Double screw plastic granule extruder line
(The picture’s only for reference)
I.General information
Output capacity | 400kg/h, Line speed: 1-35m/min |
Description of final product | 1.Thickness: 0.12-1.2mm 2.Width: ≤760mm, Can be adjusted by Cutter 3.Two side silicon oil available |
II.Main commercial terms
Project | Sheet line |
Payment terms | 40% down payment by T/T upon after signing the contract; |
Delivery time | 120 days since the date of receiving down payment |
Warranty period | The Seller warrants this Product against defects in material and workmanship for a period of thirteen (12) months from the date of completion of the installation of the whole machine. |
Validity of the quotation | The quotation is valid until 1 month after date of generation. |
III.Working condition
Power supply：AC480V±10% 50Hz 3P+E
Compressed air：0.5～0.8Mpa（DP≤10℃）
Cooling water：≤30℃ 0.2～0.4Mpa
Installation power：225KW, The real consumption only 65%-70%.
Operation side: Left from the extruder
IV.Equipment List
1. 85/40 Co-rotating Twin-screw extruder | 1 Unit |
2. Hydraulic exchanger | 1 Units |
3. Melt Pump | 1Units |
4. T-DIE | 1 Unit |
5. Three-roller calendar | 1 Unit |
6. Temperature control | 1Unit |
7. Cooling bracket | 1 Unit |
8. Trimming unit | 1 Unit |
9. Double silicone oil coating device | 1 Unit |
10. Haul off unit | 1 Unit |
11. Electrostatic eliminator ( one set from up and bottom) | 1Unit (two pice) |
12. Three-position torque winder Moment | 1Unit |
13. Electric control system | 1 Unit |
Detailed parameters:
1.85/40 Twin- screw extruder
Main features：
●Closely intermeshing screw profile with screws that are self-wiping at narrow clearance for easy production and color changes.
●Modular building-block system (4D) for screw elements and screw barrels.
●High-duty cast bronze and cast aluminum heater shells for intensive and reliable heating
●EACH barrel One temperature zone for optimal processing
●Special mixing and shearing elements with varying effects for high process flexibility
●Variable screw speed 30 to 300 rpm allow a wide range of process technologies
●Large free volume due to outer/inner screw diameter ratio Do/Di ~ 1.55 for optimum processing
1.2 Screw Barrel
The flexible modular principle is realized with screw barrel sections from the wide range of different designs possible. Fast, intensive and uniform heating of the screw barrel section is ensured by electrical heaters. The barrel sections are cooled with water, by means of an internal bore system, with bores arranged close to the inside barrel wall.
Barrel sections are available as：
●Hardness max. HV 1050
●Closed barrel section
●Barrel section with opening for material feed or for devolatilization
●Barrel section with top and lateral opening for top venting and the connection of a side feeder
The processing section is provided with stainless steel plates as a protection against accidental contact.
1.3 Screw shafts/Screw elements
The intermeshing screw co-rotate and wipe each other with narrow clearance so that no residues are left in the screw flights and cleaning effort is reduced.
The screw shaft system is characterized by the following：
●Hardness max. HV 950
●Through-going solid shafts
●Screw elements with various pitches and lengths
●Kneading blocks with various angles of stagger, numbers of kneading disks and disk widths
●Screw tips to fix the screw set axially.
●Gear teeth connection to ensure power flow between the screw shafts and screw elements.
1.4 Manifold/cooling water
The manifold is used for intensive of the TSH barrels. The feed barrel is cooled by means of a manually adjustable value.
The unit consist of：
●1 feed header (stainless steel)
●1 manual control zone
●Automatic control zones according to specification
●1 bypass
1.5 Water cooling unit
The water cooling unit is used for cooling of the extruder screw barrels (processing section). The unit is supplied ready for connection.
Following function groups are mounted in housing :
●1 water pump
●1 heat exchanger
●1 stainless water tank
●1 stainless water pipe
●1 valve
●1 filter
Technical data：
Barrel inlet temperature | Max. 75℃ |
Barrel outlet temperature | Max. 100℃ |
Cooling capacity | 50Kw |
Circulating medium | Demineralized water |
Pump capacity | 0.55Kw |
Water tank volume | 300L |
1.6 AC Main drive unit
The extruder main drive unit is a three-phase motor. Cooling of the motor is ensured by a fan mounted on motor.
Technical date – motor
Cooling method | IC 416 with axially installed external blower |
Power | 160Kw |
Brand | SIEMENS BEIDE |
Model | 1TL0001-3AB53-3AA5-132KW-B3-K09 |
Control | ABB Inventor |
Speed | 1480 rpm |
Speed adjusting range at constant torque | 1:5 |
Protection class | IP 54 |
1.7 Reducing and distribution gearbox (MADE IN TAIWAN)
The gearbox reduces the motor speed to the speed of the screw shafts and distributes it to two output shafts. It features particularly quiet running properties, even at high speeds.
The gearbox consists of：
●Involute gear teeth couplings between the output shafts and screw shafts
●Integrated thrust bearing assembly, key bearings use NSK products.
●Hardened gear surface to HRC58-62, grinding precision to grade 6.
●Housing manufactured on CNC
●Forced oil lubrication system for bearings and gear meshing, max. 70℃
●Bottom part of casing designed as oil sump
Technical data：
Permissible output torque/shaft | 2870Nm |
Torque level | 8.8 |
Speed ratio | 3.75 |
Oil filling by customer | 80 Ltr |
Motor power of oil pump 50/60Hz | 1.5 Kw |
1.8 Single-screw volumetric feeder
The single-screw volumetric feeder allows feed in powder on pellet form. Feeding capacity can be regulated by changing the screw speed.
The unit consists of：
●1 gear motor
●2 feeding barrel
●2 feeding screw
Technical data：
Outer screw diameter | 90mm |
Screw speed variable | 9-88 l/min |
Weight | Approx. 260 kg |
Drive power | 3 Kw |
1.9 Vacuum-system
The unit consists of：
●One water-ring pump
Power: 7.5KW
Made in China
●One vacuum pump
Model: SOGEVAC-300B
Power: 5.5Kw
●One vacuum tank with cooling device
Technical data：
Pump power | 1*7.5KW ，1*5.5KW, 1*4KW |
Max. Vacuum | ≤25Pa |
Swept volume | 600L/s |
2.Melt Filtering
The filtering system is hydraulic, and the construction is double pistons, column type.
The screen change parts adopts high-grade ally with super wear-proof, pressure proof and high precision. Once the hydraulic system is started, hole-to-hole screen changing can be quickly accomplished in only 2.0 second.
2.1 Net changer (double-column)
Drive-- Hydraulic system
2.2 Hydraulic Station
The unit consist of
●1 Oil pump: 3kw, 1440r/min, made in China.
●Control valve: YUKEN, Japan
●1 Accumulator model: NXQ—L10/200-H
Main technique parameters of this system
●Working pressure of the system (p): P≤21Mpa
●Flow rate: 10L/min
●The fueling charge the oil box: 100L
●Working Medium: No.46 hydraulic oil resistance to abrasion
3. Melt Pump
The shell of the pump adopts high-quality alloy-steel and the gear uses quenched chrome steel or other high-grade metallic which ensures high efficiency and leakage-proof.
Technical data：
Type | 150cc |
Speed | 5-70 r/min |
Drive | 7.5kw AC Motor Gearbox |
Control system | DANFOSS inventor |
There are three positions to measure melt pressure, that’s before the filter, before the pump, after the pump, the pressure sensor before the pump is GEFRAN, made in Italia.
4. T-die
Die construction | Hanger channel, micro-adjustable upper die lip, the die is perfect for PET single-layer or multi-layer sheet. |
Die width | 950mm |
Product width | 760mm （net） |
Product thickness | 0.12~1.2mm |
Material | German Steel H38 |
5. Three-roller calender
We use high precision servo drives on all sheet calender, and the speed of rollers is independently controlled. The rolls have a double shell construction, with multiple spiral baffles to assure high cooling fluid velocity for uniform roll temperatures.
Main construction characteristics:
●3 rollers
●Roller configuration: horizontal
●Roller opening/closing: hydraulic
●Roller gap adjustment: mechanical – manual
●Safety measure: Emergency stop button, with self-lock function
5.1 Technical data of roller：
Roller diameter | 1×∮350mm×1000mm |
Roller material | 42GrMo |
Roller surface treatment | Outer surface deeply quenched and hard chromed, the hardness can reach HRC58-65， mirror polished. |
Roller construction | cooling through spiral grooves |
Rotary joint | Brand: Taiwan Brand |
Roller bearings | Brand: NSK, Japan |
5.2 Technical data of drive：
Motor Power | 3*2.9Kw |
Motor Brand | YASKAWA, Japan |
Motor Model | SGMGV-29ADC-61 |
Speed | 1500 rpm |
Gearbox Brand | FALK, USA Brand |
5.3 Technical data of roller gap measurement：
Type | Gap adjusted by worm wheel and worm manually |
5.4 Technical data of Calender Hydraulic Station
The unit consist of
●1 Oil pump: 4.4kw, 1440r/min, made in China.
●Control valve: YUKEN, Japan
●4 Hydro-cylinder model: CJT140-FB100B50N-A-E-11
●1 Accumulator model: NXQ—L10/200-H
Main technique parameters of this system
●Working pressure of the system (p): P1=12Mpa, P2=6Mpa (1Mpa=10kg/c㎡)
●Flow rate: 10L/min
●The fueling charge the oil box: 100L
●Working Medium: No.46 hydraulic oil resistance to abrasion
6. Temperature control system
Cooling medium | Water |
Temperature range | -100℃ |
Heating power | 3*12kw |
Pump power | 3×3KW |
Heating exchanger | |
Be with alarm function of over pressure, over temperature and water shortage. | |
7. Cooling bracket
Total length | 5meters |
Roller specification | ∮80*1000mm |
Aluminum roller surface measurement | Oxidized, polished |
Roller Hardness | HV700 |
Roller Roughness | Ra 0.04 |
All the cooling roll are processed by dynamic balance, level G2.5
8. Side trimming unit
Methods | Trimming by disc blades |
Distance between knives | Adjustable, adjustment method is screw mechanism |
9. Double face silicone oil coating device
Roller diameter | 150mm |
Roller width | 1000mm |
Drying method | Oven heating, temperature controlled |
Coating method | Double surface coating， adjust by cylinder |
10. Haul off unit
Roller specification | ∮200*1000mm |
Roller material | Nitrile rubber |
Motor and gearbox | Falk gearbox, YASKAWA servo motor |
Control | Can be controlled synchronously with the three rollers or separately. |
11. Electrostatic eliminator
Roller specification | 1000mm |
Principle | Neutralization electrostatic |
Ion equilibrium | 0±10V |
12. Technical data：
Foil width | ≤1000mm |
Reel diameter | ≤600mm |
Max. weight | 200kg (sheet width:760mm) |
Control | Length automatic control, motor driven . |
Specifications | 3 inch inner core |
13. Electrical control system
PLC | SIEMENS S7-200 |
Control panel | SIEMENS Touch screen |
Air switch | LG or CHINT |
Solid Contactor | OMRON |
Breaker | IDEC |
Main motor inventor | ABB |
Roller motor and controller | Servo motor, YASKAWA Made in Japan |
IV spare parts | |
1. O TYPE circle | 3pcs |
2. Solenoid valve | 2pcs |
3. Asbestos gloves | 2 pcs |
4. Allen wrench | 1set |
5. Hexagon wrench | 1set |
6. (φ30*250）Copper rod (φ30*250) | 1pcs |
7. Screw ring | 2pcs |
7. Mold special tools | 1set |
8. Thermocouple 3m | 5pcs |
9. 5m Thermocouple 5m | 5pcs |
10. Contactor | 3pcs |
11. Relay | 3pcs |
12. Low voltage circuit breaker | 3pcs |
13. Small open | 3pcs |
14. Unpowered aluminum roller | 2pcs |
15. Pneumatic control valve | 1pcs |
16. Tube heating coil | 1pcs |
17. Flange heating ring | 1pcs |
18. Flow heating coil | 1pcs |
19. Copper feeler | 1pcs |
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