>> INFOCUS - the Coperion Newsletter.
Edition 7 I 2016
Coperion delivers compounding plants to BASF in South Korea
Reliable partner for compounding plants
For a new compounding plant in South Korea, BASF relied once again on Coperion’s expertise: In September of 2015, the plant was handed over within the contractually agreed timeframe. Since then, BASF has been successfully processing polyamides of the highest quality.
Planning and implementation of the entire plant, all under one roof
Coperion delivered the entire production facility to BASF. The project scope included planning, assembly and start-up as well as verification of guaranteed performance data under production conditions. Moreover, the scope of supply and performance included all equipment and structures to be installed. The entire utility supply was also included in the scope of the project, encompassing not only electricity, but also compressed air, exhaust air purification and pelletizing water circulation, including cooling. All applicable standards and legal regulations for the construction and operation of compounding facilities in South Korea were observed throughout the project.
Throughout the compounding plant, proven Coperion processes and components are used for energy-efficient conveying of raw materials. New to this plant is the use of high-precision Coperion K-Tron feeders. These ensure continuous precise feeding of raw materials according to a predetermined formula into the heart of each line – the high-performance ZSK twin screw extruder. Following subsequent pelletization and drying, the finished product is carefully transported to the product silos. From there, the pellets are fed into the fully automated IBP 250 FFS bagging and palletizing system, which handles weighing, filling, marking, testing, and palletizing processes in a single unit. During the planning of the facility, careful attention was paid to ensure that all steps in the process were optimally coordinated.
Coperion as a reliable global partner — global network with optimal utilization of local resources
Coperion established a specialized team ten years ago for just such projects. The team is composed of specialists from several international company locations who complement each other in process and plant planning, project management, and coordination of the assembly as well as the start-up. Using this global network ensures that the best possible solutions are realized – always taking local circumstances and opportunities into account – for clients at every location around the globe.
Steffen Bader, Tel.: +49 711 897 2515, email
New packaging lines for SABIC in Pontirolo, Italy
Confidence earns Coperion a new project with SABIC
Based on many years of cooperation between SABIC and Coperion in plastic compounding – specifically material handling and extrusion – SABIC has decided to install six Coperion packaging lines and a common palletizing island at their plant in Pontirolo, Italy.
SABIC Italy is the market leader for small lots of plastic compounds with highly customized properties requiring specialized process technologies. Since the beginning of the packaging lines project, the main goals were extreme flexibility and quick cleaning as well as continuous tracking via bar codes linked to the various recipes. The challenge was to install six fully automatic, robotized and flexible lines for valve bags while fulfilling the goals described above. Being a prototype concept plant, Coperion applied years of experience in this field during the design process with SABIC, building a dummy prototype in the first phase before proceeding to installation and startup of all six lines.
The bags, positioned in a double stack magazine, are placed in filling position by robotized integrated pick and place arms. The machines are fed easily via bins that are placed above the machines and automatically connected to a gravity feeding funnel. Operation of the bin valve is also completely automatic. The entire process is guided via barcode readers, which identify the product batch, automatically setting all parameters on the relevant bagging machine as well as the labeling. Operators may easily identify what batch is bagged in each line via maxi LCD screens which function as remote displays for the main operator interface.
The machines are placed in two rows, allowing the operator to survey the bin area and perform cleaning or maintenance tasks safely and easily. All the equipment, including the bag magazine, is designed to be moved away for quick cleaning and easy maintenance without having to interfere with the rest of the system, which remains in operation. The robotized arms remain fixed to the main steel structure. Once filled, the bags are transported via several conveyors arranged in a customized layout, fulfilling all CE requirements in terms of safety as regards interlocking and design. Finally, the bags arrive at the palletizing island, after passing a further integrated check via an online barcode, ensuring that each batch goes to the right pallet. In the palletizing area, two robots with four axes provide a flexible palletizing layout with real time measurement of bag height via integrated laser control.
Manfred Wiedmann, Tel.: +49 751 408 674, email
New electronic pressure compensation for loss-in-weight feeder
Reliable and cost-efficient solution
Coperion K-Tron has introduced a unique new Electronic Pressure Compensation (EPC) system for their high-accuracy loss-in-weight feeders. The main advantages of the new system include improved accuracy and reliability as well as lower initial cost and easier installation compared to traditional mechanical pressure compensation systems. Retrofitting options for existing feeders are available. EPC can be installed on a majority of Coperion K-Tron gravimetric feeders in almost any application and all industries.
In a closed feeding system, pressure build-up inside a feeder can significantly impair weighing accuracy. The commonly installed mechanical pressure compensation systems are sensitive to structural factors and machine alignment and may therefore be intricate or even unreliable. Coperion K-Tron has now developed a clever but simple electronic solution for accurate and steady pressure compensation in feeder hoppers. The modular design incorporates pressure sensors and electronics tailored to interact smoothly with Coperion K-Tron’s KCM feeder control system. Depending on set-up and requirements, sensors can be positioned on the feeder hopper and, if required, on the material discharge tube. The software implements a self-optimizing compensation algorithm for best performance and dynamics identical to those of Coperion K-Tron’s SFT load cells, which allows for highly accurate feeding results, even in systems with perceivable pressure fluctuations.
A separate field evaluation kit allows for the assessment of potential pressure issues in existing installations.
John Myhre, Tel.: +1 856 256 3254, email
Patent for 5A kneading blocks successfully defended
Long-standing patent case decided in favor of Coperion
Coperion has successfully defended the European patent protecting its ZSK series twin screw extruder with 5A kneading blocks in the final instance before the Board of Appeals responsible at the European Patent Office. 5A kneading blocks are used in many of the high-performance twin screw extruders of the ZSK series from Coperion.
The 5A kneading blocks protected by EP patent number 1 508 424 B2 have been proven to prevent the torsional vibration occurring in high performance extruders. These extruders are often stimulated in the resonance frequency, that may lead to cracked shafts or coupling malfunctions. To counter these effects, Coperion developed kneading blocks that can help to reduce the stimulating forces. Coperion owns said patent for the 5A kneading blocks and in April 2016, the company was able to successfully defend it. Since registering the patent in 2003, Coperion has primarily used the 5A kneading blocks for large-scale machines to avoid possible damage.
Coperion also holds patents for the 5A kneading blocks in China, Japan, India and Taiwan.
Dirk Kyrion, Tel.: +49 711 897 2486, email
Coperion ServiceBox awarded
Industry 4.0 award for new Coperion ServiceBox
Coperion, together with INTEC International, received an award for the development of the ServiceBox as part of the "100 places of Industry 4.0 in Baden-Württemberg" competition. The award recognizes companies that are characterized by innovative concepts related to Industry 4.0. The focus is on the intelligent networking of production and value-added processes.
Coperion’s ServiceBox is an integrated system for online monitoring and failure recording in extruders and compounders. The ServiceBox connects the customer’s plant network with the Coperion Service server via secure internet connection and thus enables remote maintenance of the plants delivered by Coperion.
Expensive on-site assignments of service technicians can be reduced, with the Coperion ServiceBox, as the existing network infrastructure is used for comprehensive remote online diagnosis. Data security is granted through state-of-the-art security technology. Integration and monitoring of various plants, systems and components via standardized interfaces and easy integration of condition monitoring modules is possible. Besides easy transfer of software updates online adaptation of control parameters is also possible. Our active startup guidance and fast expert support are the ideal solution for cost-effective production with effective quality control.
The ServiceBox was launched in 2010. Since then, over 800 extruder and compounders have been equipped with ServiceBoxes since then.
Martin Simianer, Tel.: +49 711 897 2636, email