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SYSTEM SOLUTIONS FOR SHEET EXTRUSION LINES
Sheet extrusion of polyolefins and engineering thermoplastics
IN PARTNERSHIP WITH INDUSTRY
KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide
Whatever you aim to achieve in plastics or rubber
processing, KraussMaffei is your partner. We are
the only company with intensive expertise across
the three main engineering fields. And we have a
strong track record in integrating this expertise to
develop new processes and systems.
Ready for any challenge
Our Injection Molding Machinery Division
supplies machinery and systems from 35 to 4,000
tonnes for standard applications and for all
processing variants, together with fully automated
solutions. We have a strong customer base in all the
relevant industries worldwide.
Our Reaction Process Machinery Division supplies
machines and complete systems for processing
polyurethanes and other reactive materials.
Completing our product portfolio, Automotive
Component Systems supplies foam molds, cutters
and routers. Our customer base is wide, with a
focus on the automotive, construction and white
appliances industries.
Our Extrusion Technology Division supplies
machinery and systems for compounding, for pipe,
profile and sheet extrusion, physical foaming, and
the production of technical rubbers and inter-
mediates for tire production. Machinery from the
company’s range – from single extruders to
complete extrusion lines – is used in many
industries, including chemicals, pharmaceuticals,
automotive, construction, furniture and packaging.
People for Plastics
We are the “people for plastics”. We are your
partners from the first exploratory discussion,
through development to commissioning, servicing
and operating your system, and final disposal. At all
times, you are assured of outstanding competence
in planning and engineering, as well as reliable and
fast spare parts, service and support.
Adding value for customers
We put our expertise to work for your success.
With machine ranges engineered for modular-
ity, we can deliver application-specific solutions
based on our wide range of standard modules and
specially engineered solutions. This strategy offers
customers technical and cost advantages.
Close to customers around the world
As an international company, KraussMaffei has
a presence in all the major markets for the plastics
and rubber processing industries and employs
around 3,000 people worldwide. Our sales and
service network keeps us close to all our
customers around the world.
Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive
Electrical / Electronics Packaging
Integrated system solutions for a huge range of PO sheet products
The use of polyolefins has been growing steadily for decades and the trend continues. One important growth area is in extruded sheet.
KraussMaffei Berstorff’s 36D single-screw extruders are ideal for extruding polyolefin sheet – both compact and foamed. We’ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It’s all at your service.
TRANSPARENT TECHNOLOGY
Take a tour of a possible configuration for a sheet extrusion line
Edge trim hacker
Longitudinal parting sawwith servo-drive, pneumatic positioning of the cutting blade and the swarf extraction unit
Roller cooling section
Haul-off Single- or double-strand haul-off, pneumatic positioning of the rubber-covered rolls, adjustable speed differential to polishing stand
Swarf extraction
Stacker with roller table
Crosscut saw or router with servo-drive
· Screen changer
· Melt pump
· Static mixer
· Protective film above
and/or below
· Laminating unit
· Embossing unit
· Corona treatment
· Thickness monitoring
Other options on
request
Optional system components
Temperature-control unituses water or oil as medium
Slit die
Single-screw extruderKME 150-36 B/PL for PO with gravimetric material feed (one to four components)Extruder shown without switch-ing cabinet or C5 control unit
Polishing standwith high-gloss, chrome-hardened rolls, individual servomotor drives and planetary gears, nip monitoring via electronic sensors, constant temperature profile over the whole width of the roll
Radiant heaterCombination of area and point heaters, adjustable zone regulation
Pressure rollfor optimizing flat-ness (temperature control and drive optional)
Page 6 Sheet extrusion of polyolefins and engineering thermoplastics
Many market segments and application areas are
turning increasingly to polyolefin sheet: Be one
step ahead of the competition with KraussMaffei
Berstorff.
Complete system solutions from the world’s
leading system supplier
KraussMaffei Berstorff has long been a world-
leading system supplier of PVC sheet extrusion
lines. In recent years, we have systematically
expanded our product portfolio. We offer com-
plete system solutions for processing different
PO sheet grades and custom PO materials. Our
machinery and process know-how can give you
a decisive competitive advantage, because we
configure and supply complete sheet extrusion
lines using high-quality components and extensive
automation. The advanced screw geometries are
a hallmark of our 36D single-screw extruders.
The screws maintain the constant pressure, high
output and uniform temperature profile essential
for the process. The extruder can also be operated
without a melt pump.
Dedicated systems for foamed PO sheet
Chemically foamed PE and PP sheet is finding a lot
of new applications, and it is also helping to cut the
cost of raw materials for products that are already
on the market. To meet high quality specifications,
the extruded foam must have a homogenous internal
structure and smooth outer surfaces. For the best
foam quality, the melt must leave the extruder as
a highly homogenous compound with the blowing
agent (added as microgranules) uniformly distrib-
uted. The melt, which is under pressure, expands
immediately on exiting the die.
36D single-screw extruders are ideal for extruding
foamed PO sheet. Such sheet has a closed pore
surface while the internal core cross-section has a
homogeneous, cellular structure. Foam formation
is triggered by subjecting the blowing agents to
heat. The complex combination of the formulation,
the plasticizing process and the special geometry
of the slit die lips produces foamed sheet with far
lower density than compact sheet. Raw materials
consumption is reduced in proportion. KraussMaffei
DETAILED PRODUCT INFORMATION
Benchmarks for PO sheet production – with 36D single-screw extruders
Fast gap and deckling systemsAdjustable coextruder adapterPO sheet die
Page 7
Output in sheet extrusion [kg/h]
Extruder type HDPE PP
KME 45-36 B/PL 140 140
KME 60-36 B/PL 220 220
KME 75-36 B/PL 320 320
KME 90-36 B/PL 400 400
KME 105-36 B/PL 500 500
KME 125-36 B/PL 630 630
KME 150-36 B/PL 800 800
KME 200-36 B/PL on request on request
Berstorff supplies a dedicated extrusion unit for this
foaming process: it consists of a 36D single-screw
extruder with grooved bush and barrier screw, a
screen changer (option) and a slit die specifically
designed for foamed PO sheet.
Detailed product information
Eccentric feedAvoids turbulence and maximizes output
TRANSPARENT TECHNOLOGY
Meet the machine: take a tour of a 36D single-screw extruder
Rugged gearingLong life, lowest maintenance costs and space savings (gearbox and motor form a U)
Gravimetric material weighing system
Deep-nitrided grooved bushOutstanding cooling performance, lowest cooling water consumption, steady material feed – independent of counterpressure – and self-cleaning
Bimetallic barrelLowest wear rates
Barrier screwFor thermal and materially homogenous melt and low melt temperatures
Optimal drive dimensionsDC (standard) or AC (option), air-cooled (standard) or water-cooled (option)
Detailed product information
Mobile operator panel
(option)
KraussMaffei Berstorff standard operator panel:
integrated in the control cabinet
Swivel-mounted operator panel (option)
DETAILED PRODUCT INFORMATION
The C5 control – one of the most advanced control and monitoring systems in the industry
Centralized control of the extrusion line
Meeting tough specifications for product quality and
output demands a stable, reliable production process.
This is where the C5 control system scores. As one of
the most advanced systems in the industry, it offers
dependable technology and intelligent functions for
centralized control and monitoring of extrusion lines.
For the operator, the C5 ensures optimal set-up and
start-up, and a clear, consistent overview of the pro-
duction process. Monitoring and control is facilitated
by efficient visualization of the status of different
extrusion line components on a series of screen pages.
Central synchronization of the whole line, including
multiple extruders, is fast and simple. The operator
panel allows direct intervention in the operation of
all key elements in the extrusion line. The current
operating status of the whole line is always displayed,
together with a customizable selection of seven actual
parameters. Prompts and alarm messages flash up
in your chosen language. The C5 offers extensive
documentation options and easy connection to a host
computer. The standard design features an integrated
operator panel; swivel-mounted or mobile panels are
offered as options. The swivel-mounted panel, for
example, enables the operator to run the whole line
from a position near the die.
Page 10
Page 12 Sheet extrusion of polyolefins and engineering thermoplastics
No matter how varied and specialized your PO
sheet production needs may be, KraussMaffei
Berstorff’s 36D single-screw extruders are more
than equal to the job.
Processing materials for a broad product range
The screws in our 36D single-screw extruders
have been engineered to deliver decisive advan-
tages in terms of product quality, productivity
and costs. With KraussMaffei Berstorff sheet
extruders, you can process materials for a whole
range of products, especially those used to make
water tanks and acid tanks.
HDPE sheet – unbeatable advantages in count-
less applications
HDPE sheet resists stress cracking, has low-tempera-
ture impact resistance, very good energy absorption,
high stress resistance, outstanding corrosion and
abrasion resistance, low water absorption and very
good electrical isolation properties. With a property
profile like this, it’s the material of choice for a broad
range of applications. Here are some of the products
that can be made of HDPE:
· Rotor blades
· Roller bearing bodies
· Storage containers
· Shuttering
· Wash basins
· Machine parts
· Seating
· Medical prostheses
· Chopping boards for the food processing industry
· Shipbuilding
APPLICATIONS AND CUSTOMER BENEFITS
All set for the markets of the future – tap into lucrative potential with new applications
HDPE sheet is used in shipbuilding Acid tank made from PP sheet
Page 13
PP-H dialysis boards
PP sheet – attractive advantages for many
applications
PP is light, offers optimum abrasion resistance,
has excellent electrical characteristics, withstands
long-term exposure to temperatures up to 90°C,
has a high surface hardness, can be nailed and
welded, and is thermoformable. It can be used in a
broad range of applications. Here are some typical
products:
· Battery housings
· Acid tanks
· Liners
· Laboratory dishes
· Mechanical components
· Shuttering
· Transport pallets
· Kitchen equipment
· Sterilizable components
Applications and customer benefits
Various kinds of extruded
PO sheet, mono or
coextruded in multiple layers
Your benefits at a glance:
· Conveying behaviour independent of counter-pressure at all speeds
· Low melt temperature levels due to high specific throughputs
· Excellent plasticizing performance
· Gentle melt processing and optimal homogeneity
· Long life through optimized pressure profiles and low wear rates
· Clear reduction in cooling water consumption for the grooved bush
· Low-maintenance drive in proven U arrangement
· Compact machines with a small footprint
· Outstanding price/performance ratio
Page 14
Rely on us for a fast and competent response to
all your service needs anywhere in the world.
Whatever you need – from troubleshooting and
training to spares or repairs – we’re on the job.
We’re dedicated to supplying service quality on a
par with the outstanding quality of our machines
and systems. We offer far more than spare parts
and hotlines. We’ll work with you to choose the
best and most cost-effective solution for your
operation. We’ll help you test new applications
and we’ll plan customized service packages.
All-round service
Our service offering is broad. We’ll configure your
system, install and commission it, train your staff,
plan measures to minimize your downtime risk and
maximize productivity, and carry out maintenance,
repairs and upgrades. You’ll find us fast, reliable
and competent. Our hotline is manned by highly-
trained and experienced service technicians.
If necessary, we’ll get a technician to you quickly.
Remote diagnosis, interfacing directly with your
machine’s control system, can be a practical
alternative. Spares for all important wear parts are
available at short notice. We’re continuously
expanding our service network to speed up spare
parts shipment. Talk to us about the right service
solution for your business.
Customer trials and prototyping in our test lab
The Extrusion Division operates a test lab fitted
with the latest machinery and equipment. We can
run trials, produce prototype parts and fine-tune
processes on your behalf. We can work with you
to test and evaluate processes, machines and
equipment in order to identify the best approach
for a particular project. Our highly-qualified
application engineers are there to help you.
Training with high hands-on content
Courses are held in our lab and training centre,
or, optionally, on your premises. We offer
clearly-structured basic and advanced training in
operation, process control and maintenance for
KraussMaffei extrusion systems. On request, we’ll
plan and hold special courses on topics of your
choice. All participants spend a high proportion
of their training working hands-on with original
KraussMaffei machines. A well-structured
training program produces skilled operators
and technicians, which will positively impact
your up-time and productivity.
SERVICE WORLDWIDE
Service, support and spare parts – when you need them, where you need them
Page 15
Worldwide hotlineWorldwide hotline numbersnumbers
Extrusion Technology ServiceExtrusion Technology Service
KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH
Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2
80997 Munich80997 Munich
GermanyGermany
Contacting us by postContacting us by postIf you need to contact any of our
international service or spare parts teams
by post, use this address:
KraussMaffei Technologies
India Pvt. Ltd.
Pune, India
Phone: +91 20 41404610
Fax: +91 20 414046 99
Email: [email protected]
Krauss-Maffei Extrusion
Technology (Zhejiang) Co., Ltd.
Jiaxing City, China
Phone: +86 573 86973888
Fax: +86 573 86967111
Email: [email protected]
KraussMaffei Technologies GmbH
Munich, Germany
Customer Service
Phone: +49 89 8899-2273 (electrical systems)
Phone: +49 89 8899-4380 (mechanical systems)
Email: [email protected]
Application Engineering
Phone: +49 89 8899-4094
Fax: +49 89 8899-2161
Email: [email protected]
Krauss-Maffei Italiana S.r.l.
Abbiategrasso, Italy
Phone: +39 02 94963181
Fax: +39 02 94699482
Email: [email protected]
Berstorff Krauss-Maffei OOO
Moscow, Russia
Phone: +7 495 9377554
Fax: +7 495 9701731
Email: [email protected] Krauss Maffei Corporation
Florence, USA
Phone: +1 859 2834307
Fax: +1 859 2830290
Email: [email protected]
Krauss Maffei de México
S. de R.L. de C.V.
Mexico City, México
Phone: +52 55 53082383
Fax: +52 55 53081727
Email: [email protected]
Krauss Maffei do Brasil Ltda
São Paulo, Brazil
Phone: +55 11 46129171
Fax: +55 11 46128366
Email: [email protected]
Krauss-Maffei (U.K.) Ltd.
Warrington, UK
Phone: +44 1925 644100
Fax: +44 1925 234284
Email: [email protected]
KraussMaffei Technologies GmbH
Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2546 ··· Fax +49 89 8899 - 4043www.kraussmaffei.com
KraussMaffei is a premium partner for the plastics and rubber processing
industries worldwide. KraussMaffei machines and systems are used wherever
plastics and rubber are converted into products. As a knowledge-driven
technology company, we build on many decades of experience and a strong
commitment to research and development.
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The 36D single-screw extruders from Krauss-Maffei Berstorff are ideal for extruding polyolefin sheet – whether compact or foamed. We‘ve got what it takes for successful production. Firstly, we supply complete integrated system solutions for a huge range of PO sheet products. Secondly, we have the intensive process and application experience and the comprehensive engineering expertise you would expect from a system supplier. It’s all at your service.