Trebling and doubling throughput on installed extruders
Baker Perkins’ process expertise, coupled with the new MAX³ feed system, is achieving major throughput increases on extruders already in service worldwide. Output was doubled at one powder coating installation and almost trebled at another where Baker Perkins was asked to review productivity.
In Korea, installing a MAX³ system and upgrading the screw configuration on an 80mm MP twin-screw extruder raised output almost 300%. The product was an epoxy coating for underground pipes – a heavy duty functional coating that is notoriously difficult to process.
In Italy, trials with the MAX³ feed system on an extruder installed in 1999 eliminated 30% torque surges and, as a result, almost doubled throughput.
These trials also involved an MP80 extruder, but the material was a black epoxy formulation with 40% low density filler. This had proved difficult to extrude due to extreme torque fluctuations caused by the low density, and is a problem the MAX³ feed system was specifically designed to resolve; it features a re-designed feed port and screws to improve flow of material into the extruder barrel and allowing air out of it.
Lightweight particles hit the intake screws and ‘bounce’ back into the infeed areas rather than flowing into the machine. This creates a cycle where, when the screw flights are starved, the motor load decreases and, when the material flows and the screws fill, the motor load increases. This torque fluctuation reduces the available throughput and can cause an overload of the main drive motor.
In extreme cases material can build up in the infeed area. It becomes progressively more difficult for air to escape, further reducing the flow of material into the extruder barrel.
Fitting the MAX³ screws, the torque fluctuation disappeared and the feed rate was increased to almost double the previous rate.
Baker Perkins’ capability to optimise productivity and quality in powder coating plants is based both on expertise gained in the field, and by trials in our Innovation Centre. These have included the successful transfer of production from single-screw and competitors’ twin-screw machines to Baker Perkins’ extruders; plus work in the pharmaceutical, speciality chemical, textile and oil industries.
Access to Baker Perkins know-how is simplified through our local agents. Dankloff Technisch Handelsbureau have been appointed agents for the Netherlands, Belgium and Luxembourg (email bart.dankloff@dankloff.com) and PLM Makine Kimya Plastik for Turkey (email info@plm.com.tr). Please look at our web site to find your local agent.
Baker Perkins Limited, Manor Drive, Paston Parkway, Peterborough, PE4 7AP UK Registered in England: No. 5708493
© 2021 Baker Perkins. All rights reserved.
Baker Perkins’ process expertise, coupled with the new MAX³ feed system, is achieving major throughput increases on extruders already in service worldwide. Output was doubled at one powder coating installation and almost trebled at another where Baker Perkins was asked to review productivity.
In Korea, installing a MAX³ system and upgrading the screw configuration on an 80mm MP twin-screw extruder raised output almost 300%. The product was an epoxy coating for underground pipes – a heavy duty functional coating that is notoriously difficult to process.
In Italy, trials with the MAX³ feed system on an extruder installed in 1999 eliminated 30% torque surges and, as a result, almost doubled throughput.
These trials also involved an MP80 extruder, but the material was a black epoxy formulation with 40% low density filler. This had proved difficult to extrude due to extreme torque fluctuations caused by the low density, and is a problem the MAX³ feed system was specifically designed to resolve; it features a re-designed feed port and screws to improve flow of material into the extruder barrel and allowing air out of it.
Lightweight particles hit the intake screws and ‘bounce’ back into the infeed areas rather than flowing into the machine. This creates a cycle where, when the screw flights are starved, the motor load decreases and, when the material flows and the screws fill, the motor load increases. This torque fluctuation reduces the available throughput and can cause an overload of the main drive motor.
In extreme cases material can build up in the infeed area. It becomes progressively more difficult for air to escape, further reducing the flow of material into the extruder barrel.
Fitting the MAX³ screws, the torque fluctuation disappeared and the feed rate was increased to almost double the previous rate.
Baker Perkins’ capability to optimise productivity and quality in powder coating plants is based both on expertise gained in the field, and by trials in our Innovation Centre. These have included the successful transfer of production from single-screw and competitors’ twin-screw machines to Baker Perkins’ extruders; plus work in the pharmaceutical, speciality chemical, textile and oil industries.
Access to Baker Perkins know-how is simplified through our local agents. Dankloff Technisch Handelsbureau have been appointed agents for the Netherlands, Belgium and Luxembourg (email bart.dankloff@dankloff.com) and PLM Makine Kimya Plastik for Turkey (email info@plm.com.tr). Please look at our web site to find your local agent.
Baker Perkins’ process expertise, coupled with the new MAX³ feed system, is achieving major throughput increases on extruders already in service worldwide. Output was doubled at one powder coating installation and almost trebled at another where Baker Perkins was asked to review productivity.
In Korea, installing a MAX³ system and upgrading the screw configuration on an 80mm MP twin-screw extruder raised output almost 300%. The product was an epoxy coating for underground pipes – a heavy duty functional coating that is notoriously difficult to process.
In Italy, trials with the MAX³ feed system on an extruder installed in 1999 eliminated 30% torque surges and, as a result, almost doubled throughput.
These trials also involved an MP80 extruder, but the material was a black epoxy formulation with 40% low density filler. This had proved difficult to extrude due to extreme torque fluctuations caused by the low density, and is a problem the MAX³ feed system was specifically designed to resolve; it features a re-designed feed port and screws to improve flow of material into the extruder barrel and allowing air out of it.
Lightweight particles hit the intake screws and ‘bounce’ back into the infeed areas rather than flowing into the machine. This creates a cycle where, when the screw flights are starved, the motor load decreases and, when the material flows and the screws fill, the motor load increases. This torque fluctuation reduces the available throughput and can cause an overload of the main drive motor.
In extreme cases material can build up in the infeed area. It becomes progressively more difficult for air to escape, further reducing the flow of material into the extruder barrel.
Fitting the MAX³ screws, the torque fluctuation disappeared and the feed rate was increased to almost double the previous rate.
Baker Perkins’ capability to optimise productivity and quality in powder coating plants is based both on expertise gained in the field, and by trials in our Innovation Centre. These have included the successful transfer of production from single-screw and competitors’ twin-screw machines to Baker Perkins’ extruders; plus work in the pharmaceutical, speciality chemical, textile and oil industries.
Access to Baker Perkins know-how is simplified through our local agents. Dankloff Technisch Handelsbureau have been appointed agents for the Netherlands, Belgium and Luxembourg (email bart.dankloff@dankloff.com) and PLM Makine Kimya Plastik for Turkey (email info@plm.com.tr). Please look at our web site to find your local agent.
Industry 4.0 – the future is digital
Baker Perkins Limited, Manor Drive, Paston Parkway, Peterborough, PE4 7AP UK
Registered in England: No. 5708493
© 2021 Baker Perkins. All rights reserved.