Cable Pellet Extrusion Line

Initial data:

Polymeric raw materials and its structure:

Polyethylene Sabik 318B granules

HDPE 273-83 granules

Carbon black concentrate 40-50% granules

Irganox 1010 powder

Dibutyltin Dilaurate (Tin Dibutyl Dilaurate) liquid

Requirements for the technical characteristics of the line:

Performance 800-1000 kg / h

Ambient temperature +10 ÷ + 40 ° C

Offered equipment: Extrusion line for the production of granules of composite material

for the cable industry based on a twin-screw extruder complete with a gravimetric dosing
system and a liquid ring granulation system.

Polymeric raw materials and its structure:

Polyethylene Sabic 318V (8-80%) granules

HDPE 273-83 (8-80%) granules

Carbon black concentrate (5-50%) granules

Irganox 1010 (0.5-5%) powder

Dibutyltin dilaurate (0.5-5%) liquid

Specifications:

Performance 800-1000 kg / h

Ambient temperature +1 ÷ + 40 ° C

Inlet cooling water temperature 15 ° C

Installed capacity:

General processing sections 710 kW

Heating and compounding section 170 kW

Compressed air:

Consumption 800 l / h

Pressure 6 bar

Quality Dry, oil free

Electric motor:

Power 11 kW

Power supply 380 V / 50 Hz / 3 f

Rotation frequency 1500 rpm

Degree of protection IP54

Material performance:

Parts in contact with water DIN ~ 1.4301 stainless steel (08X18H10)

Extruder CrMo steel with wear resistant UX155 inserts

Shafts Special hardened torsion resistant alloy

Blades / Rolls Hardened and wear-resistant steel

Standard parameters of energy carriers:

Cooling water: Solid water free of solids

Maximum water temperature vacuum system less than 15 ° C

Maximum line water temperature less than 30 ° C

Hardness of water 15 ° F French max

Pressure not less than 5 bar

Air:

Pipeline pressure 6/7 bar (dry and peeled)

Pressure deviation ± 0.3 bar max.

Electricity: Electrical equipment in accordance with CE standards

Power supply 400 V / 50 Hz / 3 f

 Accessories voltage 220 V

Degree of protection IP43 - non-condensing

Extrusion line equipment:

 Support frame;

 Reception hopper for polyethylene granules;

 Gravimetric dispenser for polyethylene granules;

 Hopper for pellets of carbon black concentrate;

 Gravimetric dispenser for granules of carbon black concentrate;

 Receiving hopper;

 Gravimetric dispenser for granules;

 Gravimetric dosing pump for dibutyltin dilaurate;

 Electric control unit;

 Twin screw extruder;

 Vacuum unit for closed ventilation circuit;

 Energy-saving extruder motor

 Electrical panel for digital converter;

 15 "touch screen electric control cabinet;

 Electrical connection inside the line;

 Pressure and temperature sensors;

 Water ring granulator;

 Closed loop cooling systems;

 Vibratory screening plant for granules.

Rubber Composite Products Production Line

Initial data: HDPE (High Density Polyethylene) M fi 3 - 5 g / 10

Filler: powdered vulcanized rubber from recycled tires. Homogeneous powde

and up to 1000 µ (recommended size 250 - 500 µ).
Max humidity: 4 - 5%

Basic Technology Formula: 30 - 50% HDPE

50 - 65% rubber powder
5 - 10% additives

The exact ratio of components is determined after a laboratory test.

Performance: extruder rated capacity: 200 kg / h

Depending on the formula of the process and the properties of the raw material. Exact data are determined after laboratory tes

Profile Form 1: embankment / material / lot 60x60

Weight: 3.55 kg / m ln
Theoretical density: 1.1 - 1.20 kg / dm3
Max linear speed 1 m / min ± 10%

Productivity: expected power with a type of material profile 60x60: 180 kg / h ± 10%
depending on the formula of the process and the properties of the raw material. Exact
data are determined after laboratory tests.

Profile Form 2: material in the form of a semi-pyramid 70x60x45

Weight: 3.125 kg / m ln
Theoretical density: 1.1 - 1.20 kg / dm3
Max linear speed 1 m / min ± 10%

Productivity: expected capacity with the type of material profile in the form of a half-
pyramid 60x70x45: 160 kg / h ± 10%,
depending on the formula of the process and the properties of the raw material. Exact
data are determined after laboratory tests.

Work principles:

1. Gravimetric feeder for HDPE (High Density Polyethylene)

2. Gravimetric feeder for recycled materials
3. Gravimetric feeder for pigment concentrate
4. Gravimetric feeder for additives in powder
5. Gravimetric feeder for filler
6. Side feed for Filler
7. Degassing

Benefits of Direct Extrusion

No need to premix / granulate the material.

Higher moisture content is applicable.
Compact.
Simple logistics management.
Energy saving.
Lower maintenance / management costs due to the smaller extruder size.
Lower maintenance costs due to the modular design of the screws and barrel (capacity).
Significant cost reduction (for energy, labor, logistics, management ...).
Higher mechanical properties due to improved filler / plastic mixing.
Less material degradation due to only one heating / separation history.
Continuous line of regulation (adjustment) of the composition.
Support of own know-how in the production process for domestic orders.

Linear components

SECTION A loading and unloading devices for raw materials

SECTION B Gravimetric feed device
SECTION C simultaneously rotating twin-screw extruder
SECTION D molds and calibrators
SECTION E main control cabinet
SECTION F equipment located downstream

Options and auxiliary systems

For section C: closed loop system for ventilating vacuum pump
Option 1 equipment for coextruded finishing layer
Auxiliary system 1 method of grinding waste
Auxiliary system 2 installation for water cooling

1. Processing of raw materials (raw material).

2. Gravimetric continuous feed devices.
3. Support frames.
4. Simultaneously rotating twin screw extruder.
5. Side feed device for filler.
6. Gear pump polymer dosage.
7. Mold for profile.
8. Calibrators and cooling bath.
9. Calibrator support table.
10. The removal of the product from the extruder.
11. Brush or stamping system.
12. Cross-sectional system.
13. Table picking (collection).

SECTION A loading and unloading devices for raw materials

Pos. A. 1 The polymer in the form of granules in bags of 25 kg

Pneumatic feeder with intake probe.
Granules will be pulled out of the box (basket) (not included in the scope of supply),
which is located on the side of the extruder.
Max horizontal distance 5 m.
Max vertical distance 6 m.

Pos. A.2 Ground waste

For flakes in a box (not included) located on the side of the extruder.
Pneumatic feeder (loading device (with intake probe.
Max . Horizontal distance 5 m.
Max . Vertical distance 6 m.

Pos. A.3 Additives in the form of granules

Manual loading from the storage rack.
Pos. A.4. Powder additives
Manual loading from storage rack.

Item A.5 Powdered filler

For fillers in large bags.
Holder design for large bags (max. Dimensions 1.1x1.1x2 m)
Suspension for large bags: manually with a forklift
Pneumatic discharge system for difficult to move powder.
Basket (box) for storage with a vibration system.
Powder filter for air ventilation.
Archimedean screw loading system.

SECTION B Gravimetric feed device for raw materials

Pos. B.1 Gravimetric feed device for polymer in the form of granules

Dosing system of continuous weighing feeder with a maximum power of up to 50% of the
capacity of the entire line.
High Resolution Screw Feeder Digital Loading Cell.
Re-loading hopper 50 l.
Level sensor.
Pneumatic discharge valve.

Pos. B.2 Gravimetric feeder for shredded waste

Dosing system of continuous weighing feeder with a maximum power of up to 15% of the
entire line capacity Screw-type feeder
with high resolution digital loading cell.
Re-loading hopper 23 l.
Level sensor.
Pneumatic discharge valve.

Pos. B.3 Gravimetric feeding device for the additive in the form of granules
Dosing system of a continuous weighing feeder with a maximum power of up to 10% of
the productivity of the entire line
Screw-type feeder with a high resolution of a digital loading cell.
Re-loading hopper 23 l.
Level sensor.
Pneumatic discharge valve.
Pos. B.4 Gravimetric feed device for the additive in the form of a powder
Dosing system of a continuous weighing feeder with a maximum power of up to 10% of
the productivity of the entire line
Screw-type feeder with a high resolution of a digital loading cell.
Re-loading hopper 23 l.
Level sensor.
Pneumatic discharge valve.

Pos. B.5 Gravimetric feeding device for powdered fillers.

Dosing system of continuous weighing feeder with maximum power up to 65% of the
entire line capacity. Screw-type feeder
with high resolution of a digital loading cell.
Re-loading hopper 200 l. special design for powder, which is difficult to pour over
the vibration level sensor.
Pneumatic discharge valve.

Pos. B.6 Control panel

For controlling up to 8 weighing systems.
Easy-to-use graphic display with touch screen.
Batch management software.

Pos. B.7 Steel support frame

For supporting the weighing batcher and loading devices.
Robust and stable design for mid-floor personnel to work without interfacing with
gravimetric weighing / control system.
Stairs for access to the drive rack.

B.7.1. Power Distribution Network

A set of cables for connecting each refill device to the control cabin.
A set of cables for connecting each gravimetric device to the control cabin, including a
special cable for communication.
Cable gutter kit for appropriate support when laying cables.

B.7.2 Compressed air distribution network

A set of pipes for connecting each device installed on the platform from a separate supply
point.
Complete with pressure regulator and air filter.
SECTION C simultaneously rotating twin screw extruder

Pos. C.1
High-performance twin-screw extruder at the same time , screw type meshed for self-
cleaning characteristics.

Screws Diameter: 71 mm

Ratio nom length / diameter: 1:40

Max screw speed: 200 rpm

C.1.1. Supporting steel welded frame

Made of durable welded steel plates and profiles.
Provided with leveling bolts.

C.1.2 tank (capacity) of

modular design, made from square container 10 sectors, each sector has a length of 4 D.
The housing of the sectors is made of steel C-50 with a removable inner lining, wear-
resistant alloy.
Integrated water cooling circuit, simple design and easy maintenance.
High efficiency heating system - cartridge heater.

C.1.3 Screw set A

special alloy piercing shaft - resistant to damage / deformation / twisting.
Modular design.
Screw elements

C.1.4. Gearbox

The torque of each screw shaft Nm 1750 of each shaft

Gear ratio 7.5: 1

C.1.5. Main ac motor
Gearbox Power 73 kW

Speed 1500 rpm

C.1.6. Water cooling unit for an extrusion tank (tank)

For supplying cooling water to each sector of the tank.
Including circulating pump.
Water / water heat exchanger with expansion chamber.
Connecting pipeline.

C.1.7. Melting point and pressure sensors

Built into the front end of the tank.

Pos. C.2. Ventilation system, including: a

vacuum pump with a water ring (closed loop system, offered as an option)
ventilation duct
smoke condenser
intermediate powder collector

C.2.1. Additional ventilation system

For waste excess moisture from filters.
Natural ventilation (not a vacuum pump).

C.2.2. Special anti-clogging system for wood flour

Double-screw device for pushing back material that comes out of the tank (tank) due to
the increase in volume and pressure of the steam.
It is necessary for a high percentage of filler filtration or high moisture content.
A vacuum hole is installed at the top opposite the screws.
The screws are made of hardened and brushed steel.
Heat-treated steel tank.
It is driven by an AC gear motor.

Pos. C.3 Twin screw side feeder

Screws, diameter: 70 mm
For feeding fillers into molten plastic.
Double screws of interlocked type.
Screws made of hardened and brushed steel.
Tank (capacity) of hardened steel with a water cooling circuit.
It is driven by an AC gear motor controlled by a digital frequency controller.

Pos. C.4 Gear 70
To stabilize the linear output and generate sufficient pressure to power the die head
without affecting the quality of the extruder.
Special design suitable for extrusion of filled materials.
Special wear-resistant coating for pump housing and gearboxes.
7, 5 kW gear motor and universal connection.
The probe (probe) of the melting pressure at the inlet / outlet.
The probe (probe) of the melting temperature at the outlet.
Heating zones incl. main office (control), a specialized control system connected to an
extruder control device.

Options for section C

Pos. C.5 Closed circuit for a vacuum pump

It is advisable not to waste water, and there is no workshop for water treatment.
An air / water separator tank is integrated in the pump support.
Integrated water / water heat exchanger.
Water needs to be changed frequently (after 305 days, depending on the level of water
pollution).

SECTION D Molds and Calibrators

Pos. D.1. Compression mold of profiles for bulk material of a profile 60х60

D.1.1. Extrusion molds for profiles

Connection with gear pump.
Built-in, stainless steel.
Heated by electric heaters.
# 5 temperature-controlled zones, incl. main office.

D.1.2. Calibration group of profiles

Dry and wet system.
Calibration device that opens by means of hinges (hinges).
Made of stainless steel.
D.1.3. Under vacuum cooling tanks.
Made of 3 sections 2 m long.
2 sections with a vacuum ring.
1 section for cooling only.
Made of aluminum and organic glass (plexiglass).
Cooling system "full water (completely water)".

Pos. D.2. Molds of profiles of bulk material in the form of a semi-pyramid, profile

70x60x45

D.2.1. Extrusion molds for profiles

Connection with gear pump.
Built-in stainless steel.
Heated by electric heaters.
# 5 temperature-controlled zones, incl. main office.

D.2.2. Calibration group of profiles

Dry and wet system.
Calibration device that opens by means of hinges (hinges).
Made of stainless steel.

D.2.3. Under vacuum cooling tanks.

The same cooling capacity will be supplied as for the shape of profiles 60x60

SECTION E Main control cabinet

Pos. E.1 Main control cabinet

PLC-based system for monitoring the entire travel sequence.
Operator interface with touch screen with color monitor.
# 18 temperature control zones (2 separate zones for molds).
Thermoregulation zones integrated in the PLC.
All air conditioning systems.
Built to EU standards.
Degree of protection: IP54.

E.1.1. Remote Service Pack

Via an industrial LAN with Internet access.
Software and hardware based on the eWon system.
Internet connection required on the field with a static IP address and an open company
firewall.

E.1.2. Connection cables
Connection cables and boxes for laying the cable from the cabinet to the extruder.
Control panel located max at a distance of 3 m from the extruder.

SECTION F equipment downstream

Pos. F.1 Calibration device holder

For profiles with a maximum width: 150 mm
Base table length: 7 m
Longitudinal and high (probably axial) displacement by AC motors.
Manual lateral displacement.
Cooling water distribution network with thermometers and flow controllers.
4 kW centrifugal pump for water circulation.
200 l stainless steel water collectors.
Water / water heat exchanger.
Vacuum distribution network with gauges and regulators.
# 3 vacuum pump 5.5 kW.

Pos. F.2 Device for removing the product from the conveyor extruder.
For max profile width 150 mm.
Steel frame and aluminum construction of conveyor holder.
Flat conveyor made of special synthetic rubber, resistant to wear.
1.5 kW drive motor for each conveyor.
Pneumatic cylinders for upper opening / closing of the conveyor, max pitch 160 mm.

F.3. Cross cutting device

For max. Profile width 150 mm.
For max. Profile height 60 mm.
Steel structure.
Vidia blade, diameter 400 mm.
Pneumatic cylinder for cylinder down stroke.
Drive motor 1.5 kW.
Safety devices.
F.3.1. Chip suction device
Metal structure for supporting the fabric air filter and receiving plastic bags.
Suction fan made of steel.
Max power 2500 m3 / h.

F.4. Assembly bench / mill for section profile

Steel structure with movable aluminum plates.
Plate dimensions: 500x6000 mm.
Pneumatic lateral ejection system for moving profiles to / from the receiving inclined
plane.

Option 1. Equipment for coextruded finishing layer

Pos. E.1. - Single screw extruder.

Screw, diameter: 45 mm
Nominal ratio of length to diameter: 1:30
Max screw speed: 100 rpm

E.1.1 Support for steel welded frame

E.1.2. Tank (capacity)
Made of LK3 nitrided steel.
Heated by ceramic heater.
The cooling system of the electric fan.

E.1.3. Screws
Made of LK3 nitrided steel.

E.1.4. Gearbox
Engine / gearbox with belt and pulley.
Forced lubrication.

E.1.5. Main ac motor

Power to gearbox shafts: 20 kW

Engine speed: 1500 rpm

E.1.6. Melting point and pressure sensor

 Pos. E.2. Additional tools for co-extruding
For molds for profiles made of 60x60 material.

Profile Extrusion Line

 

Single screw extruder 75 mm

Productivity: 60-90 kg / h profile (depending on the size and composition of the mixture)

Gearbox

for diameter 75 mm

engine 40 hp, servo with inverter

lubrication, cooling and filtration system there is

Material feed system

 drive motor: 1/2 hp, with reduction gear

 feeder: loading of 50 kg., stainless steel

Screw

length to diameter ratio 28: 1

screw diameter 75mm

screw material SACM-645

hardness of nitrided layer HRC 60 ± 2

Cylinder
 two-piece design  

first section material SKD-61

water cooling  

hardness of nitrided layer HRC 60 ± 2

second section material SACM-645

hardness of nitrided layer HRC 65 ± 2

temperature control four-zone

Control
 independent control panel

 seven-zone temperature controller

* 4 zones for a cylinder with four blowers
* 1 zone for a flange
* 2 zones for an extrusion head

 inverter speed control

Calibration table

maximum product width 300mm

stainless steel tank SUS 304

Dimensions LxWxH: 3000x700x40 + 50

liquid ring vacuum pump 5 h.p. x 2pcs

pump for pumping water 1/2 h.p.

water intake diameter 3/8 ″ x 12pcs x 2 sets

water intake 3/8 ″ x 12pcs x 2 sets

with ball valve  

inlet pipe 1 1/2 ″ x1set

outlet pipe 1 1/2 ″ x1set

aluminum construction for easy fixing of calibration molds

control system

separate water and air systems for the vacuum pump

full adjustment in three axes

 adjustable length (back and forth) 750mm
 (using a 1hp engine with stop)
 adjustable length (left-right) ± 25mm manually
 adjustable height ± 100mm manually

average height 1100 ± 50mm

Trailer Crawler

crawler type
 effective pulling length
 effective pulling width
 effective pulling height
  
800mm
180mm
160mm

automatic length reading system  

output signal for length control  

individual belt clip  

guide roller 1 set

emergency stop button  

air filter device  

maximum traction 9300N

drawing speed 10m / min

average height 1100 ± 50mm

engine 3hp with inverter

 maximum cut size WxH 200x60mm or 120x100mm

 microregulation of cut speed

 micro-clamp pressure control

 pneumatic control of the saw for line speed compliance

 precise and adjustable length control

 1 hp engine, saw diameter 14 "

 Dust collector

 3hp engine

 sound catcher

 mobile execution

Semi-automatic stacker

 stacker length 3000mm with pile structure for stacking

 maximum height 1100mm

 hydraulic stacker alignment

 hydraulic drive L.A. hp

 customizable step-by-step lowering

Press form

Mold 25 * 25

 exit to 2 streams

 extrusion head

 dimension form 300Lx1set, 50Lx1set

Mold 20 * 20

 exit to 2 streams

 extrusion head

 dimension form 300Lx1set, 50Lx1set

 Hammer drill

 bilateral shock (at the same time) execution

 linear speed 10m / min

 perforation control - inverter

 2 interchangeable heads

Automatic pasting machine

 control system

 grid position sensor

 hot-melt adhesive tank with insulation protecting the operator from thermal burns

Extruder with a productivity of 1-12 kg / hour

Extruder Specifications:
 Extruder productivity: 1 - 12 kg / hour

 Input material must be defined

 Axis height 1070 mm ± 100 mm

 The diameter of the screw and cylinder 30 mm

 Extruder equipped with hopper

 Management side will be indicated after order

 Frame, color RAL 5012

 Control panel, color RAL 7035

 The cylinder is horizontal and cannot be moved vertically

Cylinder:
 Inner diameter 30 mm with tolerance H7
 Cylinder Processing - Nitriding

 Three heating zones. Each zone is cooled separately by a fan with a capacity of

150 m 3 / h

 The cylinder is cooled at the bottom of the hopper (the customer takes care of the
coolant)

 The temperature at the bottom of the hopper is only measured and

displayed. This temperature is not adjustable.

Screw:
 30mm diameter

 Auger Processing - Nitriding

 Auger working length 24 L / D

Extruder Engine:
 Bevel gear with motor

 Power 5.5 kW

 Voltage 400/690 V

 The engine is equipped with independent cooling with a power of 0.25 kW

On the control panel of the extruder it is possible to configure the following

parameters:
 Manual control is located on the front side of the control panel.

 On the side of the control panel one service connector 230V / 16A / 1F will be
made

 The following features can be configured on the extruder control panel:

 Screw speed 5 - 90 rpm

 Start / Stop Extruder

 Temperature setting
 Values displayed on the extruder display :
 Temperature and pressure

 Screw speed

 Engine power during operation

 Temperature at the bottom of the hopper

 Signaling

Security:
 Central stop

 Pressure protection (mechanical) max. pressure 6500 Psi (448 bar)