All of our automation principles over the last 35 years have been based on gravimetric extrusion control.
The “loss in weight” principle guarantees precise measurement of throughput and control designed for all types of extrusion processes. Extrusion control has proven to be an essential first step for establishing a stable extrusion process.
Fully modular construction allows up to 6 dosing units plus main material to be fitted to each extruder (including co-extruders). Precise dosing of costly additives and master batches takes place directly above the extruder throat.
All dosing units outputs are synchronized with the main hopper output to guarantee an accurate product recipe. The latest generation of dosing unit now incorporates a high torque motor delivering a wide speed range.
RO-CLEAN comes with a complete new design of the continuous working gravimetric hoppers and conveying system with the target to reduce cross contamination (or imperfections in the film surface). Dust and sometimes residue material remain in the dead zone areas and cause the need for a time consuming cleaning process.
PRO-CLEAN works with a new conical shape weighing hopper type to replace the classical “shut off valve design” with its huge dead zones.
The gravimetric hopper is filled completely in just one conveying step and due to the conical design, all internal hopper surfaces are continuously self-cleaned by flowing granules and help avoid material or dust to stick on the walls.
PRO-DRAIN is a further development which allows to clean all gravimetric dosing units at the end of an order. The remaining granules are transported into a separate bin with the aid of a vacuum system.
At the same time, synchronised compressed air pulses clean the dosing unit of dust and residue material left over in strategic areas of the weighing hopper.
PRO-DRAIN is powered by the new PLAST-CONTROL software MMC (“material minimizing control”), which calculates the minimum necessary amount of material needed to complete an order. Using MMC ensures the weighing hoppers are almost empty at the end of an order.
Compared to the continuous dosing, the batch blender works according to the „gain-in-weight“- principle. The material gate opens for a pre-determined time and registers the gain in weight in the weighing chamber. When the batch is complete, the material is discharged and mixed in the mixing chamber. The accuracy is of ± 0.3%.
The PLAST-CONTROL batch blenders can be used off-line as a general purpose blender, online or on- line with extrusion control. The mixing hopper itself, works as a gravimetric weighing hopper in a "loss in weight" process.
The low-cost PRO-BATCH-devices are built for 4 to 6 materials and several types of throughputs: from 150/450/650 to custom sizes of up to 800 kg/h.
The new PRO-BATCH series combines many positive features and the experience of the recent decades. In the developing process, we especially paid attention to the compact construction, easy handling and operation, high precision and simple cleaning of the batch.
The new design of the slide valves, the effective helix mixer and transparent construction are meant to assist the user.
For special requirements, a combination of both dosing principles (batch and continuous dosing principle) is also possible.
PLAST-CONTROL provides software and hardware to deliver plastic pellets within a plant.
PLAST-CONTROL engineers can design plant-wide layouts or individual system configurations. A properly designed system eliminates dust and angel hair. Minimizing conveying distances and maximizing throughput rates while reducing energy needs - these have been our key-expectations while developing PRO-VIDER.
If your requirements are to convey small amounts of a single material over a short distance, or a production hall central vacuum system with several tons per hour demand - we have the technical solution and the appropriate equipment
Dust and contamination of the virgin material often creates problems in the extrusion process. Long transport distances and many elbows between the silos and the machines produce dust and angel hair. These contaminates must be removed before entering the extruder by use of filtration devices.
More and more extrusion companies are changing to a centralized vacuum supply. Advantages like energy efficiency, noise reduction at the work station and a significant higher output at lower costs are only a few reasons. The uptime is increased while the maintenance effort is decreased.
PLAST-CONTROL engineers always choose the optimum solution according to the application. Solutions can include conventional side channel, root, or claw pumps. Customers layout needs can be simulated in the PLAST-CONTROL facility test. Simulation tests verify conveying requirements of pellets with 38/50/70 mm (1.5”/2/2.5”) tubes and distances of up to 130 m (425”) horizontal and 14 m (46”) vertical.
Capacitive measurement sensors from PLAST-CONTROL in combination with direct driven scanner rings in low-weight aluminum design are the warrant for low maintenance profile measurement without any slip (precise allocation). Fast-scan versions (approx. 20 sec. for 4 m bubble circumference) are available.
Advantages:
Precise and error free measurement
The right measurement solution for all applications
Measurement of sticky (i.e. EVA) and soft film without damage
Durable and robust industrial design
Several sensor surfaces available
Integrated film temperature measurement and display
New non-contact measuring sensor
PLAST-CONTROL’s experience in building and designing measurement sensors for the on-line gauge measurement of films has given rise to several new technologies. The new patented sensor AirCC was developed especially for sticky and surface-sensitive films. The AirCC has 2 parallel working sensors which create different capacitive fields. This combination allows calculation of film thickness regardless of distance. A constantly changing air gap (range 100 to 350 µm) does not influence the result
C-SCAN solutions for barrier and cast film. A new technology as effective alternative to radioactive sourced measurement: The C-Scan is mounted after the collapsing frame on blown film lines or after the chill rolls on cast lines and measures across the web.
By using a new and patented algorithm, the system calculates the transverse profile in full 360° view. Barrier films with a capacitive system can now be measured without restriction.
As one of the pioneers in the development of automatic systems for the reduction of transverse direction (TD) profile tolerances, PLAST-CONTROL has continuously developed and refined its systems.
Our Profile Control systems utilize the profile measurement devices and transmit profile data to the computer. The software calculates and carries out the correct positioning of the actuators which, in turn, control air flow through the segmented air ring.
Functionally the computer opening or closing of actuators within the PRO-CON air ring will increase or decrease the volume of air in each segment. This influences the melt temperature and in turn the film thickness during film blowing step.
The air rings are available in six sizes. In combination with MAGIC FLOW, improvement of at least 50 % of the basic tolerances can be expected, along with higher output rates.
More than 1100 PRO-CON have been installed to date
An additional output increase becomes possible by using PLAST-CONTROL’s double air ring technology, PRO-CON DUO. Mechanical properties can be improved using DUO as well.
The Electrical controlled upper air ring elevator allows easy adjustment and accessibility. The combination of “improved output – better mechanical properties” ensures a fast return on investment
The PRO-JET Profile Control is achieved with a segmented plate that is mounted underneath an existing air ring. Adjustable air valves, located below the air ring, controls the volume of airflow in each segment. Suitable for stationary and moving dies with diameters from 100 mm - 2500 mm (4”-100”).
The basic tolerances are improved up to 50%. PRO-JET does not affect output rates.
