PolyLab System

Single Screw Extruders :

Extrusion Principle:
Feeding System

Drive Unit Extruder Barrel Pelletizer

Extruder Screw

TakeOff Device

Trained Operator

Final Product

Rheomex single screw extruder

collars for heating and cooling

Feeding cooling Screw back-pressure sensor (optional) Sensor ports (2 standard, others optional)

Rheomex Application
Extruders are generally used to:
transport material plasticize compress homogenize compound vent chemical reaction building up pressure

Rheomex Application
Measuring of process variables:
torque melt temperature melt pressure mass flow

Optimizing of process parameters:

extruder speed temperature profile pressure screw design

Optional accessories for Single screw extruders

Various control and monitor panels Wear reduced barrel Chemical resistant barrel Axial force sensor Venting port for Rheomex 252p and 332p additional sensor ports for melt-temperature and melt-pressure measurement

Screws for single screw extruders

Conical Core Screw Standard Metering Screw Short Metering Screw

Venting Screw

Mixing Screw

Screw for single screw extruder

Basic material: nitrided steel

Rotational direction

screw flights: screw flow channel: nitrided and grinded surface chrome plated surface

Pressure built-up in a single screw extruder

pressure P2 P1

P3

P4 P5

barrel - length [L/D]

0
9

11

14,5

20,5

24,5

Special bimetallic single screw extruders

Type 1:for highly filled polymers like:
ABS, EVA, LCP, PA, PC, PE, PI, POM, PS, PBTP, PETB, PVC, PP, Thermosets, Phenol resins type: 11, 12, 31 Polyester resins type: 801 to 804 Powder metal insert Rubber compounds in combination with wear increasing fillers like: minerals e.g. SiO 2, CaSiO3, CaCO3 metal oxides e.g. TiO 2, Fe2O3, ceramic materials Al 2O3 others e.g. glass fibres, carbon fibres, mica, flame retardants

Type 2: for corrosive fluorinated polymers like:

PTFE, PVDF (with and without fillers) Maximum operation temp.: 500 C delivery time: app. 5-6 month

steel barrel

10

Rheomex 104 for rubber application:

Feeding roll Motor for roll feeder Zone 1 (heating/cooling) Sensor ports Zone 2 rubber strip

extruder barrel

screw

feeding roll

11

Special single screw extruders for food extrusion

Special grooved extruder barrel:

non-wallsticking material can be extruded

extruderbarrel

grooves

extruderscrew

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PolyLab System

Twin Screw Extruders :

13

Twin-screw extruders CTW100 and PTW25

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Feeding of material into twin-screw extruders

Co-rotating
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Counter-rotating

Twinscrew Extruder
Counter-rotating Rheomex Twinscrew Extruders: - Defined residence time (good for i.e.rigid PVC) - Selfcleaning - No controlled feeding needed - High shearing - High pressure builtup Co-rotating Rheomex Twinscrew Extruders : - Mixing of shear sensitive material (i.e. Polyolefins) - Compounding, Masterbatch production - Venting - Controlled shearing - Flexible screw design - Controlled feeding necessary
16

Conical Twin Screw Extruder Rheomex CTW100p

conical design of barrel and screws: mechanical stability / easy cleaning counter rotating screws: defined resident time / forced material transport selfcleaning 6 sensor ports: exact examination of sample behaviour dosing via sensor ports possible venting opening: easy venting with venting screws 3 different screw geometries: - intensive mixing screws - standard screws - venting screws

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Rheomex CTW100p

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Rheomex CTW100p

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Screw geometries for CTW100p extruder

Venting screw

Intensive mixing screw

Standard screw

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Parallel twin-screw extruder Rheomex PTW Processing tasks - 1

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.

21

Parallel twin-screw extruder Rheomex PTW Processing tasks - 2

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

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Parallel twin-screw extruder Rheomex PTW Examples of application

Polyethylene (LLDPE/LDPE/HDPE) Nanocomposites (Clay, MWCT) Polypropylene (PP) ABS Polystyrene (PS) PVC (soft) Polyester Polyamide Polyformaldehyde Cellulose ester Polyuretthane (PU) Polycarbonate (PC) Food Starch Polyphenylene oxide (PPO) Polysulphone (PSU) Polyacrylonitrile Toner Masterbatch Powder coating materials curing moulding compounds Ceramic materials Pharmaceutical products Polymethylmethacrylate (PMMA)

23

New PTW16 XL for PolyLab OS

Horizontal split, with a lift-off top to be opened for ease of cleaning, simple removal of the screws and visualisation of the melting process. The segmented top barrel part is built with 4D modules to be easily reconfigured by the user. Barrel segments are available for cooling feeding solids, liquids and for venting.

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Maximum flexibility ... Feed ports... ... Lenght ...

... Screw design ... ... Split Barrel

25

Rheomex PTW16 flexible screw configuration

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PTW16 OS - Maximum flexibility ... Split Barrel

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PTW16 OS - Maximum flexibility

25 L/D + 15 L/D = 40 L/D

28

PTW16 XL: 25 + 15D extendable

what is the right length for my application: L/D 25, or better L/D 40? Why dont you buy two compounders!
Flexible Length: not for all applications a long extruder is useful, as shear sensitive materials can degrade and 25D is long enough for basic applications. Optional 15D barrel extension to enhance e.g. residence time (for reactive extrusion) or multiple feed ports, easy to use (< 15 min by operator!) Software recognizes the Extension unit
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Example: Compounding

Metering Feeder for PEEK Pellets Cabon Fiber Roving (endless) Pelletiser Varicut T = 380C 20-40% C-Fiber (wt/wt)

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Rheomex PTW16p
Technical Specifications 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

31

Rheomex PTW16p Screw elements:

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Rheomex PTW24p

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Economic PTW24p models

comparison to 24 HC type
Vacuum venting Venting to Atmosphere Or option Liquid feed

secondary feed

main

PTW24/40p (HC) 4D modular Elements

Side feed 2

Side feed

PTW24/25p (TC)
Vacuum venting secondary feed

main

PTW24/30p (TC)
Side feed option

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Rheomex PTW24p
Technical Specifications

Speed range: Pressure range:

0 - 500 rpm
(optional 0-1000 rpm)

100 bar
(150 bar optional)

Temperature range: max. 300 C

(400C optional)

Screw diameter: 24 mm Barrel length (L/D) : 28:1 to 40:1 (using the optional
barrel extension unit)

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Rheomex PTW24p

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Rheomex PTW24p Advantages:

Extruder barrel: segmented and hinged

Segmented screw Sidefeeding

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Rheomex PTW24p
Technical Details:
Bore diameter: Screw Centres: Channel Depth: Clearance: Total barrel length: 24 mm 18.75 mm 5.2 mm 0.2 mm 672 mm. (28:1 L/D, in 4:1 modules)
Barrel extendable to 40:1 length with optional barrel extension

Feed Zone: Processing Zones: Extrusion Die:

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Water Cooled Electrically Heated / Water cooled Electrically heated

Rheomex PTW24p Screw elements:

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Parallel twin-screw extruder Rheomex PTW Screw segments 1/3 Conveying elements:
Profiles with open chambers are used: - in the feeding sections - for melt exchange (longitudinal mixing) - for degassing (venting) Profiles with closed chambers are used: - for high pressure built up - in front of kneading elements

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Parallel twin-screw extruder Rheomex PTW Screw segments 1/3 Conveying elements:

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Parallel twin-screw extruder Rheomex PTW25

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Parallel twin-screw extruder Rheomex PTW Screw segments 2/3 Kneading blocks :
Kneading blocks are used to introduce shear energy to the extruded materials. 5 disks are arranged in a block and arranged in different offset angles used for:

- plasticizing - mixing - dispersing

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Parallel twin-screw extruder Rheomex PTW Screw segments 2/3 Kneading blocks :

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Mixing elements

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Parallel twin-screw extruder Rheomex PTW25 Screw segments 3/3 Toothed blocks :
Toothed blocks are special mixing elements, used for the distribution of even small quantities of additives. The shearing energy introduced to the polymer is significantly lower than that of the kneading elements. The open worked flights of the mixing discs have a special asymmetric design.

46

Parallel twin-screw extruder Rheomex PTW25 Screw segments 3/3 Toothed blocks :

47

Rheomex PTW Side-feeding

Application: Feeding of glass fibres, fillers or other additives into the molten polymer. Venting of the introduced air.

Venting

Flow direction
Requirement: 2 separate feeders necessary for side feeding. One side stuffer with constant (high) dosing speed to press the material into the barrel. One feeder to controll the feeding rate. For constant feeding ratio between polymer and additives gravimetric controlled feeders can be used.
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Side feeding

557- 5001 Rheomex PTW 25 x 20D

Venting Feeding

Barrel segments: Feeding barrel Closed barrel Open barrel Measuring barrel 4D 6D 6D 4D

Application: Melting of polymers Venting

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557- 5031 Rheomex PTW 25 x 32D Production of Masterbatch

Venting (vacuum) Venting (atmosphere) Venting (atmosphere) Feeding (polymer)

Barrel segments: Feeding barrel Closed barrel Combi barrel Closed barrel Open barrel Open barrel Measuring barrel
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Side-feeding (pigments)

4D 6D 4D 4D 6D 4D 4D

Material PP, PE, PET, PC, PA,etc. pigments

Shape powder or granulates powder

Quantity in % 60 - 80

20 - 40

Dry-Blend

25/1/2

37.5/1/2

37.5/1/2

Screw configuration Rheomex PTW25/38

37.5/1/2

Liquids

37.5/1/2

37.5/1/2

25/1/2

For typical food extrusion

25/1/2

25/1/2

ZB-37.5

25/1/2

25/1/2

E-KB-25/LI 25/1/2

25/1/2

E-KB-25/LI 25/1/2

25/1/2

E-KB-37.5/LI

25/1/2

25/1/2

E-KB-37.5/LI

E-KB-37.5/LI

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

Screwtip

Cooling

Venting Steam

Cooking

Mixing/Hydration

Feeding

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Masterbatch production
Atmosphere Premix

Parallel twin-screw Water bath Pelletizer

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Vacuum

PolyLab System

Feeding systems :

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Metering Feeder Principle sketch:

glass window interchangeable feeding tube Standard Hopper

Motor with gearbox

Metering screw

Closure for Cleaning

Extruder
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Metering Feeder (adapted to PTW25p)

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Metering Feeder Application:

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

56

Metering Feeder Features & benefits :

compact design: easy to handle wide feeding range various inserts: suitable for pellets and powder control box: speed control via Rheocord or manual speed control via potentiometer easy to combine with a second metering-feeder for controlled compounding

57

Force Feeder
Motor with stepless speed control

Principle sketch:
Application:
feeding of sticky materials: - food extrusion feeding of bridge-building materials - some PVC Dry Blends feeding of not flowing material - grinded film - soap powder

Hopper

Force Feeding Screw Extruder Screw Extruder Barrel

58

PolyLab System

Extruder Application :

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Cast 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
60

Sheet 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: 360C 1 measuring port

61

PVC -Dies
New PVC Slit dies 50mm, 100mm, Height 1mm Moldflow (FEM) Simulation Optimizied Flow Compact design

62

Sheet and Ribbon Take Off

adjusting the gap polished and temperable steel rollers rubber rollers take-up roller

Motor waterbath

circulator

63

New PostEx Design

New Sheet & Ribbon TakeOff
- New design to be used with Haake and Prism products - Two Options: 2-Roll TakeOff 3-Roll TakeOff - Easy access to the rollers - Easy handling - Height adjustable - Adjustable speed ratio between the steel rollers and the take-off rollers

64

Cast film application

PVC sheets: good & bad

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Blown film application

Instruments: Rheocord 300p Extruder (single- or twin-screw extruder) Screws Blown film die Cooling ring Blown film take-off Pressure sensor (Screen package) (OQT 512)

Application: small production of films Testing the processability of compounds Testing of additives Testing and optimisation of processing conditions Results: Fish-eye testing Pigment distribution surface quality

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557- 3175 Blown Film Die

Ring diameter 25mm (35mm) Pin diameter 24mm (34mm) Gap width 0-0.8 mm Measuring ports 2 Max. temperature 480C

adjustable die gap

Air

67

PolyLab blown film combination

With optical testing unit OQT Lightning Device Blown film take off CCD-Camera PolyLab System with extruder

68

OQT- Graphical display of defects

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OQT- Graphical display of the data and defects

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Compounding
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

71

557- 3235 Horizontal 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 pressureand temperature-measurement

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557- 3150 Vertical 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 pressureand temperature-measurement

73

Vertical rod die Application Example

Application: Universal die for extrusion tests, here testing of Processing additives (Dynamar) at Dyneon (NL). Build up of non stick layer (right picture) improves the quality. The effect and concentration of the processing aid can be tested with various base polymers and temperatures.
EPPM info nr. 34 6,3 / p12 (2004)

74

557- 3180 Multistrand 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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Pelletizer, optional with VARICUT: adjustable lenght

76

Rubber extrusion
Instruments: PolyLab RC300p Rheomex 104p or 203p Screw(s) Pressure sensor(s) Garvey die Conveyor belt Test results: Testing of the processability of rubber and elastomer compounds Testing of the influence of additives Testing and optimisation of the processing conditions Visual testing of the material flow at edges with different angle

77

557-3230 Garvey-die

Technical data:
Die profile according to ASTM 2230-63T max. temperature: 360 C die profile does not allow to install sensor ports

Application:
Extrusion of elastomers and rubber for testing the flowability.

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Wire coating application

Instruments: Rheocord 300p Extruder (single- or twin-screw extruder) Screws Wire coating die Wire coating take off Pressure sensor

Application: small production of cables Testing the processability of compounds Testing of additives Testing and optimisation of processing conditions

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557-3195 Wire coating die

di: 0.7 - 2.0 mm da: 0.8 - 4.0 mm Standard: 1.2 / 2.0 mm Max. temperature: 480C Measuring ports 2

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Fibre spinning
Instruments: PolyLab RC300p Rheomex extruder (single or twinscrew) Screw(s) (Melt pump) Pressure sensor(s) Screen package Fibe spinning die with spinning plate Test results: Testing of the processability of polymer compounds Testing of additives at different formulations Testing and optimisation of processing conditions small production of polymer fibres

81

557-2376 Spinning Die

Application: Fiber spinning

Technical data of spinning plate: number of holes: 10 diameter: 200 m length: 0.5 mm entrance angle: 60

screen package breaker plate spinning plate

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Meltpump:

Principle

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Filter Test ( EN 13900-5 )

Instruments: PolyDrive with Rheomex252 Melt pump Pressure sensor(s) Screen package Filter die

Test results: Testing the distribution of fillers and pigments in polymer compounds Pressure increase in front of the screen package

84

557-2413 Filter Die

according EN 13900-5 (draft) Measurement of the pigment distribution Testing of the purity of polymers Geometry of the Filterdie according to the new standard EN 13900-5 (draft)
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Hydraulic screen changer

86

Filter (screen life) test EN 13900-5 (draft) Constraints:

Single Srcew extruder: D = 19 30 mm, L/D = 20 - 30 - PolyDrive 252 Pressure at end of the extruder : constant at 30 60 bar - via pressure feedback loop Melt pump: 50 60 ccm/min - Thermo Haake meltpump Defined meltfilter: - filter geometry according to EN 13900-5 proposal Defined breaker plate geometry (free area of filter): - die geometry according to EN 13900-5 proposal

87

Filter Test Software

Pmax

ts :

determination of basepressure Ps and filling of the hopper with masterbatch mixture End of masterbatch mixture and filling of base polymer End of pressure measurement and evaluation of maximum pressure Pmax

t:

Pressure increase in front of the filterpackage

Pmax- Ps

te :

Ps
Conditioning with base polymer

Masterbatch

Purge with 100g base polymer

ts
88

te

Filter Test:

Calculation according EN 13900-5 (draft)

(Pmax - Ps) FPV = mc

FPV (filter pressure value): Ps: Pmax: M c: Filter-Pressure-Value in bar per grams [bar/g] Starting pressure in bar Maximum pressure in bar Pigment weight in gram

89

Filter Test Software Evaluation:

90

Filter Test Software Configuration:

91

92

Test Report for EN 13900-5 (draft)

93

Filter package type 1 ( 25 )

d = diameter of wire w = distance of two wires sievepackage type 1, part.no.: 005-0001 The sievepackage consists of layers:

d direction of flow

1. layer : W = 0,14 mm, d = 0,042 mm (615/108 mesh) 2. layer : W = 0,63 mm, d = 0,40 mm

layer 1, 2
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Filter package type 2 ( 14 )

d = diameter of wire w = distance of two wires sievepackage type 2, part.-no. 005-0002 the sievepackage consists of layers:

d direction of flow

1. layer : W = 0,13 mm, d = 0,042 mm (615/128 mesh) 2. layer : W = 0,63 mm, d = 0,40 mm

layer 1, 2
95

Pipe extrusion
Instruments: PolyLab RC300p Rheomex extruder (single or twinscrew) Screw(s) Pressure sensor(s) Pipe or catheter die Conveyer belt Test results: Testing of the processability of polymer compounds Testing of additives at different formulations Testing and optimisation of processing conditions small production of polymer pipes

96

557-3215 Pipe & Tubing Die

di: 5 - 12 mm da: 10 - 15 mm Standard: 9 / 12 mm Max. temperature: 480C

97

557-3185 Catheter Die

di: 1.5 - 7.0 mm da: 2.0 - 8.0 mm Standard: 2.4/4.5 mm Max. temperature: 480C

98

Dieswell Measurement
Instruments: PolyLab RC300p Rheomex extruder (single or twinscrew) Screw(s) Pressure sensor(s) Rodcapillary or rod die Dieswell Capillary (Conveyer belt) Laser Dieswell tester

Test results: Testing the elastic behaviour of polymer melts Measuring the strand diameter

99

Dieswell Measurement
detecting elastic polymer behaviour

Capillary (d)

D-d * Dieswell = 100% d

LASER-BEAM
(D)
100