NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14
What costs should we reduce ?
Cost per Kg of output.
Cost per part produced.
Factors Include:
Kg or parts per hour
But good parts – minimize scrap.
Energy costs.
Output vs Screw Wear
00
20
40
60
80
100
120
140
160
180
200
.10 .20 .30 .40 .50 .60 .70 .80 .90 1.0
GRAM/SEC
CLEARANCE PER...
118.20
118.40
118.60
118.80
119.00
119.20
119.40
119.60
119.80
120.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2...
Special Coatings: X830
Hardfacing
Base
Material
X8000TM
Carbide CoatingStandard Surface Finish: (60 Ra)
Polished Surface F...
RATE OVER TIME
00
20
40
60
80
100
120
140
160
180
200
RATEGRAM/SEC
TIME
Screw 120 mm
____ = 4140/C56/Cr
____ =4140/X830/X-...
Most Machines have „GP‟ Screws
(„General Purpose‟)
(Or „Generally Poor‟ ?)
(Or „No Purpose‟)
Mixing Screw Illustration (Pulsar Mixer)
POLYCARBONATE LENS PROJECT
 RESIN: PC (TYP 740-4) CLEAR
 100% CHECK ON BLACK SPECS
PROBLEM: SCRAP RATE ~ 20%
 DEMAG 200...
44,80
44,85 39,60
39,58
43,0
39,7
44,4
-0,05
-0,1
258
240
159
100
DIA 38,0
12,010,2
59,0
-0,1
-0,2
± 0,5
STAMP:“ SN-XXXXX”...
RESULTS:
CYCLE TIME REDUCTION: 3 seconds
 SCRAP RATE REDUCED FROM 20 % to 1.5%
BASED UPON 6000 hrs:
productivity improv...
NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14
AUTOMOTIVE PROJECT
 I.M.M. BATTENFELD HM 19000 - 2700
 SCREW DIAMETER 130 MM
 L/D RATIO 26:1
 SCREWSPEED MAX: 120 RPM
...
SN-#
4765 O.A.L.
395
1285
119,8
119,7
STAMP -
NOTE: STAMP NUMBERSSO THEYCAN
SPLINESACC. DIN 5480
BESEEN BYOPERATOR
130 MM ...
RESULTS:
CYCLE TIME DEDUCTION: 4 sec = 5.7%
BASED UPON 6000 hrs:
productivity improvement 18702 pcs = 6%
INCREASE IMPAC...
Product: Bucket: 10 Ltr.
Resin: PP MFI: 8
Shot-weight: 584 GR
Screw diameter: 98mm with LD = 25
OE solution 32,9 gr/rev
XA...
TWINSHOT
The TWINSHOT®
Co-Injection Technology
enables a conventional
machine with a single
barrel and screw to inject
two...
 SKIN RESIN:
PP+20%CaCO2
 CORE RESIN: Regrind
PP+CaCo2+blowing agent
 SHOTWEIGHT: 3800 Gr.
 INVESTMENT: 117500
 ROI: ...
Nordson XALOY
PRESENTATION
Integrated Barrel
Heating Technology
Sustainability requires True Innovation
nXheat®
Induction heating
Mica band-heaters
Ceramic band-heaters
Infrared heater
s...
Introducing , a heating coating
for barrels
A barrel heating technology that offers the:
 Best process control
 Most ene...
What is ?
 Plasma sprayed metallized-ceramic heater
coating
 Pure resistive heating
 Simple retrofit of existing heater...
Benefits
• Improved Process Control
 Less Scrap – Higher Yield
• Superior Energy Savings
 Reduces your costs & saves mon...
Improved Process Control
Non-uniform temperature distribution Uniform temperature---Fully insulated
What benefits could ap...
Improved Process Control
 Uniform heat profile leads to a more stable process and
consistent part
Part Weight Variability...
Improved Process Control
 Ramps to target 30% faster using 23% less energy
 Response time to maintain temperature is qui...
Superior Energy Savings
 30%-60% more energy efficient than band heaters
 Design watt density is 60% of band heaters
(10...
Superior Energy Savings
Lab Machine Trials -- Power Distribution Profile
(36 mm screw, PP, 28 sec cycle, 38 gram shot, 249...
Safer Operation
SmartHeat™ barrels are supplied with a thermal insulation wrap and straps.
The complete system provides “C...
Safer Operation
 Eliminate fire hazard from
numerous wires from multiple
heater bands
 All wiring run under
thermal insu...
Melt Pipes
SmartHeat Melt Pipe
• Uniform heat end to end
• No loose wiring (buried under the
insulation)
Conventional Heat...
Maintenance Free
 Eliminates heater band maintenance
 Simple retrofit to existing heater band wires and control
 Plasti...
Typical ROI
Southern US Southern U.S. (FL, TX, GA, AL, MS)
about 12 months air conditioning
Example
Customer: processor in...
Typical ROI
Midwestern US (OH, MO, IN, CA)
about 8 months air conditioning
Typical ROI
Northern US (MI, MN, WI, MA)
no air conditioning
Customer Testimonial
Siemon Company
55 Ton Milacron Roboshot Machine
8 cavity mold running Makrolon PC
Electrical Connecto...
Customer Testimonial
Piolax Corporation
50 Nissei FN4000 Machine
32 cavity mold – 24 sec cycle
Automotive Interior Parts
•...
on Melt Pipes
Features
• Uniform heater coating around the
melt pipe
• Integrated heating system with
SmartHeat™ as part o...
on Melt Pipes
Application photos
on Melt Pipes
Application photos / Paragon Films
on Nozzles
Feature
• Eliminate nozzle band heaters and
all their maintenance
• Uniform heater coating around the
entire no...
Superior Process Control
Better Shot Consistency
Stable, Uniform Heat Profile
Maximum Energy Savings
Maintenance Free
Extr...
Polymer Processing Cost Saving Workshop - 05 Screw design and smart heat
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Polymer Processing Cost Saving Workshop - 05 Screw design and smart heat

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Polymer Processing Cost Saving Workshop - 05 Screw design and smart heat

  1. 1. NIPA Cost Saving Workshop Screw Design & Smart Heat 21/03/14
  2. 2. What costs should we reduce ? Cost per Kg of output. Cost per part produced.
  3. 3. Factors Include: Kg or parts per hour But good parts – minimize scrap. Energy costs.
  4. 4. Output vs Screw Wear 00 20 40 60 80 100 120 140 160 180 200 .10 .20 .30 .40 .50 .60 .70 .80 .90 1.0 GRAM/SEC CLEARANCE PER SIDE in mm Screw Diameter = 120 mm. 130 RPM.
  5. 5. 118.20 118.40 118.60 118.80 119.00 119.20 119.40 119.60 119.80 120.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 SCREWDIAMETERmm Plot of Screw Diameter: Measured Max OD Min OD
  6. 6. Special Coatings: X830 Hardfacing Base Material X8000TM Carbide CoatingStandard Surface Finish: (60 Ra) Polished Surface Finish: Ra = 0.2 (16-32 Ra)
  7. 7. RATE OVER TIME 00 20 40 60 80 100 120 140 160 180 200 RATEGRAM/SEC TIME Screw 120 mm ____ = 4140/C56/Cr ____ =4140/X830/X-8000
  8. 8. Most Machines have „GP‟ Screws („General Purpose‟) (Or „Generally Poor‟ ?) (Or „No Purpose‟)
  9. 9. Mixing Screw Illustration (Pulsar Mixer)
  10. 10. POLYCARBONATE LENS PROJECT  RESIN: PC (TYP 740-4) CLEAR  100% CHECK ON BLACK SPECS PROBLEM: SCRAP RATE ~ 20%  DEMAG 200-840  SCREW DIAMETER 45 MM  L/D RATIO 22:1  SHOTWEIGHT: 50 Grams  CYCLE TIME: 23 Sec. TARGET:  IMPROVE PRODUCT QUALITY  REDUCE SCRAP RATE
  11. 11. 44,80 44,85 39,60 39,58 43,0 39,7 44,4 -0,05 -0,1 258 240 159 100 DIA 38,0 12,010,2 59,0 -0,1 -0,2 ± 0,5 STAMP:“ SN-XXXXX” “17-4PH+ ST12-L1 2 x 30° SPLINES OD= 44,4 -0,05/-0,1 CD= 40,0 -0,05/-0,1 NUMBEROFTOOTH = 21 1020 1278 45 MM SCREW Drawn by: almh Date: Drawingnr.: SCHR_291NOTES:REVISIONS: 5. 4. 3. MATERIAL: 17-4PH-ST12-L1 1. CUSTOMER: 2. I.M.M. DEMAG 200-560/840This drawing is the property of NordsonXaloy-Europe GmbH. Reproduction or disclosure of any part of this drawing or information therein and the use thereof for making other drawings or for making apparatus therefrom are prohibeted without priar written consent of NordsonXaloy-Europe GmbH. • DISTRIBUTIVE MIXER • LOW SHEAR • LOW MELT TEMPERATURE • SUITABLE FOR SHEAR SENSITIVE RESINS POLYCARBONATE LENS PROJECT
  12. 12. RESULTS: CYCLE TIME REDUCTION: 3 seconds  SCRAP RATE REDUCED FROM 20 % to 1.5% BASED UPON 6000 hrs: productivity improvement 625000 pcs = 41% TOTAL INVESTMENT € 5000 (screw only) ROI: 21 days POLYCARBONATE LENS PROJECT
  13. 13. NIPA Cost Saving Workshop Screw Design & Smart Heat 21/03/14
  14. 14. AUTOMOTIVE PROJECT  I.M.M. BATTENFELD HM 19000 - 2700  SCREW DIAMETER 130 MM  L/D RATIO 26:1  SCREWSPEED MAX: 120 RPM GOAL:  PROCESS PP + 40% LGF  SHOTWEIGHT: 4400 Grams  OVERALL CYCLE TIME: 70 Sec.  IMPROVE PRODUCT QUALITY
  15. 15. SN-# 4765 O.A.L. 395 1285 119,8 119,7 STAMP - NOTE: STAMP NUMBERSSO THEYCAN SPLINESACC. DIN 5480 BESEEN BYOPERATOR 130 MM SCREW FOR LGF Drawn by: almh Date: Drawingnr.: SCHR_458NOTES:REVISIONS: 5. 4. 3. MATERIAL: 1. CUSTOMER: 2. I.M.M.:BATTENFELD HM 19000This drawing is the property of NordsonXaloy-Europe GmbH. Reproduction or disclosure of any part of this drawing or information therein and the use thereof for making other drawings or for making apparatus therefrom are prohibeted without priar written consent of NordsonXaloy-Europe GmbH. • DISTRIBUTIVE MIXER • LOW SHEAR • LOW MELT TEMPERATURE • SUITABLE FOR SHEAR SENSITIVE RESINS AUTOMOTIVE PROJECT
  16. 16. RESULTS: CYCLE TIME DEDUCTION: 4 sec = 5.7% BASED UPON 6000 hrs: productivity improvement 18702 pcs = 6% INCREASE IMPACT STRENGTH 10% TOTAL INVESTMENT USD 88500 (screw,barrel,valve) ROI: 270 days AUTOMOTIVE PROJECT
  17. 17. Product: Bucket: 10 Ltr. Resin: PP MFI: 8 Shot-weight: 584 GR Screw diameter: 98mm with LD = 25 OE solution 32,9 gr/rev XALOY solution 35,5 gr/rev Our design: MeltPro Barrier + Z-Mixer Investment: 7500 EUR Benefit: • Cycle time reduction by 7.5% • ROI: 40 days PACKAGING
  18. 18. TWINSHOT The TWINSHOT® Co-Injection Technology enables a conventional machine with a single barrel and screw to inject two materials in a single shot with one material totally enclosing the other.
  19. 19.  SKIN RESIN: PP+20%CaCO2  CORE RESIN: Regrind PP+CaCo2+blowing agent  SHOTWEIGHT: 3800 Gr.  INVESTMENT: 117500  ROI: 160 days TWINSHOT EXAMPLE
  20. 20. Nordson XALOY PRESENTATION Integrated Barrel Heating Technology
  21. 21. Sustainability requires True Innovation nXheat® Induction heating Mica band-heaters Ceramic band-heaters Infrared heater systems Insulating blankets SmartHeatTM Integrated Melt-Stream Heating 1950 1960 1970 2003 2006 2011 Melt-Stream Heating Evolutionary Timeline
  22. 22. Introducing , a heating coating for barrels A barrel heating technology that offers the:  Best process control  Most energy efficient  Most reliable  Most compact  Safest …barrel heating system on the market today
  23. 23. What is ?  Plasma sprayed metallized-ceramic heater coating  Pure resistive heating  Simple retrofit of existing heater bands  Eliminates exposed wires for maximum safety  Supplied with thermal insulation Plasma heater layer Integrated heating technology Easy to thoroughly insulate
  24. 24. Benefits • Improved Process Control  Less Scrap – Higher Yield • Superior Energy Savings  Reduces your costs & saves money • Safer Operation  Less operator injury risk or fire potential
  25. 25. Improved Process Control Non-uniform temperature distribution Uniform temperature---Fully insulated What benefits could apply to your processes if you could rely on a 55% improvement in temperature consistency shot to shot? Temperature Response with Band-Heaters 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 0 5 10 15 20 25 30 35 40 45 50 Elapsed Time (minutes) Temperature(o C) 32 96 160 224 288 352 416 480 544 608 672 736 Temperature(o F) Temperature Response with SmartHeatTM 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 0 5 10 15 20 25 30 35 40 45 50 Elapsed Time (minutes) Temperature(o C) 32 96 160 224 288 352 416 480 544 608 672 736 Temperature(o F)
  26. 26. Improved Process Control  Uniform heat profile leads to a more stable process and consistent part Part Weight Variability -0.5 -0.4 -0.3 -0.2 -0.1 0.0 0.1 0.2 0.3 0.4 0.5 0 5 10 15 20 25 30 Cycle Number DeviaitonfromMean(grams) Conventional Barrel New Barrel Band Heaters SmartHeat Barrel
  27. 27. Improved Process Control  Ramps to target 30% faster using 23% less energy  Response time to maintain temperature is quicker
  28. 28. Superior Energy Savings  30%-60% more energy efficient than band heaters  Design watt density is 60% of band heaters (1000 watt band heater = 600 watt SmartHeat™)  Virtually eliminates heat losses to the environment  Save on A/C expense  For process temperatures up to 750oF (400oC)
  29. 29. Superior Energy Savings Lab Machine Trials -- Power Distribution Profile (36 mm screw, PP, 28 sec cycle, 38 gram shot, 249o C/480o F melt) 0 200 400 600 800 1000 1200 1400 1600 Nozzle power Discharge Middle Feed Power(watts) A) Band-heaters -- not insulated B) SmartHeat -- not insulated C) SmartHeat -- insulated 50% Less Energy over Heater Bands
  30. 30. Safer Operation SmartHeat™ barrels are supplied with a thermal insulation wrap and straps. The complete system provides “Cool to the Touch” operator safety and the covered electrical connections provide for significant fire hazard safety improvements.
  31. 31. Safer Operation  Eliminate fire hazard from numerous wires from multiple heater bands  All wiring run under thermal insulation for safety Elimination of all the loose wiring
  32. 32. Melt Pipes SmartHeat Melt Pipe • Uniform heat end to end • No loose wiring (buried under the insulation) Conventional Heater Bands • Non-uniform heat • Loose wiring
  33. 33. Maintenance Free  Eliminates heater band maintenance  Simple retrofit to existing heater band wires and control  Plastic resin easily chips off Hardened resin just pops right off
  34. 34. Typical ROI Southern US Southern U.S. (FL, TX, GA, AL, MS) about 12 months air conditioning Example Customer: processor in Texas Machine: 60 mm Engel machine Utility Cost: $0.12/kWh. ROI: about 12 months
  35. 35. Typical ROI Midwestern US (OH, MO, IN, CA) about 8 months air conditioning
  36. 36. Typical ROI Northern US (MI, MN, WI, MA) no air conditioning
  37. 37. Customer Testimonial Siemon Company 55 Ton Milacron Roboshot Machine 8 cavity mold running Makrolon PC Electrical Connectors • ROI of less than 1 year • Cut start up time by 50% • 80% Improvement in shot to shot consistency
  38. 38. Customer Testimonial Piolax Corporation 50 Nissei FN4000 Machine 32 cavity mold – 24 sec cycle Automotive Interior Parts • Energy savings of 59% • Multiple SmartHeat being ordered
  39. 39. on Melt Pipes Features • Uniform heater coating around the melt pipe • Integrated heating system with SmartHeat™ as part of the melt pipe • 25% energy savings or more • Eliminate band heaters and their maintenance • Resin will not stick to SmartHeat™ coating Benefits • Consistent and uniform heating of polymer providing a stable process and fewer rejects • Considerably less wiring creating a safer, cleaner work environment • Improved ROI using SmartHeat™ • Less downtime when SmartHeat™ is an integrated part of the melt pipe • Less downtime from cleaning
  40. 40. on Melt Pipes Application photos
  41. 41. on Melt Pipes Application photos / Paragon Films
  42. 42. on Nozzles Feature • Eliminate nozzle band heaters and all their maintenance • Uniform heater coating around the entire nozzle • Resin will not stick to SmartHeat coating Benefits • Less downtime when SmartHeat™ is an integrated part of the nozzle • Consistent and uniform heating of polymer providing a stable process and fewer rejects • Less downtime from cleaning
  43. 43. Superior Process Control Better Shot Consistency Stable, Uniform Heat Profile Maximum Energy Savings Maintenance Free Extremely Durable & Safe Summary

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