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Coperion displays new compounding processes and machinery at K 2004

Coperion Holding GmbH : 01 August, 2004  (New Product)
Germany's Coperion Werner & Pfleiderer GmbH & Co KG is presenting a range of new machinery at the K 2004 (Stand 14 /C17 in Hall 14), which is being held on 20-27 October 2004 in Dusseldorf/Germany.
Germany's Coperion Werner & Pfleiderer GmbH & Co KG is presenting a range of new machinery at the K 2004 (Stand 14 /C17 in Hall 14), which is being held on 20-27 October 2004 in Dusseldorf/Germany.
Coperion Werner & Pfleiderer has developed a two-stage compounding extruder ZSK-NT for compounding bimodal polyethylene. As a result of a special polymerisation process, such polymers contain short polymer chains for good processability and chains of high molecular weight for good functional properties.
During compounding of the powdery raw polymer to form pellets ready for processing, two process steps are of crucial importance for the final product quality: melting the polymer without overheating and the homogenisation of the constituents with their different viscosities. With the newly developed ZSK-NT, these two process steps have been separated for the first time and can therefore be optimised independently of one another. The first, relatively small ZSK compounder melts the polyethylene powder gently and with a low energy input at a high screw speed before transferring the melt to the larger, slower rotating homogenising extruder. Specially developed screw elements distribute the high molecular weight components them uniformly and gently at low temperature in the lower molecular portion of the material without breaking them down. This creates pellets that can be easily processed without further homogenisation to produce high quality products such as tubes, films or filaments that are free from fish eyes.
Coperion Werner & Pfleiderer is presenting the ZSK MEGAcompounder PLUS, a further improved version of the ZSK MEGAcompounder. A design modification of the machine, in particular an increase in the specific torque at the screw shafts, has enabled the throughput to be increased by up to 20 % with the same size of machine.
The laboratory and mini-batch extruder ZSK 26 Mc, on display for the first time at the K 2004 offers Coperion Werner & Pfleiderer customers new features. A direct scale-up to the ZSK MEGAcompounder series is possible because the screw and drive of the ZSK 26 Mc are designed to the same key data. The machine is supplied as a compact unit with integral control cabinet, reducing floor space requirements and permitting quick and easy commissioning.
The higher values for drive power and torque, compared with the predecessor model permit speeds of up to 1800 rpm, and higher throughputs, but without hindering the production of very small volumes right down to 1 kg batches.
The 'classic' method of reducing costs in plastics applications involves the integration of functions into components. An equally interesting method that is still in the early days of its development is process integration, in other words the elimination of production steps through direct processing. Coperion Werner & Pfleiderer is presenting two such current technologies at the K 2004:
For wood/plastic composites the ZSK MEGAvolume, and a specially developed process technology, enable profiles with a high mechanical strength to be manufactured in a single process step from a basic polymer -- polypropylene or polyethylene -- and high-quality wooden fibres without pre-drying. Pellets suitable for injection moulding can be produced even more easily.
For the compounding and direct extrusion of polyethylene terephthalate, neither pre-drying of the materials nor the crystallisation and agglomeration of reclaim are necessary through the high degassing efficiency of the ZSK MEGAcompounder. This technology also allows mixtures of virgin material and reclaim to be processed for direct production of film, fibres or injection moulding pellets. After a 12-hour solid phase post-condensation, the pellets can even be used in the foodstuffs sector.
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