>> INFOCUS - the Coperion Newsletter.
Edition 11 I 2012
Complete plants for the processing of bio-materials
Bio-materials impress with special qualities
Coperion produces complete plants for the processing of bio-materials and offers its customers comprehensive know-how and decades of experience. The bio-materials include biodegradable as well as bio-based plastics and plastics reinforced with wood or other natural fibers.
Processing of biodegradable materials makes very high demands on the compounding process because of the variety of possible base polymers and the great differences in the recipe mixtures. A typical application of biodegradable plastics for example are starch-based, expanded packing materials. The biodegradability offers particular advantages especially for disposable products with a short useful life.
Other applications for the processing of biodegradable products on a ZSK twin screw extruder are for example:
· Thermoplastic starches for foils, deep drawn foils or injection moldings.
· Polylactide (PLA), PVOH, synthetic copolyester, PBS, PHA, PCL, CA
· Pelletizing of PLA, polymerization of PLA
Bio-based raw materials are being used increasingly especially for engineering plastics. Non-pre-dried polyactide is processed similarly to PET, for example, to produce flat foils by direct extrusion.
The ZSK twin screw extruder has been established on the market for the processing of Wood Plastic Composites (WPC) for many years. Developments such as the ZS-EG side devolatilization machine by means of which wood fibers can be processed up to a moisture content of approx. 5% without pre-drying, make a major contribution to the product quality and cost effectiveness. The Feed Enhancement Technology (FET) enables bulk goods with a very low bulk density, such as fine wood fibers, to be fed into the extruder effectively in larger quantities. This increases the throughput rate and filling level in the machine process section and reduces the specific energy input SEI and thus the product temperature. This is very important for WPC and in general for the incorporation of natural fibers because this preservative method prevents discoloration or development of smells and avoids heat damage to the fibers.
Typical examples for the use of natural fibers are
|Filling and reinforcement of PP or PE with 40 to 70 weight-% wood fibers|
|Filling and reinforcement of different basic plastics with natural fibers such as flax, hemp or cellulose|
|Processing of WPC for injection molding applications|
|Direct extrusion of WPC profiles|
BULK-X-CHANGE® for future installations at OCI Nitrogen
Bulk materials heat exchanger BULK-X-CHANGE®
At the beginning of 2012, in line with the expansion of its plants, the fertilizer producer OCI Nitrogen, situated in Geleen, Netherlands has decided to make further use of two more bulk materials heat exchanger BULK-X-CHANGE® for cooling down calcium ammonium nitrate (CAN).
The reliable operation of this new technology, which offers considerable technical advantages through both its circular design and its completely closed construction led to the decision of OCI (formerly DSM Agro) to use the BULK-X-CHANGE® as key component in future projects.
|Capacity:||60 t/h CAN|
|Cooling down:||from 105°C to < 35°C|
|Diameter:||< 2.500 mm|
|Total length:||approx. 16 m|
Delta produces compounds with ZSK MEGAvolume PLUS
Twin screw extruder for producing conductive plastics
Delta Kunststoffe AG with its headquarters in Weeze relies on the extensive system and process know-how of Coperion GmbH. Delta utilizes the advantages of the ZSK MEGAvolume PLUS twin screw extruder from Coperion GmbH to produce electrically conductive plastic compounds.
The extruder is used to incorporate conductive carbon black in plastics such as polypropylene, polyethylene, polystyrene or polyamide. Depending on the requirements – from anti-static to well conducting – the twin screw extruder with a screw diameter of 76 mm produces compounds with 15 to 40 weight-% carbon black and achieves throughput rates of 1,000 to 1,500 kg/h.
In addition to the functional benefits, the profitable investment cost / throughput rate ratio, low personnel costs and low specific costs for energy, maintenance and servicing convinced the Delta Kunststoff AG.
The compounding plant has been in operation since August 2011. “We made the right decision in buying the ZSK 76 MEGAvolume PLUS twin screw extruder”, so Manfred Fiedler, Site Manager Delta Kunststoffe AG. “We achieve high throughput rates. But, above all, we benefit from a high compound quality and the flexibility of the modular structure of the ZSK. These features enable us to react on changing or new market requirements.”
Bernd Ormanns, phone: +49 711 897 3459, e-mail
Eberhard Dieterich, phone: +1 201 825 6408, e-mail
The advantages of the ZSK 76 MEGAvolume PLUS
|Constantly high, reproducible product quality|
|Only one feeding point necessary for the conductive carbon black due to large free screw volume (diameter ratio Do/Di = 0 1.8)|
|Effective devolatilization of the melt by ZS-EG twin screw side devolatilization unit|
|Gentle processing by feeding carbon black directly into the melt and low shearing of the product due to deep cutted screw flights|
|Homogeneous distribution of the carbon black in the plastic matrix with special mixing elements of the screw|
Coperion's practice-based training courses for customers and partners
High plant availability and productivity due to qualified staff
In order to guarantee our customers high plant availability and productivity, Coperion offers its customers an extensive qualification program in addition to the 24/7 emergency hotline.
Training courses are an investment that quickly pays off in practice. The production process and the safety are optimized, the downtimes and maintenance times are reduced and the product quality is improved. Coperion's comprehensive training program familiarizes your production and maintenance staff for their work with technically sophisticated machines and plants. The course contents range from machine and plant technology, mechanical engineering, basic principles of pneumatic conveying technology, processing and control technology to maintenance and service. Coperion provides all the know-how necessary for operating, maintaining, setting up and repairing Coperion plants. Our training courses are aimed specially at the needs of the participants – from the beginner to the expert. Naturally, we also keep you up to date on interesting and informative technical topics and new products.
The theoretical and practical course units are presented by experienced specialists within the scope of our proven qualification program. The courses are held in small groups on machines and subassemblies of the latest generation. The courses take place either in our Training Centers in Stuttgart, Weingarten and Ramsey (USA) or on site at your request. We present you with a certificate of participation.
We will gladly help you choose the optimum course or develop a tailor-made solution for you.
Contact us – we look forward to hearing from you soon.
Your contact - Compounding & Extrusion:
Udo Bode, phone: +49 711 897 2379, e-mail
Your contact - Materials Handling:
Carsten Packeiser, phone: +49 751 408 619, e-mail
Your contact in USA:
Paul Andersen, phone: +1 201 825 6428, e-mail
Coperion at the VDI Annual Convention “Processing Technology”
The focus at this year’s VDI Convention “Processing Technology” is on how compounder, machine and raw material manufacturers can meet the new requirements for their processes and products. It is being held on November 27 and 28, 2012 in Baden-Baden, Germany.
Do not miss the lecture by Peter von Hoffmann, General Manager, Business Unit, Engineering Plastics & Special Applications, Coperion GmbH, Stuttgart, on Tuesday, November 27, 2012 at 14:45 h.
Discuss with experts and benefit from exchanging experience with colleagues and lecturers.
The topics at a glance
|Different machine concepts for different customer circles and applications|
|Production concepts for machines and systems in various regions of the world|
|Which parts of a processing plant can be procured locally?|
|Example of a production site in China Requirements, quality assurance, opportunities and risks|
|Worldwide service: Expectations from machine suppliers and their solutions|
|Implementation philosophies of processing customers in expansion|
|Examples of international expansions of globally operating compounders|
Frank Lechner, phone: +49 711 897 3168, e-mail