Validated by results from installations around the world, the new MAX³ feed system for Baker Perkins’ twin-screw powder coating extruders is providing impressive increases in output.

In the USA, trials with two 65mm machines at the same customer saw output increased by 275%. The test machine was a new MPX65, fitted with a MAX³ feed port and screw configuration. The other is an original MP65 with the same power and speed but without MAX³ or additional cooling developments.

 

The result - 1,200 kg/hour (2,640 lb/hour) on the new extruder versus 435 kg/hour (960 lb/hour) on the previous model - was an exceptional increase. These trials involved exactly the same formulation to ensure a true comparison.

 

Also in the USA, a MP65 600rpm extruder that was only able to achieve 34% torque due to issues feeding a low bulk density black epoxy was fitted with new MAX³ twin lead feed screws, and was able to increase the torque to 56%. This resulted in throughput going up from 308 kg/hr (680 lb/hr) to 517 kg/hr (1,140 lb/hr) - a 67% increase.  The customer is now using these feed screws on all their lines.

 

In Italy, the target was to reduce main drive torque fluctuations of 30%, and to increase output on a machine running a black epoxy resin with 40% filler, which was proving difficult to extrude. MAX³ twin lead screws were fitted to replace conventional Alpha/Beta screws in order to reduce feed material ‘bounce’ and allow the lower bulk density fillers to fall into the screw flights. The torque fluctuation disappeared and the feed rate doubled from 800 to over 1,600kg/hour. The only thing that prevented even higher outputs being achieved was the capacity of the downstream equipment and 1,560 kg/hour proved to be the optimum rate.

 

In the UK, a customer running a semi-gloss polyester had torque instability, fluctuating between 45% and 58%. Product was also bridging and backing up the feeder funnel. When we fitted new MAX³ lead screws, the torque stabilized at 48%. As bonuses, throughput increased by 9% to 1,157kg/hour, and labour costs were reduced because a dedicated operator was no longer needed to watch over the torque fluctuations.

 

The MAX³ incorporates a radical re-design of the intake feed port and screws. It improves the flow of material into the extruder barrel and air out of it to eliminate material build up in the extruder infeed that leads to restricted output and torque surges. On some occasions, as in the USA, a new feed port and screws are needed to resolve a problem; elsewhere feed screws alone are the solution.

 

MPX19 benchtop machine upgraded with remote support

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