Kreyenborg Weblog

Flight Plastics utilise Backflush technology producing top quality sheet from bottle flake

Flight Plastics, Winchester, United Kingdom :- recently expanded their sheet extrusion capacity by investing in a twin screw sheet extrusion line. The company, for years a leading producer of PET Sheet reel stock, uses this new line to produce top quality sheet from post consumer PET bottle flake.
 

To help accomplish this, Flight Plastics has equipped the extruder with a KREYENBORG four channel backflush screen changer for improved results during the melt filtration process. This innovative screen changer is based on the piston-type melt filter design, well known in the industry, but with the added feature of automated backflushing capabilities. The screen changer is completely automated - as contamination builds up on the screen pack, the melt pressure increases; when a pre-defined, adjustable, process pressure is reached, the filter elements are cleaned automatically by the backflush function. Further information from Kreyenborg UK agents www.regismachinery.co.uk
Posted by David Bargery View David Bargery's profile

FOAMALITE Install Infra-red Dryer System

 Some recent project highlights include delivery of a Kreyenborg  Infra-red dryer to Irish sheet producer FOAMALITE (www.foamalite.ie)

We have delivered an energy efficient infra-red drum for the Crystallizing and drying of PET flakes that is installed in a new multi million Euro installation of a complete sheet extrusion line at Ireland’s specialist sheet extruder FOAMALITE Loch Gowna site. Kreyenborg Infra red drying technology is widely acknowledged as the leading system for the rapid crystallizing and drying of PET. Not only for virgin PET
pellets, but also for a variety of mixes through to 100% regrind sheets.

For further details visit www.kreyenborg.com

View the 3D Video animation of the KREYENBORG IR Dryer Click Screen below

Replacement of Extruder Control at A. Schulman compounding plant

Schulman identified that although their twin- screw extruder was, in hardware terms, relatively new (built 10 tears ago), the control system was rapidly becoming outdated. The original control system did not offer the reliability, performance and features necessary to operate in todays competitive marketplace within the Masterbatch industry.
VIEW PHOTO SLIDESHOW

(Naturally capacity and performance of all PC’s and plcs have improved exponentially since this line was originally conceived – the world has progressed from computers with MS-DOS through to the world today with PC’s with ever increasing speed and huge memory capacity plus of course, the Internet)
The first Schulman complete extrusion line project which we finished last year, was to replace an old instrument based panel on a Farrel compounding system producing (4) tonnes per hour of masterbatch. As soon as that control system was in place the feedback from ALL of the line operators was extremely positive.

They really appreciated the ease of operation and the logical interface, which was provided by a single Siemens operator panel (HMI) controlling every single aspect of the complete line from extruder heating zones, through to screen changer and underwater pelletizer. Schulman were keen to replicate the success of the BSG ONE operator interface and decided to install a complete extruder control system for one of their twin screw extruders. This control system was retrofitted onto the twin screw extruder on schedule within the two week summer shutdown. BSG Engineers provided installation and commissioning support, with all functions being tested and I/O check (Inputs and Outputs) completed before the complete new operator control was handed over to the production team.

More details and video online of this CASE STUDY at  www.BSGcontrols.com

The new BSG One Control features the latest SIEMENS S7 plc hardware which offers a range of benefits including faster data processing, support for Open communications via Profibus, and built in 24 hour remote assistance support from BSG CONTROLS via modem link.

To view the video Case Study Click on VIDEO BELOW (Browser requires Adobe Flash Plug in www.adobe.com/flash



CONTACT REGIS MACHINERY (SALES) Ltd for more information www.regismachinery.co.uk

AURORA install compounding line with backflush filtration

 
United Kingdom based specialist compounder, AURORA Manufacturing, have installed a new Compounding line including completely automated backflush KREYENBORG screen changer, BKG Pelletizing system and BSG ONE extrusion line control. The Leigh, Lancashire based compounder and recycler is using the backflush screen changer to ensure that high quality PP Compounds are produced efficiently with no need for the operator  to make frequent screen exchange. AURORA feed the line with PP Flake from a variety of post industrial production scrap, the feed material can at times contain the metal threaded bushes from injection moulded parts. Previously with a  conventional lantern ‘slide plate’ type screen changer these metal parts can lead to an extremely short screen life, with the operator having to frequently exchange screens. The new Kreyenborg screen changer is completely automated and reacts to varying levels of contamination. The differential pressure is monitored, and once the pressure reaches a pre-defined level, the system initiates the automatic backflush process – without the need for an operator to attend to the line. The backflush process automatically cleans the screen packs and ejects the dirt particles out of the screen changer housing. An excellent demonstration of this backflushing process can be seen in the 3D Video animation below.
As part of the new compounding line project for AURORA REGIS MACHINERY also supplied a complete BSG ONE extrusion line control system (www.bsgcontrols.com) that takes care of every aspect of the 90mm twin screw compounding line control. From the control of the screw speed and heating zones, to the automatic start-up process of the complete line (Including the Kreyenborg screen changer and BKG hydraulically adjusted underwater Pelletizer)
For further details please contact KREYENBORG UK Agents Regis Machinery (Sales) Ltd www.regismachinery.co.uk
Aurora Website :- www.auroramanufacturing.co.uk

VIDEO ANIMATION - Press on the Screen Below to view the 3D VIDEO Animation

Kreyenborg backflush for automated filtration

The PowerBackflush screen changer has proven to give superb automatic cleaning of the screens not only in PET applications but also with a wide range of other plastics.

 In applications processing HDPE and PP the Power Backflush enables huge savings in costs associated with screen changing. The screen packs can be re-used  this offers the advantage of
Dramatic reduction in costs for replacement screens
Dramatic improvement in utilization of operating personel

Dramatic reduction in costs for replacement screens each year
As the screen packs can be automatically cleaned by backflushing each woven wire screen pack has an extended life. This dramatically reduces the number of screens you need to purchase each year.

Dramatic improvement in utilization of operating personel
If you can imagine that with conventional screen changers every time the screens become blocked by contamination with traditional systems an operator must come and manually exchange screens.
With the POWERBACKFLUSH as the cleaning process is completely automated – Instead of the operator making 100-200 manual screen exchanges – He can be better utilized elsewhere in your extrusion plant. The automated backflushing will take care of screen cleaning each and every time the screens become blocked by contamination

Test results with a PowerBackflush screen changer - 

In one trial the material was quite heavily contaminated therefore the system automatically cleaned screens by backflushing every hour. It was decided to stop the line and check the screens after four days of continuous running. On examination of the filter elements it was found that the screens had shown an extremely good level of cleaning With the result that there was still no need to change the screens even after 4 days of operation with highly contaminated material.
 

                                                                                      Click on the image for full size picture

High quality packaging film manufactured from recycled PET

High quality packaging film is now manufactured from recycled PET on a new line at Sharp Interpack’s Bridgwater, Somerset site. The new line allows up to 100% recycled PET sheet to be produced direct from hot caustic wash plants.

The operation is now further enhanced with a Power Back-Flush (V-type) screen changer from Kreyenborg GmbH- Germany that gives highly efficient cleaning of the screen packs without additional pressure from the extruder.

The system is particularly effective when processing especially high portions of recycled material with a high pollution degree such as PET bottle flakes.  The new line at Sharp Interpack has a capacity of 1.500 kg/h, using 100% recycled PET.
The feedstock, originating from consumer waste is pre-cleaned in a washing line and then directly extruded removing harmful substances from the plastic. The process is covered by robust PIRA certification and meets all EU requirements. A key line component for the processing of the recycled polymer is the melt filter. In this extrusion line  - a Kryenborg Power Back – Flush (V-type) screen changer that automatically flushes filter screens independently of the extruder for interruption-free, constant pressure extrusion.
With each back-flush a constant quantity of material is discharged, so that in comparison to other systems, the material losses are very low and the screen life long. 
The growing use of recycled polymers are required to meet strict EU regulations on plastics destined for direct food contact so now, more than ever, there is a need to screen out contaminants.
In the field of plastics extrusion any kind of contamination in the melting process is unacceptable not only affecting the quality of the product but also impeding the operating process. Sharpak lead the way in the use of recycled materials and was the first manufacturer to introduce recycled PET from post consumer waste into its soft fruit punnets and is now well ahead in its development of 100% r-PET.
www.sharpinterpack.com 

KREYENBORG Trial Facilities
For customers wishing to see a demonstration of a KREYENBORG screen changer in the KREYENBORG trial facility in Muenster, Germany please contact UK agents Regis Machinery www.regismachinery.co.uk
Video of trial facilities

Kreyenborg Trial Facilities from Regis on Vimeo.