Koga Recyclingtech Offers specialised consultancy in recycling, solid waste recovery and alternative fuels. Koga represents some of the world’s leading and most specialised plant and equipment manufacturing and consulting companies in this field including • Lindner Recyclingtech (Austria) - Specialists in Shredding and Air Separation Machinery and Solid Alternative Fuel Processing Systems • Lindner Resource (Germany) – Shredding & Granulation technology for plastics. • M.A.S (Austria) - Dry Cleaning Systems for Reprocessing of Plastic Films; NCT-Conical Twin Screw Extruders for Plastics Processing • Calamit (Italy) – Magnetic Separation systems for metallic materials • Lechtenberg & Partner (Germany) - World renowned specialists in Solid Alternate Fuels and Waste Recovery for the Cement, Lime, Steel, Power Generation and Brick Industries, • Screen Machine Industries (USA) – Mobile screening and quarry equipment.
Koga Recyclingtech eMagazine provides information about the M.A.S. (Austria) range of recycling & compounding equipment available.
eMagazine Contents: M.A.S. NCT brochure 2010 M.A.S. PET brochure 2010 M.A.S. Compounding brochure 2010
For more information about contact: Geof Pile Email: geofp@koga.com.au Phone: 0419 558 600
Simply multifunctional, highly profitable: the MAS extruder exceed your expectations.
The New Conical Technology (NCT) developed by MAS combines the benefits of conical extruders with those of parallel co-rotating twin screw extruders. The co-rotating design provides perfect homogenisation. Generously dimensioned screw shafts paired with strong back pressure bearings result in an extremely robust design with a long service life. This makes them the perfect solution for highly efficient compounding and processing of polymers with fillers and additives.
WPC Profile Extrusion The MAS twin screw extruder provide ist stamp on future material extrusion. A wide range of products made of WPC can be compounded using PE, PP or PVC. These commonly contain up to 80% fibre.
Recycling Due to the versatile applicability, MAS compact systems are ideal for all impurities, which can be removed by friction, such as sand, soil or organic fibre contamination on fabrics and films. These materials are compounded into high quality pellets. The MAS compact system combines dry cleaning and extrusion.
PET Processing The conical, co-rotating MAS extruder offers a wide range of applications, like the production of high quality pellets or direct extrusion from various PET into sheet or fibres. The MAS extruder offers extraordinary performance when different PET input qualities are processed - e.g. resin pellets with flakes for producing pre forms or thermoforming film for packaging.
Compounding Many compounding products demand gentle processing, minimal shear and clearly defined energy input. The conical MAS Co-rotator offers extremely high torque and high intake volumes. Substantially reduced rotational speeds mean significantly less energy input and considerably lower polymer melt shear. Consequently, this gentle processing allows the homogenisation of particularly light starting material and thermally sensitive polymers.
Simply smart, highly efficient: MAS technology and drive concept. MAS Extruder with direct drive The conical co-rotating MAS extruder offers energy savings of up to 40%. The extruder, developed by MAS, boasts the processing advantages of a parallel co-rotating machine, while its conical co-rotating design is capable of accommodating significantly higher pressures and moments. Optimum filling of the screws results in less energy consumption. Processing of thermally sensitive polymer requires high specific output at low screw speed leading to a low melt temperature and a process gentle on the material.
In comparison with various extruder drives, the torque drive provides up to 10% higher efficiency. The torque drive also offers a constant maximum torque from zero up to nominal speed. Consequently the extruder is able to use its full torque which essentially increases its scope of application.
Direct Drive
MAS Extruder with underpelletizing system
As the torque is controlled with a precise drive control unit, the robust design permits a power transmission without couplings. Even in case of an overload caused by foreign parts, the control unit switches off the extruder safely. Due to its compact design, the plasticising unit can be easily integrated into production lines. In addition the torque drive runs silent and is maintenance free. The torque drive is available for all MAS extruder models.
Efficiency of Extruder Drives at 50% load 100 Direct Drive
90
AC Motor
Efficiency [%]
80 DC Motor 70 60 50 M-A-S Maschinen- und Anlagenbau Schulz Gmbh A-4055 Pucking, Hobelweg 1 T: +43 7229 78 999 F: +43 7229 78 999 10 info@mas-austria.com www.mas-austria.com
40 0
20
40
60 RPM Motor [%]
80
100
120
Simply smart, highly sustainable: The MAS Extruder for PET Recycling. Energy-saving and gentle process.
MAS systems have the answer to every PET extrusion challenge. Versatile : processing spectrum The conical, co-rotating MAS extruder offers a wide range of applications, like the production of high quality pellets or direct extrusion into sheet or fibres from the following materials:
› › › ›
PET re-grind or pellets A-PET, C-PET, G-PET Washed PET flakes or URRC-PET flakes PET flakes or pellets add with pigments, fillers, etc…
The MAS extruder offers extraordinary performance when different PET input qualities are processed - e.g. resin pellets with flakes for producing pre forms or thermoforming film for packaging. It is also possible to add various types of plastics to polyester flakes or pellets. Pigments and fillers or additives such as chain extenders can also be homogenised, the different polymers are mixed perfectly with outstanding melt quality.
Exclusive : Your benefits The conical co-rotating MAS extruder principle delivers substantial processing benefits due to its compact design and process innovations:
› › › › ›
possibility to add re-PET at previously unattainable levels without degrading the material energy savings of up to 40% reduced production costs in-line recycling for films, tapes, fibres and monofilaments gentle processing, highest possible IV values, best colour values
Efficient : cost-effectiveness MAS extruders offer extensive technological and economic advantages:
› › › › ›
consistently high output output performance not dependent upon high screw speed self-cleaning and short dwell times optimised degassing (also with high-performance vacuum) outstanding added production value
02 MAS-PET-RECYCLING
MAS gets more out of your polymer.
MAS 55
Innovative : Processing unit The New Conical Technology (NCT) developed by MAS combines the benefits of conical extruders with those of parallel co-rotating twin screw extruders. In comparison to conventional extruders, the conical design offers substantially higher filling volumes at the material intake. This results in a higher screw filling level which gives the highest possible output with comparatively high pressure ratios and low melt temperatures. The co-rotating design provides perfect homogenisation. Generously dimensioned screw shafts paired with strong back pressure bearings result in an extremely robust design with a long service life. This combination of benefits provides the perfect solution for highly efficient PET compounding and processing applications.
MAS-PET-RECYCLING 03
Our performance
exceeds your expectations. Practical : Maintenance Clear design provides a unique coupling housing, which allows easy movement of the barrel for fast demounting of extruder screws. Cleaning the processing unit, if required, or re-placing the mixing parts of the screws, is possible in a very short time.
Logical : Operation The control system, based on an industrial PC (1.1 GHz) with touch screen panel, is simple and logical to operate. The system offers a wide range of functions, such as a formula storage, production and trend analyses, recording and storing of production data plus remote telephone / GSM / WLAN maintenance.
Reliable : Degassing The lowest possible input moisture levels are essential when processing PET, despite this, effective extruder venting is often required in order to achieve best possible IV results. The conical design of the MAS extruder offers a large degassing area, paired with extremely large screw surfaces. High performance degassing systems, providing vacuum <5mbar, in combination with sophisticated process monitoring ensures consistently high product quality. In addition atmospheric degassing, placed immediately after feeding section, can be supplied on request in order to remove moisture even before melting the material further enhancing the extruderâ&#x20AC;&#x2122;s performance.
Individual : Configuration The extruder screw consists of a rear part and an front part. Each is manufactured from one piece and is available in different pitch and flight design. Tailor made mixing and shearing elements are placed in between rear and front part. The barrel zones are equipped with heating elements and an air or liquid cooling on request. The degassing openings are fitted with exchangeable inserts. Depending on its size and features, the MAS extruder has an atmospheric venting port and/ or one or two venting zones.
04 MAS-PET-RECYCLING
Double venting
Gear box
Conical barrel Heating/cooling zone (Liquid cooling)
Cooling unit oil/ air heat exchanger
Condensate tank
Swivelling barrel mounting
Barrel with double venting
AC drive (direct drive optional)
intake
!
venting
! !
venting
plasticising
! ! mixing
! pressure bild up Schematic
MAS-PET-RECYCLING 05
MAS Extruder built for reliable high performance. Perfect : Mechanics
Impressive : melt pressure build up
Due to a robust mechanical engineering, MAS extruders have a particularly long service life and are easy to service. The conical design of the screw ensures minimal mechanical stress in the screw shaft, even at extremely high torques. The large intake zone centre-to-centre distances enable the use of maximum-sized drive shafts. The back-pressure bearings are also generously dimensioned. The compact design of the MAS extruder ensures a very small footprint.
The conical screw design allows high and stable melt pressure built up, supported by the well designed geometry of the discharge section and robust, large back pressure bearings with a minimum service life of 40,000 hours, calculated at a pressure of 250 bar.
Optimized : Performance
Robust : Material and design Premium quality steel, robust design and solid quality workmanship guarantee high availability and a long life time. Barrels and screws are designed for maximum wear-resistant: The barrels are made of tool steel, case hardened or nitrited with the screws being hardened, tempered and nitrited. The screw land can also be equipped with anti-abrasion protection on request.
06 MAS-PET-RECYCLING
Melt pressure in barrel 200 180 160 Pressure in bar
Excellent process characteristics of MAS extruders are provided by the huge material intake volume and high overlapping of the screw flights. Due to the conical design of the processing unit, the intake volume is significantly bigger than the discharge volume, resulting in a very high screw fill level. The melting zone is specified by an exceptionally large inner/outer diameter ratio. Consequently, MAS extruders offer an outstanding homogenization and mixing performance. High discharge rates can therefore be achieved even at low screw speed, providing high melt pressures at low melt temperatures. In most cases, melt pumps are not required.
140 120 100 80 60 40 20 0 Venting ports
Pressure profile MAS 55 for a melt throughput of 500kg/h at 270 rpm
Screw tip
Direct Drive
MAS Extruder with underpelletizing system
Throughput data for washed bottle flake kg/h 2000 1900 1800 1700 1600 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
MAS 45
MAS 55
MAS 75
MAS 90
undried
dried and pre-heated
MAS-PET-RECYCLING 07
Representations in ( Australia ( Europe ( Asia ( Africa ( North and South America
MAS Austria General Management Günther Klammer Tel: +43 7229 78 999 10 Sales Stefan Lehner Tel: +43 7229 78 999 17 MAS International Switzerland / France Staub Technologie GmbH René Staub Sonnhaldenstrasse 7 A CH-4653 Obergösgen staub@mas-austria.com Poland / Ukraine MT Recykling Sp. z o.o. Tomasz Zujkiewicz Ul. Byslawska 82 PL-04-994 Warszawa t.zujkiewicz@weima.pl Spain Elba Ramon Xifra Ctra. De la Bruguera, 10 ES-17150 Sant Gregori r.xifra@cgac.es www.elba-spa.it
T: +43 7229 78 999 F: +43 7229 78 999 10
UK / Ireland John Wood & Associates Julian Wood UK-14 Ladythorn Road, Bramhall julian@johnwoodassociates.com www.johnwoodassociates.com Benelux Habro Handel & Advies BV Arjan Brouwers Het Wolbert 19 7547 NL-RA Enschede brouwers@winza.com www.habrobv.nl Sweden / Norway Prominova AB Erik Skoglund S. Stationsv. 6 SE-517 33 Bollebygd info@prominova.se Bulgaria Gebrüder Paschev GmbH Daniel Paschev Georgi Benev Str. 3 BG-4003 Plovdiv daniel.paschev@g-paschev.com www.g-paschev.com
info@mas-austria.com www.mas-austria.com
USA / Canada eFACTORTHREE Hartmut Bendfeldt 15720 John J. Delaney Drive Charlotte, NC 28277, USA hbendfeldt@efactor3.com www.efactor3.com Mexiko Interplast, DA DE CV Ben Propfe José Ma. Rico No. 102 Desp. 103 Col. Del Valle 03100 México, DF benpropfe@interplast.com.mx
Technische Änderungen vorbehalten
M-A-S Maschinen- und Anlagenbau Schulz Gmbh A-4055 Pucking, Hobelweg 1
Australia / New Zealand Koga Group Geof Pile PO Box 6010 Victoria, Australia geofp@koga.com.au www.koga.com.au
Iran Pasargad Rahpouyan Kish Co. Kambiz Megharazi Nr. 6 Pialeh st. Nakhjawan st. Theran-Iran, 1975744571 pcciran@gmail.com MADE IN AUSTRIA
Simply intelligent, and robust: MAS compounding plants. Extremely high torque and huge volume.
MAS opens new compounding opportunities For masterbatch and alloy production.
Conical : mechanical benefits Many compounding products demand gentle processing, minimal shear and clearly defined energy input. The conical MAS co-rotator offers extremely high torque and huge intake volumes. Substantially reduced rotational speeds mean significantly less energy input and considerably lower polymer melt shear. Consequently, this gentle processing allows the homogenisation of particularly light starting material and thermally sensitive polymers.
Versatile : Performance spectrum Input materials are resin or recycled from industrial plastics such as PS, ABS, PA, POM, PET, PPE, PES, PC, Biopolymers, PVC, as well as waxes and bitumen. The MAS extruder is used not only in classic compounding applications, but also in direct extrusion. Typical use of the MAS extruder:
›
Homogenisation of fillers, additives and pigments*
› › › › › › › ›
Talc CaCo3, BaSo4 Wood meal Hollow glass balls Graphite Soot TiO2 Fire retardants
› ›
Polymer alloys Production of long fibre compounds*
› › › ›
Fibreglass / Rovings Carbon fibre / Rovings Natural fibres Paper
80% 80% 80% 60% 70% 70% 80% 70%
60% 50% 80% 90%
* Mentioned feeding values are maximum figures and depend on the polymer to be used
02 MAS-COMPOUNDING
NCT (New Conical Technology) makes more of your polymer.
MAS 55
Innovative : Technology
Multifunctional : Diverse applications
The New Conical Technology (NCT) developed by MAS combines the benefits of conical extruders with those of parallel co-rotating twin screw extruders. In comparison to conventional extruders, the conical design offers substantially higher filling volumes at the material intake. This results in a higher screw filling level which gives the highest possible output with comparatively high pressure ratios and low melt temperatures. The co-rotating design provides perfect homogenisation. Generously dimensioned screw shafts paired with strong back pressure bearings result in an extremely robust design with a long service life. This makes them the perfect solution for highly efficient compounding and processing of polymers with fillers and additives.
MAS compounders are suitable for almost all compounding applications:
› › › › › › ›
Processing powder, pellets, agglomerate Homogenisation of masterbatches, lubricants and additives Adding fillers Degassing plastic melts Producing masterbatches and alloys Direct extrusion Inline compounding
MAS-COMPOUNDING 03
MAS compounder
perfectly fit your company. Individual : configuration The extruder screw consists of a rear part and an front part. Each is manufactured from one piece and is available in different pitch and flight design. Tailor made mixing and shearing elements are placed in between rear and front part. The barrel zones are equipped with liquid or air cooling as required. The venting ports are fitted with exchangeable inserts. The barrel is segmented so it is possible to provide additional ports or side feeders. Depending on its size and features, the extruder has a single atmospheric venting port and/ or 1 to 2 vacuum venting zones.
Logical : plasticising unit The control system, based on an industrial PC (1.1 GHz) with touch screen panel, is simple and logical to operate. The system offers a wide range of functions, such as a formula storage, production and trend analyses, recording and storing of production data plus remote telephone / GSM / WLAN maintenance.
Screw volume and screw surface area 2000 1800 1600 1400 1200 1000 800 600 400 200 0
Volume TSE 55 parallel
Schematic
04 MAS-COMPOUNDING
Venting ports
volume cm3 surface area cm2
Intake feeder (optional) Double venting
Gear box
Conical barrel Heating/ cooling zone (liquid cooling)
Condensate tanks
Conical : plasticising unit The plasticising unit consists of several functional zones. The feed zone has a comparatively large chamber volume to guarantee the perfect filling level of the screws. The melting zone is completely filled by the back up from the baffle zone. The large surface area of the screws ensures efficient energy transfer to the material. The flight volume of the baffle with the reduced pitch essentially determines the plasticising performance of the screws. Due to the modular design, the plasticising unit can be adapted individually to meet each customer's specific needs. Mixing and kneading elements serve to homogenise the melt. The following discharge zone is responsible for pressure build up. Due to the high overlapping of the screw flights a significant pressure build up, combined with consistently high output and outstanding venting performance, is achieved. High outputs can therefore be obtained, even at low screw speeds with high melt pressures at low melt temperatures.
Customer oriented : Masterbatches As the bulk weight of pigments is often minimal, the generous feed volumes of the MAS compounder is particularly important in order to work gently even at low screw speeds.
Swivelling barrel mounting
AC Drive (optional direct drive)
Your benefits at a glance:
› › › › › ›
Huge feed volume Swivelling barrel mounting for easy screw replacement High screw filling level and minimal shear Short processing unit Easy to clean system Safe and reliable degassing
Melt pressure in barrel 200
Screw tip
180 160 140 Druck in bar
Cooling unit Oil/ air heat exchanger
120 100 80 60 40 20
0 Venting ports
Pressure profile MAS 55 for a melt throughput of 500kg/h at 270 rpm
MAS-COMPOUNDING 05
MAS compounder
exceed your expectations. Perfect: Mechanics
Complete : Additional equipment
Due to a robust mechanical engineering, MAS extruders have a particularly long service life and are easy to service. The conical design of the screw ensures minimal mechanical stress in the screw shaft, even at extremely high torques. The large intake zone centre-to-centre distances enable the use of maximum-sized drive shafts. The back-pressure bearings are also generously dimensioned. The compact design of the MAS extruder ensures a very small footprint.
› › › › › › › ›
Strand dies (incl. downstream equipment) Underwater pelletizing Watercooled die face pelletizing Air pelletizing Dosing units Side feeders Vacuum unit Feeding devices
Mixing parts
Robust : Material and design Premium quality steel, robust design and quality workmanship guarantee high availability and a long life time. Barrels and screws are designed for maximum wear-resistant: Wear protection
Screws
Heat treatment
Wear
Corrosion
Tool steel
fully hardened
+++
+++
Case hardened
hardened
++
++
Nitrided steel
nitrided
++
++
Cold work steel wear bush
hardened
++++
+++
Nitrided steel
tempered and nitrided
++
++
Nitrided steel
flights clad with stelite 1
++++
++++
Nitrided steel
flights clad with stelite 6
+++
++++
Shear rate and Viscosity in MAS 55 barrel 100
+ light ++ medium +++ strong ++++ very strong
640 620
80
Back pressure bearing Shear rate 1/s
70
600
60 50
580
40 560
30 20 10 0 Venting ports
06 MAS-COMPOUNDING
Screw tip
90
Shear rate Viscosity
540 520
Viscosity in Pa!s
Barrel
Steel quality
Direct Drive
MAS Extruder with underwater pelletizing system
kg/h
MAS 45
MAS 55
MAS 75
MAS 90
1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 300 200 100 0
Throughput data depends on polymer, type of filler and filling degree
MAS-COMPOUNDING 07
Representations in ( Australia ( Europe ( Asia ( Africa ( North and South America
MAS Austria General Management Günther Klammer Tel: +43 7229 78 999 10 Sales Stefan Lehner Tel: +43 7229 78 999 17 MAS International Switzerland / France Staub Technologie GmbH René Staub Sonnhaldenstrasse 7 A CH-4653 Obergösgen staub@mas-austria.com Poland / Ukraine MT Recykling Sp. z o.o. Tomasz Zujkiewicz Ul. Byslawska 82 PL-04-994 Warszawa t.zujkiewicz@weima.pl Spain Elba Ramon Xifra Ctra. De la Bruguera, 10 ES-17150 Sant Gregori r.xifra@cgac.es www.elba-spa.it
T: +43 7229 78 999 F: +43 7229 78 999 10
UK / Ireland John Wood & Associates Julian Wood UK-14 Ladythorn Road, Bramhall julian@johnwoodassociates.com www.johnwoodassociates.com Benelux Habro Handel & Advies BV Arjan Brouwers Het Wolbert 19 7547 NL-RA Enschede brouwers@winza.com www.habrobv.nl Sweden / Norway Prominova AB Erik Skoglund S. Stationsv. 6 SE-517 33 Bollebygd info@prominova.se Bulgaria Gebrüder Paschev GmbH Daniel Paschev Georgi Benev Str. 3 BG-4003 Plovdiv daniel.paschev@g-paschev.com www.g-paschev.com
info@mas-austria.com www.mas-austria.com
USA / Canada eFACTORTHREE Hartmut Bendfeldt 15720 John J. Delaney Drive Charlotte, NC 28277, USA hbendfeldt@efactor3.com www.efactor3.com Mexiko Interplast, DA DE CV Ben Propfe José Ma. Rico No. 102 Desp. 103 Col. Del Valle 03100 México, DF benpropfe@interplast.com.mx
Technische Änderungen vorbehalten
M-A-S Maschinen- und Anlagenbau Schulz Gmbh A-4055 Pucking, Hobelweg 1
Australia / New Zealand Koga Group Geof Pile PO Box 6010 Victoria, Australia geofp@koga.com.au www.koga.com.au
Iran Pasargad Rahpouyan Kish Co. Kambiz Megharazi Nr. 6 Pialeh st. Nakhjawan st. Theran-Iran, 1975744571 pcciran@gmail.com MADE IN AUSTRIA
Thank you for viewing KogaRecycylingtech eMagazine For more information contact: Geof Pile Email: geofp@koga.com.au Phone: 0419 558 600