Two (2) 58mm lines – Mexico - 2000
One (1) 70mm line – Argentina – 2001
One (1) 50mm line – Brazil – 2001
One (1) 70mm line – Brazil – 2004
One (1) 70mm line – Indiana (USA) – 2006
One (1) 58mm line – Brazil – 2006
One (1) 40mm – Brazil – 2008
One (1) 50mm – Kingdom of Saudi Arabia - 2010
One (1) 58mm – Kingdom of Saudi Arabia - 2011
One (1) 50mm – Brazil – 2013
Three (3) 58mm –Western China – 2013
One (1) 50mm – Western China – 2013
One (1) 50mm – Brazil – 2014
One (1) 70mm – Brazil – 2014
The EVOLUTION of Apex Modular Extrusion™ Systems
1st Generation Modularized Sections and Modular CCC Building
2nd Generation with Completely Modularized System
Robust equipment and design
Client flexibility for equipment make/model
Cost advantage to traditional stick built
Schedule improvement vs traditional line
Incorporate Lean Practices
Better equipment access for operations and maintenance
Easy to clean for small lot production
Modules to fit in a single level warehouse (8M clear)
Modules to fit in shipping containers
All equipment to be pre-piped / pre-wired
Latest technology for data collection and controls
VPN connection for Client and for Apex
2nd Generation Design Basis - Modular Extrusion™
Shorter schedules: Standardized lines can be built in parallel with building construction.
Standardization: Engineering reduced, cost reduced, schedule reduced for additional lines.
Cost advantage: Shop construction is 20-30% lower. Less risk of scope changes.
Minimal plant site interruption: Reassembly is typically 3 wks.Welding is not required.
Client resources minimized: Single source responsibility and standardization reduce
Cash flow end loaded: Production begins prior to final payment.
Advantages of Modular Extrusion
Twin Screw Extruders
40mm – 50mm – 58mm - 70mm
Up to 1000 hp extruder motors
Lab Line machines
Number of Feeders
Eleven (11) solids feeders
Three (3) liquid feeders
Pigment cleaning stream
Gaylord box or Octabin
Silo or bulk transfer
Gaylord box or Octabin
bulk rail or truck
Module Equipment Sizes
Silos / DayTanks / Bulk Bag Unloaders / BoxTilters
Transfer Pipe to Modules
Fume Duct to Hoods
DustCollection Duct to Modules
CoolingTower to Modules
Air Compressor to Modules
Nitrogen to Modules
Utility Power to Modules and Main Drive
Utility Power to Auxiliaries (Mixers / Packaging / etc.)
Floor LoadingAdequate for Modules
HEAF (if necessary) for FumeCollection
CableTray from CCC to Modules
Labor and Equipment to erect / assembly Modules
VPN Communication to CCC
Screener / Pelletizer /Waterbath / Strand Dryer
Modular Plant is the integration of all utility equipment
necessary for the operation of Modular Extrusion Lines
Design Basis for Modular Plant
Standardized in three systems to handle from 1-5 extruders. Each system can support
production rates of 3.5 ton/7 ton/15 ton per hour).
Integrated Controls by specifying a controls platform that is identical to the “Modular
Extrusion System” controls platform. Equipment would simply have a power connection
and Ethernet connection for integrated control.
EDM “ Extruder Data Management” - The modular plant is provided with historian and
recipe management servers. All data from each extruder line is collected and
summarized in productions reports. Packaging and labeling options can also be added.
UCC (Utility Control Center) will house all control equipment, data collection / recipe
servers and power distribution equipment.
Engineering to be reused to offer quicker schedules and lower costs.
Equipment to have the flexibility to be placed inside or outside.
Less client management required. Client needs to lease or erect a building and provide
the power/water sources.
HMI - Dual Language - English / Native - Language is selected from the main HMI screen.
PLC - PLC code will be Dual Language English / Native if supported by automation platform.
Drawings will be in English / Metric units - all language will be English.
Equipment manuals will be provided in native language if available.
All equipment will have a manufacturer’s warranty of 12 months after shipment .
All programming will be tested and signed off at the time of startup. If a programming issue should
service in the first 12 months after startup, ACS will fix over theVPN connection.
Apex will provide a list of all parts manufacturers and their local contacts.
Apex will provide a list of all parts manufacturers and their local contacts for any mechanical issues.
AVPN connection will be utilized for 24/7 support of any automation issue.
A local automation company will be identified to support the process if needed.
Apex Engineering will supply a list of critical spare parts.
Control System Design-Build Capability
Panel Fabrication & Testing
Apex Controls Specialists, LLC
Functioning extension of clients’ Engineering and Control services
Diverse Control Panel & Control Room Design Build experience
HMI & PLC design and programming
Start-up and commissioning services
Extensive support capabilities
Training for client-specific systems and hardware
PLC is master controller.
Entire system utilizes Ethernet
Feeders are connected for Ethernet
communication, set points, actual values
and diagnostics. Start/Stop of feeders is
Feeder controllers are integrated into the
compounding system’s main PLC over
AllAC drives are controlled over Ethernet
communications with a hardwired E-stop.
Programming software is RSLOGIX 5000
A stand alone temperature controller is
used for precise temperature control of
extruder barrels. A Eurotherm MINI 8 is
All remote I/O on Ethernet connections.
MCC – Main
Drive – Heater
Heating / Air-
location fits in
CCC (Compounding Control Center)
Lower Operational Costs
Lower Total Cost of Ownership Easy to Maintain
Standard Open Networks
Informed decisions with Real Time Information Scalable Flexible Systems
High Speed Ethernet controls network
Tightly integrated drive systems, simple Ethernet connection
Real Time data for process analysis to support a quality product
Reduced wiring with Intelligent MCC and remote Ethernet I/O
Control architecture is truly integrated - Intelligent MCC –
Ethernet drive systems Ethernet remote I/O. Feeders have
Feeders are connected to the PLC over Ethernet for easy
interlock and setup.
Advantages of Integrated Controls
Easy operation through one common HMI system
Process diagnostics, identify issues quickly for less downtime
On-line historical trending
On-line SPC software
Extruder setup data for each run “Lot – Grade – Color”
Integrated Safety features
Advantages of ACS Software
Process data historian
Recipe management systems
Material verification systems
Packaging systems – material weight and labeling
Lot tracking – Materials used –Yield calculation -
(Industrial Data Management)
Wireless HMI /Troubleshooting interfaces using
Modular software blocks for adding equipment
New Modular Plant interfaces
Updated Historian and Recipe management
Complete Ethernet based systems for I/O, MCC
3rd Generation Controls
To request a modular extruder system formal quotation, please contact:
PH: 812-838-0148 ext. 2102
To request a modular control system or a control system upgrade, please contact:
PH: 812-838-0148 ext. 2113
To request a site visit by the Apex Modular Extrusion team, please contact:
PH: 270-395-4121 ext. 1105