Sheet extrusion lines
Our history Bandera was established in 1947 by Luigi Bandera and soon proved to be a strongly expanding company, thus contributing to the actual development of plastics processing industry in Europe. In 1950 Bandera became a joint-stock company. In 1960s - 1970s, company activities underwent remarkable expansion to reach an industrial scale production, offering a wide and diversified range of extrusion products (pipes, profiles, sheet). In 1980s - 1990s the company was acknowledged as one of the leading companies in extrusion line manufacturing field, in Italy and worldwide. In 1998 Bandera received ISO 9001 Quality Certificate. Bandera has recently focussed its product range on three main fields: blown film, foil & sheet, and pipes (including specific technology for steel pipe coating).
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News Bandera is headquartered in Busto Arsizio (VA), just a 10-minute drive from Milan Malpensa International Airport. Bandera buildings were recently renewed to combine industrial series production with quality check procedures. The company is currently managed by Piero and Franco Bandera, the founder’s sons, who are keeping investing in technical improvements of production tools and machinery, and in the company key source: human resources. Please find below a brief description to better outline Bandera company: 3 production areas (100,000 sqm) 175 employees ISO 9001 certified manufacture methods and procedures A wide and complete range of full extrusion lines (pipes, blown film, sheet and foil) Engineering and R&D Depts, keeping Bandera on the cutting edge of innovation Bandera has recently allocated its manufacturing process in three sites: B1: Administration and marketing offices, assembly department, test room, and shipping department B2: Screw, barrel, and extrusion head (CNC instrumentation) manufacturing site B3: R&D Department, with dedicated test rooms
Sheet extrusion lines Bandera is widely acknowledged as world leading manufacturer of sheet extrusion lines. Pushing on its broad expertise acquired over many years, its customeroriented philosophy and its R&D Dept efforts focussed on new applications and technologies, Bandera is today able to satisfy the broadest range of production needs. The configuration of the extrusion lines offered can be arranged to suit the most demanding requirements in terms of layout, automation, and ancillary equipment. Best-selling standard sheet extrusion lines are outlined in this brochure. Bandera is definitely proud of the top technical standards applied to its extrusion lines. Any bandera extrusion line is manufactured to suit the broadest customer needs. Perfectly tailor-made.
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Sheet extrusion line for shockproof products Process materials: ABS, HIPS, PE, PP, ASA Standard thickness range: 1,5 mm รท 12 mm Sheet width: up to 3000 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1200 Kg/h
Sheet extrusion line for refrigerators Process materials: PS Standard thickness range: 1,5 mm รท 7,0 mm Sheet width: up to 900 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1200 Kg/h Worldwide construction standardization of home appliances has led to an optimization of the extrusion process size. Finished product width ranges between 600 mm and 900 mm. The extrusion line is equipped to provide high outputs. Production line control is eased by sheet standardized width.
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Sheet extrusion line for caravan and sanitaryware applications Process materials: ABS, PS, PS-K, PMMA Standard thickness range: 1,5 mm รท 12,0 mm Sheet width: up to 3000 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1200 Kg/h
Sheet extrusion line for building and industrial applications Process materials: polyolefin resins Standard thickness range: depending on finished product embossing Sheet width: up to 3200 mm max Sheet structure: single-layer or coextruded Hourly output: up to 800 Kg/h Available selection of finished product grammage, and non-wovens coupling grammage to suit any customer requirements.
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High optical quality sheet extrusion line and for acrylic products Process materials: PMMA, PC, PET-G, PS-K, SAN Standard thickness range: 1,2 mm รท 12,0 mm Sheet width: up to 3000 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1000 Kg/h The production of high quality acrylic sheet from PMMA and PC intended for top-level prestigious architectural applications require specifically arranged extrusion lines. Besides standard - and suitable - chemical and physical-mechanical features, the finished product - in order to be classified as fine optically superior product - must have outstanding aesthetic characteristics, among others: No blend residues Requirement compliant hue Brightness and transparency Perfect blend of master batches and additives No optical distortions The must-have features for a valuable product. L. Bandera has been investing in technical innovation for over 20 years to offer superior-product manufacturing machines, focussing on high-tech research aimed at ongoing process enhancement.
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Sheet extrusion line for furniture industry Process materials: ABS, PMMA, PET Standard thickness range: 0,4 mm รท 12,0 mm Sheet width: up to 2200 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1500 Kg/h Masking unit for the application of sheet protective film Due to optimal PET characteristics required for furniture applications, Bandera extrusion lines feature co-rotating twin-screws - of which Bandera is world-leading manufacturer. The innovative corotating twin screw extruder L/D:52 grants multiple advantages: Outstanding venting efficiency: larger vacuum areas prevent process material pre-treatments (drying and dehumidification process) Quick colour switching over, due to minimized material residence time Excellent mixing capacity Power saving (-30% if compared to a single-screw extruder) Multi material processing capacity obtained with standardized screw geometry
Complete 3-layer ABS/PMMA extrusion line
Estrusore bivite corotante
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Sheet extrusion line for geoliners Process materials: polyolefin resins Standard thickness range: 0,5 mm รท 2,5 mm Sheet width: up to 7000 mm max Sheet structure: single-layer or coextruded Hourly output: up to 2000 kg/h Possibility of surface embossing, brushing and corrugating. The extruded product shall guarantee weldability, resistance to atmospheric agents, and suitable mechanical strength. The extrusion line can be designed and manufactured to meet any customer requirements.
Geomembrane extrusion line. Standard configuration layout
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Sheet extrusion line for waterproofing applications Process materials: polyolefin resins, polyesters, glass fibres and mineral fillers Standard thickness range: 0.2 mm รท 3.0 mm Sheet width: up to 2200 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1000 Kg/h The line is equipped with no. 2 flat die heads. Further to product application studies carried out by Bandera R&D Dept, the mechanical resistance to elongation, tear, punching and drilling of the extruded product is maximized. Resistance to light, ozone, chemical agents, high and low temperatures, fire (halogen and mineral filler free composition) and - needless to say - water, is 100% guaranteed. The application range is extremely wide: foundations, tunnels, subways, swimming pools, etc.
Extrusion line for waterproof applications. Standard configuration layout
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Sheet extrusion line for automotive Process materials: polyolefin resins, mineral fillers and powder stabilizers, liquid plasticizers Standard thickness range: 0.5 mm รท 3.5 mm Sheet width: up to 2500 mm max Sheet structure: single-layer or coextruded Hourly output: up to 3000 kg/h Exclusive cutting edge technology for internal lining with both aesthetic and functional purposes, intended for top-class vehicles Dimensional stability even after thermoforming High-performance soundproofing and thermal insulation Over fifteen applicable formulations
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Sheet extrusion line for coating lamination Process materials: polyolefin resins Standard thickness range: depends on composite finished product to be obtained Sheet width: depending on composite finished product to be obtained Sheet structure: composite, single-layer or coextruded Hourly output: depends on composite finished product to be obtained (coupling material grammage, and extrusion line output) The line core feature consists in the in-line manufacture of a finished product via “in-calender� coupling of semifinished reels (nonwovens, paper, aluminium, etc.) with polyolefin sheet exiting the flat head. Line accuracy and user-friendliness depends on the high level of design and construction. The finished product, besides complying with coupling chemical and mechanical requirements, features extremely refined aesthetics. Composite products obtained with coating extrusion lines have a wide application range (from building and construction fields to food and industry sectors).
Extrusion line for coating applications. Standard configuration layout
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High-thick sheet extrusion line Process materials: HDPE, PP (and high molecular weight resins ensuring elevated chemical and physical-mechanical features) Standard thickness range: 1.0 mm รท 40.0 mm (2 flat heads) Sheet width: up to 3000 max Sheet structure: single-layer or coextruded (twin-screw and/or single-screw extruders) Hourly output: up to 2000 Kg/h The line is intended for semi-finished products for chemical-industrial applications (liquid tanks), cut flatbeds, technical components (e.g. flanges, gears, outsoles, etc.). Being stress-cracking, and cut-, abrasion- and impact-resistant (typical characteristic of some materials), high-thick sheet can be used in the automotive field for external covers (e.g. pick-ups). High-thick sheet extrusion lines outstand for their specific design. Extremely high thicknesses require dedicated post-sizing in-calender sheet processing and thermal stress relieving (for sheet dimensional stability) to avoid issues at cutting and thermoforming stages. Possibility to obtain blends with mineral fillers and straighteners directly in line (extrusion line with co-rotating twin-screw extruders) Calender equipped with hydraulic system for up-down displacement (available sheet path up to down or down to up) Movable and power-driven double roller bed. Independently temperature controlled rollers Multi-emission point X-ray heating system for sheet molecular thermal stress relieving
High-thick sheet extrusion line
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Sheet extrusion lines for paper and cardboard industry Process materials: PP, PET Standard thickness range: 200 µm ÷ 1.2 mm Sheet width: up to 1200 mm max Sheet structure: single-layer or coextruded Hourly output: up to 1200 Kg/h Calenders in vertical, inclined or horizontal configuration, equipped with chromium-plated (and super-finishing), satinized or embossed rollers. Air blade systems and simple or double effect vacuum box for thin sheet.
Sheet extrusion line for solar panels Process materials: EVA (Ethylene Vinyl Acetate) Standard thickness range: depends on finished product to be obtained Sheet width: up to 2500 mm Sheet structure: single-layer or coextruded Hourly output depends on finished product to be obtained The silicon photovoltaic module is normally obtained with sandwiched together material layers - the so-called “laminated layer” - and with other ancillary materials making the sandwich suitable for use. As a standard, the laminated layer is made of the following materials: Glass (4 mm thick, as a standard) EVA - Ethylene Vinyl Acetate Monocrystalline or polycrystalline cells Backsheet (made of PET or glass)
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Co-rotating twin-screw extruders Sheet extrusion lines are increasingly provided with co-rotating twin-screw extruders. A choice due to top flexibility and versatility offered by twin-screw technology. Co-rotating twin-screw extruders are thoroughly designed and manufactured by Bandera. Extrusion screws are made in high performance wear resistant XDBD steel, and extrusion barrels are made in nitrided steel and/or bimetal alloy (screws and barrels consisting of independent modular sections, accurately assembled). Co-rotating twin-screw technical features - the result of R&D studies and yearly expertise - offer the extrusion line several advantages, as follows. Versatility and flexibility The standardized geometry of the extrusion screws enables various materials processing (PET, PP, PS, ABS, HDPE,LDPE, …) and ensures no material stress, besides easing production control and schedule. Possibility to process up to 100% ground skeleton material (industrial waste), to manufacture products obtained by Chemical (dedicated additives) or physical (gas injection) foaming processes, and to use mineral filler powders, e.g. talc, calcium carbonate, titanium dioxide (see photo here beside) Mixing and self-cleaning The intermeshing and co-rotating extrusion screws guarantee minimized material residence time, together with quick and easy colour switching, thus resulting in outstanding time and material waste reduction - a peculiar characteristic deriving from the compounding sector Melt purification The outstanding efficiency of the venting system (up to 10mBar ÷ 15mBar residual vacuum, sufficient for the whole extrusion barrel) allows for hygroscopic material processing with no need for material pre-treatment (dehumidification, drying, crystallization, …). Furthermore, it is undoubtedly worth mentioning that Bandera technology is FDA approved in the food packaging sector
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Power saving The important power saving ensured by co-rotating twin-screw extruders is due to the reduced motor torque if compared with single-screw extruders. Power saving can be up to 35%, depending on process material. Bandera twin-screw extruder production range is detailed in the table below.
Co-rotating twin screw
L:D ratio
2C 55 mm 2C 70 mm 2C 85 mm 2C 105 mm
34:1, 42:1, 52:1
2C 135 mm 2C 170 mm
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Single-screw extruders Single-screw extruders currently play an important role in sheet extrusion line manufacturing. Today, Bandera offers its customers a wide range of extruders to comply with all market needs in terms of productivity, efficiency, and quality. Bandera designs, manufactures and tests its machines independently and manufactures extruders up to 380 mm in screw size. Extrusion screws are made in nitrided steel. Possibility to apply special wear resistant alloys onto the thread edge (Stellite or Colmonoy 56/57). Extrusion barrels are made in nitrided steel and/or bimetal alloy. Thanks to its long-lasting experience (Bandera single-screw extruder No. 3 dates back to 1943 and is proudly displayed at Bandera premises) and to several technological innovative enhancements over the years, Bandera has always been a leading company in this field. Sheet extrusion line production range is mainly divided into 2 categories: Single-screw extruders for polyolefins and polyamide (PE, PP, PA, ...) non vented (for processing non-hygroscopic materials) Single-screw extruders for styrene and acrylic polymers (PS, ABS, PC, PMMA, ...) vented (for processing hygroscopic materials)
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Single-screw extruders for polyolefins and polyamide (PE, PP, PA, ...) Single screw extruder
L:D ratio
TR 35 mm TR 45 mm TR 50 mm
25:1, 28:1, 30:1
TR 60 mm TR 65 mm TR 75 mm TR 80 mm TR 85 mm TR 90 mm TR 100 mm TR 120 mm
30:1, 35:1
TR 140 mm TR 160 mm TR 180 mm TR 200 mm
Single-screw extruders for styrene and acrylic polymers (PS, ABS, PC, PMMA, ...) Single screw extruder
L:D ratio
TR 50 mm TR 60 mm TR 65 mm TR 75 mm TR 80 mm TR 85 mm TR 90 mm
35:1, 38:1
TR 100 mm TR 120 mm TR 140 mm TR 160 mm TR 180 mm TR 200 mm
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Dosing and loading systems Proper material loading and dosing into the extruder is undoubtedly one of the key factors to be taken into account - in fact, it is considered the first process variable. Single- and twin-screw extruders are equipped with different dosing systems: Continuous gravimetric dosing system, of the loss-in-weight type, for co-rotating twin-screw extruders (the so-called starve-fed extruders) Volumetric dosing system for single-screw and co-rotating twin-screw extruders Gravimetric dosing system of the batch type (by weights) for single-screw extruders Bandera designs and properly sizes various dosing systems to meet any customer needs: the material can be dosed in different form, e.g. granules, production waste, flakes, additives, masterbatch, filler powders (mineral or otherwise). In case of low-density ground materials, the single-screw extruder is completed with a force feeder to ensure utmost process efficiency. Bandera prefers to include the above equipment into the scope of the supply, so as to integrate full extrusion line control in the general control desk.
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Melt filtering Melt filtering is a key step of the extrusion process to ensure final product quality. Besides, it is important to safeguard gear pump, extrusion head and calender roller integrity, especially in case of recycled materials. Standard filtering systems are hydraulically operated, and equipped with filtering screen plates (2, 4, 8, ‌) for screen changing without production interruption (continuous filtering) and without altering of foil/sheet quality. Process stability is ensured by melt pressure and temperature control, arranged upstream and downstream of the filter.
Melt gear pump The basic function of the melt gear pump is to grant constant melt flow (i.e. under precise and constant pressure and output conditions) from the extrusion head: high precision gearing is aimed at ensuring the finest accuracy tolerances. Gear pump dimensioning and design depend on process material features and required outputs. Due the integrated control system provided by Bandera control panel, the operator can easily control production variables by regulating melt gear pump parameters. Process stability is ensured by melt pressure and temperature control, arranged upstream and downstream of the pump.
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Sheet extrusion line feedblocks Provided the very wide range of products required by the sheet sector (raw materials, structures, thickness an width ranges, outputs, ‌), Bandera flat heads are ad hoc designed and manufactured for each extrusion line. Besides, as a standard, they are equipped with a feedblock whenever sheet structure is multi-layer. The feedblock comprises a tempered and stabilized stainless steel case: inner melt flow channels are superrefined and/or chrome plated. Layer distribution is managed by interchangeable selector plugs and apposite melt flow and orientation diverter valves. Flow channels are designed and manufactured depending on process material rheology and single layer output: these features are of core importance for the utmost precise distribution of sheet layers.
A feedblock for the production of sheet featuring AB-A, B-A-C-D and A-B-A-C-D structure (picture and 3D layout above).
Here below, feedblocks for the production of 3- and 7-layer sheet.
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Flat heads for sheet extrusion lines An extrusion head (either single-channel or multi-channel) is made in tempered and stabilized stainless steel: inner melt flow channels are superrefined and/or chrome plated. Flow channels are designed and constructed depending on material rheology and global machine output. Thermoregulation of head and lips is extremely accurate and involves specifically designed high efficiency cartridge-type resistance heaters. The extrusion head can be complete with several appliances, depending on production needs, such as: Internal or external decklers to easily and quickly adjust sheet width Distribution bar to evenly distribute the melt flow over the entire sheet width Fast-gap adjustment system to regulate the gap by moving part of the head body Air blade systems and vacuum box for the production of thin sheet In the pictures here below, manufacturing process and operation of single-channel die head for the production of mid-thick sheet. It is worth highlighting that in case of multi-layer sheet from different rheology materials, the employ of extrusion heads with separate channels is of the utmost importance for high-quality extrudate. Multi-channel extrusion heads are more complex, besides requiring independent thermoregulation and melt flow control.
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Calenders In sheet extrusion and co-extrusion lines, the calender is the actual process core, where material is sized and cooled at the extrusion head outlet. Calenders
differentiate
for
several
design
and
construction
characteristics, e.g.: Configuration: horizontal, (15째, 30째, 45째, 60째) inclined and vertical Roller closing system, i.e. hydraulic, pneumatic and mechanical Roller gap adjustment, i.e. mechanical - manual, mechanical power-driven, pneumatic with special design valves Width, diameter, and quantity of the cooling/calibrating rollers Roller construction, i.e. spiral or transverse hole cooling Roller cooling/thermoregulation, i.e. by water or by oil Roller surface finishing, i.e. mirror polished, satinized, or embossed Drive and electronic control
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Innovative cooling and polishing technology for composite sheet Pushing on a number of calenders manufactured over the most recent years and the expertise derived from a proactive cooperation with its customers, Bandera meets the most various and demanding requests. To continue along this positive trend and offer its customers an ongoing professional service, Bandera has dedicated an exclusive productoriented staff to this series of extrusion lines. For process optimization as well as for special production needs, Bandera calendering systems are completed - among others - as follows: Hydraulic system for calender vertical displacement (available sheet path up to down or down to up) Movable and power-driven upper and/or lower roller beds complete with independently thermoregulated rollers Multi-emission point X-ray heating system for sheet molecular thermal stress relieving
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Downstream ancillary equipment Ancillary downstream equipment for semi-finished product further processing: Bandera ultimate machinery:
Calender roller cleaning systems, power-driven, to reduce frequency of line downtime Idle and/or power-driven roller beds with independent thermoregulation for calibrating high quality and high-thick sheet Sheet ennoblement (lacquering, surface treatments‌) Infrared ray heating systems aimed at sheet thermal stress relieving
Calender roller cleaning system, by movable power-driven cart equipped with pneumatic pad and detergent solution distributor
Various laminating systems for sheet ennoblement and/or composite sheet production Masking machine for the application of protective film on the extruded sheet Heavy-duty haul-off units Multiple and combined longitudinal and transverse cutting systems Side trim cutters and transversal sheet breakers Blade granulators complete with granule conveying equipment Manual stacking systems, either semi-automated or fully automated Thin and/or flexible sheet winding systems In-line extruded sheet quality control system, via video cameras and/
Masking unit: installed on a longitudinally sliding roller bed. Calender roll control stations arranged underneath the roller bed
Single or multiple roller beds equipped with powerdriven rollers temperature-controlled by dedicated thermoregulation stations
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or polarized lights
Longitudinal “K� cutters with heated blades, sliding on roller bed
Trim edge-cutting system with breaker and belt conveyor to the blade granulator
Transversal cutter for acrylic materials
Haul-off unit and transversal cutting unit for acrylic materials
Transversal cutter for acrylic materials
Combined transversal cutting unit: Guillotine-type (shear) and circular saw blade
Longitudinal cutting system with power-driven circular blades
Movable transverse cutting system with swarf exhauster
Automatic stackers for shockproof and embossed materials
Automatic stackers for high quality sheets
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Line control and centralized management The centralized control of all extrusion line parameters has proved to be a key factor in production management. Markets have increasingly become sensitive about labour costs, quality control, product traceability systems and connection to company network (or remote connection) for production line software check and inspection. To meet its customers’ - and prospects’ - needs, Bandera has designed a specific software control architecture. The control system is based on an industrial workstation for Windows operating system. The line master PLC, interfaced with the industrial workstation, is in turn connected with ancillary equipment PLCs and with single unit remote I/O module via field bus. Due to the control architecture, all line parameters are available for remote connections aimed at production control, material management or remote assistance by Bandera technicians. The user interface has been designed with special care - from hardware, with a wide colour monitor to software, with intuitive synoptic graphics, from which the operator interacts via the touch screen HMI. Bandera is proud to mention that its customers have played a key role in Bandera machine development: following their suggestions, today Bandera machine quality definitely outstands on the global market.
Operator Panel EWon
Company/Factory LAN
Machine LAN Serial
PSTN, ISDN PLC
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Technical service Bandera relies upon its specialists to support its customers with an accurate after-sales service, both at the line start-up and testing, and at the production stage. Cutting-edge technology is at Bandera customers’ disposal, at any time. In order to comply with its customers’ maintenance needs, Bandera has established a dedicated efficient Aftersales and Spare Parts Division. Pushing on its high tech solutions, Bandera offers its customers turnkey extrusion lines - from engineering and design to construction, assistance and assembly stages. Besides, Bandera has drawn up specific training programs dedicated to customers’ personnel - the best way to understand how to operate new machineries and to retrofit existing ones. 27
PLASTICS MACHINERY EXTRUSION TECHNOLOGY SINCE 1947 Visit www.luigibandera.com to view Bandera complete production program
EXTRUDERS
PIPES & COATING
PELLETIZING
Costruzioni Meccaniche Luigi Bandera S.p.A. C.so Sempione, 120 | 21052 Busto Arsizio (VA) ITALY Tel. +39 0331 398111 | Fax +39 0331 680206 lbandera@lbandera.com | luigibandera.com
Technical specifications provided for illustrative purpose only and subject to change without prior notice.
REV3/SHEET/GB/12/11
BLOWN FILM