quality ProvidingA) Lower process and melt temperatureB) Lower machine back pressureC) Higher acceptable screw speeds

G) Lower additive costsH) Lower base material costs

I) Shorter cooling timesJ) Faster screw output/recoverytimesK) Less energy usage

Quality

Cost

Speed

D) Lower scrap ratesE) Material savingsF) No re-grinding costs


QuestionnaireInjection Molding Mixing Nozzle / Technical Specification Questionnaire

Improve Spots,Streaks and Clouds of ColorImprove overall Color Problems

Reduce Colorant UsageReduce Reject Rates

Improve Part DistortionImprove Part Quality with Regrind

Improve Melt FlowReduce overall Cycle Time

Improvements Desired________________________________________

Name

Company

Address

Position

City

State/Zip

Date

Phone (include extension)

Fax

E-mail

Contact Information

Make/OEM

Screw Diameter

Shot Size

Compression Ratio

Screw Design (mixers)

Screw Tip Valve Type

Machinery

Part Description

Material

Material Manufacturer

Additive (color) Percentage

Additive Manufacturer

Total Shot Size with Runner

Additive Form GPellet GLiquid GPower GOther

Regrind Max. Percentage

Describe Process of Feeding Additives and Regrind

Describe Problem(s)

Process (A)Part Description

Material

Material Manufacturer

Additive (color) Percentage

Additive Manufacturer

Total Shot Size with Runner

Additive Form GPellet GLiquid GPower GOther

Regrind Max. Percentage

Describe Process of Feeding Additives and Regrind

Describe Problem(s)

Process (B)

L/D Ratio

18

NNNNNOZZLEOZZLEOZZLEOZZLEOZZLE S S S S SPECIFICAPECIFICAPECIFICAPECIFICAPECIFICATIONSTIONSTIONSTIONSTIONSNNNNNOZZLEOZZLEOZZLEOZZLEOZZLE S S S S SPECIFICAPECIFICAPECIFICAPECIFICAPECIFICATIONSTIONSTIONSTIONSTIONS

G120 G240 G other (please state)

G J G K G other (please state)

G3/4 G1/2” G other (please state)

Gzero G1-3/4” G2-3/4” G3-3/4” G4-3/4” G5-3/4” G6-3/4” G other

Nozzle Heater Voltage

Thermocouple Type

Nozzle Tip Radius Size

Nozzle Extension at Discharge*

The required information should be taken from the current nozzle. (see drawing below)

Thread length

Rear opening

IIIIINPUTNPUTNPUTNPUTNPUT - M - M - M - M - MAAAAACHINECHINECHINECHINECHINE S S S S SIDEIDEIDEIDEIDE OFOFOFOFOF U U U U UNITNITNITNITNITIIIIINPUTNPUTNPUTNPUTNPUT - M - M - M - M - MAAAAACHINECHINECHINECHINECHINE S S S S SIDEIDEIDEIDEIDE OFOFOFOFOF U U U U UNITNITNITNITNIT

Relief length

Relief diameter

ABCDE

Customer

Contact Person

Machine Make

Date

Machine Model

Shot Size

(right / left hand pitch)

This length must be longer than the depth of the machines nozzle adapter to allow forproper sealing.If unsure of thread size, provide the major OD of the very tops of the threads. Threadpitch should be taken with a pitch gage.

Rear opening size should match end cap (nozzle adapter) for proper flow.

Some machine makes will have long relief areas or counter bores for added sealing andalignment

AAAAADDITIONDDITIONDDITIONDDITIONDDITIONALALALALAL I I I I INFORMANFORMANFORMANFORMANFORMATIONTIONTIONTIONTION_______________________________________________________________________________________________________________________________________________________________________________

AAAAADDITIONDDITIONDDITIONDDITIONDDITIONALALALALAL I I I I INFORMANFORMANFORMANFORMANFORMATIONTIONTIONTIONTION

Orifice Size:

right / left hand pitch

Thread size


Specifications

19

GTyPhoon X GTyPhoon XF GTyPhoon XMTyPhoon Configuration Style

Documents

S , BRIGHTON, MI 48116 - Plasti-coplasti-co.com/links/Typhoon-X Brochure Pages.pdf · 37 SUMMIT STREET, BRIGHTON, MI 48116 (810) 227-2266 FAX: (810) 227-5566 Temperature The second