3Extruder, specifications of extrusion die

1. 1
Resent Developments
In Extrusion lines

2. 2
DOUBLE SPIDER DIE HEAD - RD SERIES

3. 3
SALIENT FEATURES:-
• LOWER PRESSURE BUILD UP.
• SIMPLE CONTROL OF EXTRUSION PROCESS.
• EXCELLENT WALL THICKNESS CONTROL AT HIGHER
THROUGHPUT RATES.
DOUBLE SPIDER DIE HEAD – RD SERIES

4. 4
ADVANTAGES:-
• ELIMINATION OF SPIDER LINES DUE TO STAGGERRED
DOUBLE DECKER SPIDER.
• IMPROVED MECHANICAL PROPERTIES.
• INCREASED OUTPUT RATE.
• PROCESSING OF THICK WALL PIPES WITHOUT SPIDER LINES.
• INCREASED DIE HEAD CAPACITY.
• WIDER DIAMETER RANGE PER DIE HEAD. HENCE DOWN
TIME DUE TO CHANGE OVER ELIMINATED.
DOUBLE SPIDER DIE HEAD – RD SERIES

5. 5
ACCOUNTANCY
75 / 250 : 20D – 75D
110 / 250 : 63D – 110D
200 / 400 : 63D – 200D
250 / 600 : 90D – 250D
RD – 1 : 20D – 110D
(725Kg/Hr.)
RD – 2 : 63D – 280D
(910Kg/Hr.)
EXISTING DIE HEAD
NEW RD SERIES DIE HEAD

6. 6
vTWIN DIE HEAD 2-75/250 or 2-200/400.
vTWIN VACUUM CALIBRATOR WITH 2-VI-110
OR TWIN SPRAY BATH 2-SK-110.
vTWIN CATERPILLAR HAUL-OFF 2-R110 S.
vTWIN CUTTER 2-SPR 110.
vTWIN TRIPPING CHUTE 2-KR-110.
vPIPE RANGE OF 20-110MM.
INCLUDES:-
TWIN SCREW RPVC PIPE PLANT WITH
TWIN LINE

7. 7
TWIN SCREW RPVC PIPE PLANT

8. 8
TWIN SCREW RPVC PIPE PLANT WITH
TWIN DISTRIBUTOR

9. 9
Resent Developments
In
TAPE STRETCHING LINE
“Kabratec”
Tape stretching Lines

10. 10
WHAT IS NEED FOR DEVELOPMENT OF
“KABRATEC”
TAPE STRETCHING LINE ?
0

11. 11
TO OPTIMISE ENERGY CONSUMPTION
BY INCREASING LINE SPEED WITH
HELP OF ELECTRONIC WINDER AND
OVERCOMING WATER CARRYING PROBLEM.
1

12. 12
POWER CONSUMPTION
PLANT kwh / kg
TAPE LINE WITH BLOWN FILM TECHNOLOGY
L/D RATIO 24:1 TO 26:1 > 1.2
TAPE LINE WITH SHEET DIE
L/D RATIO 28 : 1 0.9 –1.0
TAPE LINE WITH SHEET DIE
L/D RATIO 30 : 1 0.7 – 0.75
NEXT GENETATION TAPE LINE
L/D RATIO 32 : 1 < 0.6

13. 13
ENERGY BREAKUP
IN
WOVEN SACK INDUSTRIES
TOTAL CONSUMPTION = 1.1 – 1.4 kW/kg
EXTRUSION LINES
( > 0.6 )
OFFICE & SHED
(0.1)FINISHING
(0.1)
UTILITIES
(0.1 – 0.2)
LOOMS
(0.3 – 0.5)
3

14. 14
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
ENERGYCONSUMPTIONkWH/kg
EXTD GODET OVEN * OTHER WINDER
52%
(0.30)
6%
(0.035-
0.037)
13%
(0.07-0.08)
6%
(0.035-0.037)
23%
(0.13-0.14)
ENERGY BREAKUP
OF
NEXT GENERATION TAPE STRETCHING LINE
4
* OTHER : END TRIM, ASPIRATION, WATER SUCTION.
TOTAL CONSUMPTION : < 0.6 kWH/kg

15. 15
56%
(0.255-0.28)
7.5%
(0.035-
0.037)
14%
(0.065-0.070)
7.5%
(0.035-0.037)
15%
(0.07-0.08)
5
* OTHER : END TRIM, ASPIRATION, WATER SUCTION.
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
ENERGYCONSUMPTIONkWH/kg
EXTD GODET OVEN * OTHER WINDER
ENERGY BREAKUP
OF
“KABRATEC” TAPE STRETCHING LINE
TOTAL CONSUMPTION = 0.48 – 0.52 kWH/kg

16. 16
PRODUCTION / ANNUM = 3600 MT/ANNUM
( 500 – 510 Kg/Hr )
ENERGY SAVING = 36,00,000 x 0.1
= 3,60,000 UNITS/ANNUM
COST OF POWER = Rs. 4.5 per Unit
ANNUM SAVING IN ELECT. BILL = 3,60,000 x 4.5
= Rs. 16,20,000 / ANNUM
ENERGY SAVING

17. 17
EXTRUDER : 110MM 32:1
MELTING CAPACITY (PP) : 600 kg/Hr
DENIER RANGE : 500 – 2000
CONT. SCREEN CHANGER : HYADRAULIC OPERATION
T-DIE : 1750 mm
WATER QUENCH WITH : 1700 mm
INTEGRATED HOLDING UNIT
ORIENTATION OVEN : 1750 mm
COMBINED STRETCHING / : 5 GODET ROLLER SYSTEM
ANNELAING UNIT (1700 mm)
LINE SPEED : 350 m/min
CHEESE WINDER : KGS-110E
ENERGY CONSUMPTION : 0.48 – 0.52 kW/kg
7
KABRATEC 110/600 TAPE
LINE
 PP 2.5mm TAPE, 850 DENIER
 KGS WINDER (320 m/min) : 500 kg/Hr
 HSS WINDER (280 m/min) : 450 kg/Hr

18. 18
KABRATEC 110/600 TAPE
LINE
8

19. 19
SCREW LIFE COMPARISION
TYPE : BARRIER PROFILE – WITH
SLOTTED MIXING RING AND
HOMOGENISING MIXER.
- BI- METALLIC
(COLMONOY-56)
COATING IN HIGH
WEAR ZONE.
9

20. 20
SECTIONAL GROOVED FEED BUSH
BARREL :
 GROOVED FEED BARREL FITTED
WITH BI-METALLIC (XALOY-800) LINER.
 ENERGY SAVING BY MEANS OF
CERAMIC PERFORATED HEATERS
AND INSULATED COOLING JACKETS.
FEED BUSH : BI-METALLIC (XALOY-800)
BARREL LIFE COMPARISION
CERA.PERFORATED HEATER
0

21. 21
EXTRUDER
Start Stop Procedure (extruder with grooved feed bush)
- Temperature profile of the barrel zones ( Z1, Z2, Z3…) to be kept at minimum level
during starting.
- As the extruder screw speed is increased gradually, increase the barrel zone
temperatures gradually.
- When full speed as per requirement is achieved, temperature of barrel zones (Z1, Z2,
Z3..) are to reach to the requirement.
- Water circulation for the feed bush is to be kept on, before putting temperatures of the
barrel zones on.
- To stop the plant, close the shutter of hopper, let the material in the feed bush and
barrel flush out and then stop the drive.
- When the plant is stopped, water circulation should be kept on till the barrel zones cool
down. The water circulation should be stopped only after the barrel zones Z1, Z2, Z3
cool down.

22. 22
EXTRUDER
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Minutes
%MaxRPM
Purging of Extruder (Disco Purge method by Dupont)

23. 23
AUTO-SCREEN CHANGER
ADVANTAGES :
NON STOP RUNNING OPERATION SINCE AUTOMATIC &
NO WASTAGE OF MATERIALS.
NO OPERATOR ATTENTION.
UNIFORM QUALITY IF TAPE THROUGHOUT OPERATION
& HENCE NO BREAKAGE OF TAPE
NO MOVING PARTS & HENCE LONGER LIFE
µ
µ

24. 24
CONTINUOUS SCREEN CHANGER
 CONSISTANT DENIER THROUGHOUT OPERATION.
 MINIMISE START-UP WASTAGE.
 HYDRAULIC OPERATION.
 PRE-FILL ARRANGEMENT FOR CONTINUOUS OPERATION.
 THERMALLY BALANCED.
4

25. 25
CONTINUOUS SCREEN CHANGER
 CANDLE TYPE EASY MANUAL OPERATION.
 CONSISTANT DENIER THROUGHOUT OPERATION.
 MINIMISE STARTUP WASTAGE.
 INCREASE IN PRODUCTIVITY DUE TO CONTINUOUS OPERATION.
5

26. 26
WATER QUENCH WITH
INTEGRATED HOLDING UNIT
6

27. 27
WATER QUENCH SECTION
 2 SETS OF HARD CHROME
PLATED MIRROR FINISHED
TAKE-OFF ROLLS.
 FILM TAKE-OFF BY MEANS
OF FREQUENCY CONTROLLED
AC DRIVES.
 WATER REMOVAL SYSTEM.
 SS CYLINDER PROVIDED TO
HAVE UNIFORM CONTACT
WITH FILM TO MINIMIZE GAUGE
VARIATION.
7

28. 28
SIX STATION INDEXABLE MULTISLITTER (OSCILLATING)

29. 29
SLITTER SECTION
 OSCILLATING TYPE.
 LONGER BLADE LIFE.
 CONTINUOUS OPERATION.
 MINIMUM STARTUP WASTAGE.
 INCREASE PRODUCTIVITY.
 METAL EXPANDING ROLLER TO REMOVE
WRINKLES ON THE FILM.
9

30. 30
KOLSITE GROUP OF COMPANIES
0