Smart
Feeding & Application Example
Conveying
Solutions
Introduction
The worldwide film demand is
steadily growing. Growth in biaxi-
ally-oriented films for the packag-
ing industry is especially strong.
Biaxially-oriented films can be
divided into two categories:
- Commodity films, which need to
be produced as cost-efficiently
as possible due to strong price
pressure from the market.
- Specialty films, where a higher
price is possible, however this
is usually related to higher de-
mands in technology and there-
fore also higher production costs.
Application
There is a clear trend in specialty
film production to multi-layer
film types, where more and more
co-rotating twin screw extruders
are utilized. This enables film
manufacturers to simultaneously
feed a large variety of additives
directly into the extruding process,
increasing flexibility and reducing
production costs. This is very ben-
eficial in the production of multi-
layer high barrier films, balanced
shrink films, etc.
Above: a typical biaxially-oriented
PP film process factory layout
Above right: K-Tron K4G Continuous Blending System
with four feeders and integrated pneumatic refill
Biaxially-Oriented Film Production
Typical Process outlet are minimal, which results
in the smooth operation of the
The production of biaxially-ori- film line.
ented PP,PET, PS, PA, etc. film is
a continuous process. In most
cases it is a co-extrusion process,
Ingredients
Depending on the size of the film
where up to 6 single and/or twin line and how many layers are in-
screw extruders are involved. volved, the typical flow ranges are
Usually the base polymer and ad- as follows:
ditives are fed via a continuously
- PP-Pellets
operating loss-in-weight feeder
100 - 20’000 dm³/hr
into the single screw extruder. A
3.5 - 706 ft³/hr
further cost efficient alternative
- Masterbatch Pellets
is gravimetric feeding of additive
5 - 500 dm³/hr
powder directly into a twin screw
0.18 - 18 ft³/hr
feeder for optimal dispersion. The
melt the passes directly inline via - Rework (edge trims)
the usual process for cast film, 10 - 5’000 dm³/hr
then transfers to longitudinal and
transverse stretching elements.
0.35 - 180 ft³/hr
- PET Chips
The performance and short term 10 - 5’000 dm³/hr
accuracy of the gravimetric feed- 0.35 - 180 ft³/hr
ers is key in this process. This
- Additive powder
concept gives the producer high
1 - 500 dm³/hr
flexibility and high quality of the
0.04 - 18 ft³/hr
end product, as well as substan-
tial cost savings.
When the feeders deliver the The desired accuracy is typi-
desired massflow with an ac- cally ± 0.5-1% at 2 sigma
curacy of ± 0.5% at 2 sigma with for the base resin and ±
a sample time of 5 seconds, the 0.2-0.5% at 2 sigma for
pressure changes at the extruder the additives.
1
Biaxially-Oriented Film Production

Feeding System K-Tron Advantages

For PP/PE base resin pellets and K-Tron’s K4G systems are avail- S60, K2-ML-S100 or KML-S500 is K-Tron’s K4G continuous blend-
masterbatch pellets, the flexible able in 1-, 4-, and 6-ingredient generally the right choice for the ing systems with integrated refill
K4G Continuous Blender can be versions, specially designed to be job. As an alternative, a Smart guarantee high short term accura-
easily adapted to the character- mounted directly on the extruder Weight Belt Feeder such as the cy with a high setpoint turndown.
istics of the bulk material and in a highly compact configuration. SWB-300, with a S100 or S500 K-Tron’s advanced Smart Force
required feed rates. The K4G is de- To facilitate cleaning or mate- pre-feeder, could be utilized. Transducer (SFT) digital weighing
signed for on-line blending of up to rial changeover, each K4G feeder To maintain a steady flow above technology offers outstanding
six components at low to medium easily swings out providing full, the single screw extruder, a short-term accuracy. High resolu-
rates. The modular K4G design unobstructed access. continuous level monitoring de- tion weighing and powerful on
also allows pneumatic conveyors For additive powders, twin screw vice makes sure that the feeder board digital signal processing
to be directly integrated into the feeders such as a K-ML-KT20 or throughput is automatically ad- ensure precision feeding even
K4G stand to refill the feeders. K2-ML-T35 can handle most free- justed according tio the material at short intervals or in vibration-
A variety of K-Tron screw feeders flowing to difficult materials (e.g. consumption of the extruder while prone plant environments
are available for use in the K4G sticky, bridge-building). a constant ratio of the individual K-Tron’s SmartConnex Control
system, as well as the new Bulk For PET-chips and rework, which in ingredients is guaranteed. technology ensures long term
Solids Pump (BSP) feeders. The most cases has an irregular par- stability, good repeatability and
BSP’s outstanding feeding perfor- ticle shape, a single screw loss- consistent feeding quality.
mance makes it ideal for a uniform in-weight feeder such as a K2-ML-
and pulse-free material flow.

K-Tron Smart Commander

with host communications

K4G Feeders
K2-ML-S100 with Refill
KCM KCM

CAUTION - Disconnect power before opening. CAUTION - Disconnect power before opening.
115/230 VAC 50/60 HZ, 2000 Watts (Max) 115/230 VAC 50/60 HZ, 2000 Watts (Max)

K4G Feeders
with Refill
KCM

CAUTION - Disconnect power before opening.

115/230 VAC 50/60 HZ, 2000 Watts (Max)

KCM

CAUTION - Disconnect power before opening.

115/230 VAC 50/60 HZ, 2000 Watts (Max)

to downstream
process

KCM

Main Twin Screw Extruder

CAUTION - Disconnect power before opening.
115/230 VAC 50/60 HZ, 2000 Watts (Max)

KCM

CAUTION - Disconnect power before opening.

115/230 VAC 50/60 HZ, 2000 Watts (Max)

Co-Extrusion 2

Co-Extrusion 1 Example of BOPP Film Process with 3 Layers

Manufacturing plants:
K-Tron America Inc. Premier Pneumatics Inc. K-Tron (Switzerland) Ltd
Routes 55 & 553 606 North Front St. / P.O. Box 17 Lenzhardweg 43/45CH-5702
Pitman, NJ 08071 USA Salina, KS 67402-0017 USA Niederlenz
Tel: (856) 589-0500 Tel: (785) 825-1611 Tel: +41 62 885 71 71
Fax: (856) 589-8113 Fax: (785) 825-8759 Fax: +41 62 885 71 80
e-mail: info@ktron.com e-mail: info@ktron.com e-mail: ks@ktron.com www.ktron.com
2 © 2005 K-Tron International, Inc. A-800105-en (0590000461) 2009-11