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In order to produce high-quality compounding products, highly precise and efficient processes have to be ensured. In view of this, new technologies and equipment play an important role in compounding lines. Many new solutions are also capable of processing recyclates.

The COMPEO series is suitable for the production of high quality compounds.
The COMPEO series is suitable for the production of high quality compounds.

Smart controlled compounder increases profitability

BUSS, a Swiss specialist in compounding systems for demanding applications, has been adopting smart control for its machines years ago.

The company’s advanced COMPEO compounder easily and thoroughly mixes significant volume of additives, and is suitable for production of high quality compounds, increasing the profitability of the compounding sector.

COMPEO is put together from standardized modules and the series permits cost-effective configuration of specifically optimized compounding lines for a range of processing tasks and temperatures.

These extend from traditional segments such as PVC and cable compounds via highly filled polyolefins to engineering polymers with processing temperatures of up to 400°C.

In addition, the COMPEO compounder can combine conventional three or four-flight kneading elements with new elements comprising two or six flights and use them at any position in the process section.

BUSS's new COMPEO 88 and COMPEO 110 kneaders for plastics and elastomers were introduced at K 2019. They join the smaller COMPEO 55 which was launched to the market around one year ago. All three models are available with process lengths from 13 L/D to 25 L/D, the model size indicating the screw diameter in mm.

Typical throughputs for processing thermoplastics are 150-300 kg/h (COMPEO 55), 600-1200 kg/h (COMPEO 88) and 1200-2400 kg/h (COMPEO 110). This gives operators the opportunity to use a system size optimally adapted to their requirements and thus work with maximum efficiency.

The new COMPEO 110 presented at the company booth is the current largest system, with a processing length of 18 L/D, including a downstream side feeder alongside their new conical twin screw discharge unit. In this configuration the system is suitable, among other things, for compounding filled and reinforced thermoplastics, including natural fiber-reinforced and bio-based plastics as well as HFFR cable compounds.

With a process length of 25 L/D, the new COMPEO 88 is optimized for compounding black or colored masterbatches and it can be fitted with one or two additional side feeders if required.

Conversion of recyclates into high quality compounds

Coperion has acquired an excellent reputation in markets where compounds are made from recycled plastics. The company designs systems which ensure the smooth interaction of all process steps from material handling to feeding, twin screw extrusion, pellet treatment (cooling, drying and homogenization) and finished product handling.

Depending on the materials, Coperion and Coperion K-Tron systems have high achievable throughput rates of up to 6,000 kg/h. The produced high quality recycled compounds are used, for example, in the automotive and packaging industries.

Coperion’s ZSK and STS twin screw extruders are the heart of the recycling process. The extrusion systems are used for the upcycling of the recyclates, such as for the reprocessing of PET, PP or HDPE.

With their good processing properties and high devolatilization performance, they are suitable for the processing of all types of ground products or recyclates as well as mixing of these materials.

When it comes to inline processing of PET, Coperion has developed a technology which neither pre-drying of the materials nor crystallization and agglomeration of recyclates are necessary in comparison with conventional PET processing techniques. This direct extrusion process enables the production of semi-finished products in one process step.

There are various advantages of processing PET with twin screw extruders in comparison with the single screw method. The twin screw extrusion ensures high quality of the end product because only a minimum iV degradation occurs during processing and the crystal clear material does not become yellowish.

Besides, the process offers high flexibility because recipes and colors can be changed quickly due to the good self-cleaning behavior of the twin screw extruder.

At the same time, a much simpler logistics is necessary because pelletized new product and different regenerates (ground product, agglomerates, flakes) can be processed together even if they have different iV values.

For feeding equipment, Coperion K-Tron offers a wide range of products for accurate feeding of raw ingredients including twin screw feeders, single screw feeders, bulk solids pumps, vibratory feeders, etc. The K4G blending station allows up to six feeders to be arranged closely around an extruder inlet.

One-stop shop for new material handling solutions

With the new products SPECTROPLUS, METROFLOW, LUXOR CA A and the new material loader range METRO SG, motan presents the one-stop shop for new material handling solutions.

The new synchronous dosing and mixing unit SPECTROPLUS was developed for extrusion and compounding and will replace the previous GRAVIPLUS range. With their modular design it is suitable for a large range of different materials – from powders, granulates and regrinds to liquids and flakes.

Additionally, the synchronous dosing unit can be augmented with the SPECTROFLEX dosing modules, which are also available as gravimetric or volumetric versions.

The SPECTROPLUS is controlled with the brand new SPECTROnet control, which can control both the volumetric and gravimetric SPECTROPLUS dosing modules as well as external dosing units.

The METROFLOW gravimetric material loaders are used in pneumatic conveying systems, for example to convey material from a silo to a drying bin or to the processing machine.

With their precise weighing technology, the METROFLOW loaders are particularly suited for monitoring material consumption in real time, which means that the units are predestined for use in an Industry 4.0 environment.

The new compressed air dryer LUXOR CA A with optimized control and integrated ETAplus technology is designed for small to medium material throughputs.

The dryer operates in a temperature range from 30 to 180°C. It can be installed directly on top of the processing machine or on a mobile frame. The dryer is available in four sizes with bin volumes of 8, 15, 30 and 60 litres respectively.

motan has extensively reworked and expanded the METRO range of material loaders. The new material loaders METRO G (Granulate) for large material throughputs is now available in three sizes with 60, 100 and 150 litre capacities respectively.

The METRO R (regrind) is specifically designed for processing regrind, and is also available in the three sizes 60, 100 and 150 litres.

The METRO F (Flakes) loaders units are designed for processing flakes and are also available in the same three sizes. As a non-free-flowing material, flakes are prone to bridge-building. This is why these material loaders are equipped with an extra-large outlet flap.

Meanwhile, with the METRO SG material loaders, motan offers an affordable range in the usual motan quality for standard applications that is quick and easy to install.

The new METROVAC SG conveying station with conveying control, blower and central dust filter, which can supply up to eight material loaders and four purging valves, is compatible.

In addition, new conveying control METROnet SG provides the matching control, from which eight material loaders and one stand-by blower can be managed via its color touchscreen display.

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