MACHINE OF THE MONTH: Complete plant for the extrusion of filaments and pipes in special materials like PU and PA
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28 aug 2018
FRIUL FILIERE presents a complete extrusion system for the extrusion of special plastic materials. Look at the photo gallery and in detail the units that compose it.
FRIUL FILIERE has recently built a complete plant dedicated to the production of polyamide filaments with application on gardening machines. These filaments have different sections (for instance circle, square, etc) according to different applications. This system can produce single or multiple filaments at 60 mt / 1 ' speed.
This technology guarantees the final product particular characteristics of physical-mechanical resistance which their application requires.
Ideal for all applications subject to abrasion, this plant comes complete with technology and processes developed by the in-house research and engineering team of Friul Filiere.
The whole plant is more than 60mt long and it is composed by several machines and customized units in order to manage a triple coextrusion, control different phases of the extrusion process and over all successions of heating phases and cooling phases during the production of rods in a very special material such PA6.
Nr. 3 OMEGA SINGLE SCREW EXTRUDERS
Equipped with dedicated screw designed by Friul Filiere, NR.3 single-screw Omega 38 and Omega 60 extruders combine energy saving and high output rates thanks to specific technology that reduces absorption.
DIE HEAD AND SPECIAL CALIBRATION SYSTEM
The extrusion head and calibration system are extremely important and contribute to the positive result of the whole process. The head features the Tubeasy patented system that rapidly centres the material flow in the start-up phase by simply adjusting two screws. It appears almost incredible given the fact that traditional adjustment systems are difficult and slow to manage because of the numerous screws placed around the head that are used in order to move the flow. Tubeasy instead reduces start-up scraps by 60% and controls the material in order to improve not only the production performance of the whole plant, but also the quality and physical-mechanical properties of the end product. The cooling system makes an important contribution to the positive outcome of the process. Friul Filiere has developed a dedicated calibration system. This solution requires the application of special technology designed by the Friuli-based company for the management of complex and extreme materials like PA and PU. This technology can control flows that are otherwise difficult to calibrate and create smooth surfaces and sections that meet the minimum dimensional tolerances.
The extrusion line had to be equipped with different auxiliary machinery:
- An automatic material loading system
- MIXING UNITS
- Automatic FEEDING SYSTEMS
- Masterbatch dosing units on the extruders
- nr.2 dedicated ovens, each 7 mt long
- Two special haul-offs equipped with several barrels (from 3 to 10)
- An automatic winder at the end of the line
FRIUL FILIERE SOFTWARE
The machines meet the requirements of INDUSTRY 4.0 since they are equipped with PLC and Friul Filiere software that allow the management of the entire centralized process on the extruders even if the complete plant is complex and more than 60mt long.
This software is set up for a remote assistance service through the use of the Ethernet network installed on the machines. In case of problems during production, the customer anywhere in the world, can request the support of Friul Filiere that acts in real time solving those problems remotely.
A TECHNOLOGICAL SOLUTION FOR SPECIAL MATERIALS
This plant delivers the opportunity for production performance levels that have never been reached before, as well as high quality finished products. In this case, the products are PA monofilaments for gardening machines, agriculture and industry applications. However, this special calibration system and the whole know-how of the process can be used on extrusion plants in order to produce different typologies of pipes and rods in other special materials such as TPU, PP-HDPE, PMMA or PC.