Breakthrough technology available on all Baker Perkins extruders delivers a step change in output while also improving quality and reducing running costs.

 

Baker Perkins’ patented MAX³ feed system delivers a 40% to 100% throughput increase from twin-screw extrusion systems and combines this with a top feeding arrangement that significantly reduces cost-of-ownership.

 

The key to improved throughput is the design of the infeed port. This has been carefully sculpted to feed the material uninterrupted around the feed screws and into the barrel while allowing entrained air to escape. The improved flow characteristics enable throughput to be increased significantly on all types of material, but are particularly effective on low density powders and fines.

 

The result is that it is no longer necessary to use side feeding. It has long been known in the industry that forcing the material into the feed screws with a side feeder leads to high wear, poor quality and slow changeover so top feeding has always been the preferred option. The patented features of MAX³ mean that this is now available for every application.

 

Top feeding has a naturally bigger infeed port than side feeding because the width of the barrel is greater than the height and the only pressure needed to feed the material is gravity. By contrast, side feeders are forcing the material through a narrower aperture and generating heat and pressure in the infeed. This causes pre-melting of resin on the screws, reducing conveying capacity and leading to poor quality, while the pressure leads to high wear and increased maintenance costs for both extruder and feeder.

 

With side feeding, the main drive and feeder speeds must be precisley matched to avoid over-feeding, which causes excessive wear on the barrel liners, screw elements and feeder. Achieving precise synchronisation is difficult as there is very little detectable difference between a machine that is correctly set up and one that is overfeeding. Top-fed machines are much more tolerant as the operator can see at a glance when the optimum feed rate is being achieved.

 

The ability to use top-feeding means that MAX³ also contributes to easier cleaning and faster changeovers. Access to the clamshell barrel is gained simply by removing the feed chute and leaving the feeder in place, whereas a side-feeder and its refill system have to be physically disconnected and moved.

 

Results at customers’ sites show the MAX³ reliably leads to throughput increases between 40 and 100%, depending on formula. When retrofitted to existing machines as part of a process optimization programme results have been even more spectacular with increases between 175% and 275% achieved.

 

The key development that has made these spectacular increases possible is designing the MAX³ infeed port to work in harmony with a top feeder and the intake screws to ensure a smooth and even flow of material into the extruder. The patented design significantly increases output across the full range of materials, especially lightweight ones that have traditionally been side fed, as well as increasing quality, improving process stability and reducing ownership costs.

 

This is breakthrough technology that really delivers.

 

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