High-Precision Checkweighing for Renowned Paint and Render Manufacturer Thanks to Innovative Special Solution From Minebea Intec

The challenges of filling paints and liquid renders mainly relate to the large weighing range of the containers to be weighed. The customer’s variations for this Best Practice range from 1–50 kg net per container. Minebea Intec supplied a highly flexible weighing solution for the legal checkweighing.

Project goal and implementation

The project had a clear goal, namely to provide a highly efficient weighing solution that also covers an exceptionally large weighing range. The manufacturer’s weighing process was further complicated by the different properties of the render and paint products, for example the flow rate. As a result, the individual products had to be assigned to certain filling plants and it was not possible simply to group the production lines according to filling amount. A flexible weighing solution.

The  special  solution  created by Minebea Intec consists of a weighing platform IS (ISEDE- 50-OAW), which is defined as a multi-interval scale with a duel range capability, up to 20kg has a resolution of 2g and to 50kg a “We have great confidence in the technologies from Minebea Intec, which have been built up over decades. The weighing solution makes our process more efficient day after day.”

Customer’s production manager

then has equipped two further plants with the system. The weights and measures authorities tasked with confirming conformity carried out the necessary measurements within the tolerance.

The manufacturer is very happy with the results from the first year. The earlier concerns that this high- resolution  weighing  platform  IS resolution of 5g readability. This resolution meets the requirement of the German Verpackungsverordnung [Packaging regulation] and it is the only solution on the market with this special weighing range. The connected weight controller Maxxis 5, is a freely programmable terminal and with an “Automatic Checkweigher” project application, carries out the control tasks and communicates with the higher-level control unit directly via digital signals or via the ProfiNet field bus. The data for inspection is transmitted via OPC to the weight controller Maxxis and forwarded to the SPC Enterprise for logging.

Manufacturer is very happy with the precision and speed. This combination of weight controller Maxxis 5 and weighing platform IS was granted PTB [German National Metrology Institute] approval as a checkweigher. During this process, the plant runs in start-stop mode, i.e. the Minebea Intec systems stop the belt and weigh at a standstill. The producer completed then has equipped two further plants with the system. The weights and measures authorities tasked with confirming conformity carried out the necessary measurements within the tolerance.

The manufacturer is very happy with the results from the first year. The earlier concerns that this high- resolution  weighing  platform  IS would not withstand the mechanical strain or that the start-stop operation would slow down the plant have been dispelled. The performance remains very precise and in these applications the stopping took less time than the filling itself – 1 to 5 seconds depending on the container. This means that Minebea Intec has proven once again that no individual challenges are too much for the company’s weighing and inspection technologies.

www.minebea-intec.com

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XSYS Unveils Catena Proservx for Real-Time Equipment Monitoring, Alerting and Reporting

New cloud-based solution elevates Catena plate processing and ThermoFlexX TFxX Imaging equipment with real-time remote monitoring capabilities, advancing customers to Industry 4.0 operations. This prepress software provides deep insights into machine performance and consumable usage, helping to ensure consistent quality, waste reduction and optimization of Overall Equipment Effectiveness (OEE). 

 XSYS is proud to introduce Catena ProServX, a cloud-based, real-time equipment monitoring tool for proactive maintenance and superior quality control. By precisely measuring equipment performance, energy consumption, and consumable usage, ProServX empowers customers with unparalleled insights into their operations. With this data, decision-makers can make informed, data-driven choices  to optimize OEE and ensure the highest quality standards, while minimizing waste for sustainable plate making.

“Catena ProServX, the latest innovation from XSYS, represents a significant leap forward in digitalizing equipment management and KPI reporting. It is a connected, cloud-based solution that delivers immediate data about asset performance and consumable usage according to industry 4.0 principles,” said Bert Eeckhout. “This new software development, provides a unique access to plate processing data which until today was not available. Now, with the launch of ProServX customers can access and use this data to optimize their operations, and make fact based decisions.”

ProServX provides in-depth production reports at regular intervals detailing the number of plates produced during the specified period, along with the materials consumed. Alerts are sent out if any abnormal activity is registered, such as excessive solvent usage or a malfunctioning lamp, enabling customers to engage in proactive error management and predictive maintenance actions.

Another standout feature of ProServX is its ability to generate individual reports for each job with detailed insights into every aspect, from laser exposure to plate finishing. With this level of traceability, platemakers can ensure 100% quality control, promptly identify and resolve issues, and optimize resource allocation for enhanced efficiency and productivity.

The data provided by ProServX accelerates remote service capabilities to new heights and reduces unnecessary travel for technicians. “Catena ProServX represents a holistic approach to remote equipment management by offering advanced statistics, comprehensive reporting, and unparalleled support. It is not just a software solution but a real catalyst for improving production performance, and achieving sustainable business success in today’s dynamic landscape,” concludes Bert Eeckhout.

xsysglobal.com

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Schenck Process FPM is Becoming Coperion

Effective August 1, 2024, the company will officially transition its name under Coperion

Following its September 2023 acquisition by Hillenbrand , Schenck Process Food and Performance Materials (FPM) is transitioning its name and brand to Coperion. The full legal change to Coperion will be completed by August 1, 2024.

Coperion is an operating company of Hillenbrand with 140 years’ experience in some of the world’s most critical processing industries. Schenck Process FPM has contributed an integral part to its divisions, which support processing solutions for manufacturing in polymers/performance materials, food, health & nutrition and aftermarket sales & services.

Schenck Process FPM expertise, team members, manufacturing sites, test and innovation centers, and technologies remain in place. This includes flagship brands such as RBS, Stock, Baker Perkins, Kemutec and Mucon. Customers can experience a seamless transition bolstered by more resources and broader technology capabilities available through Coperion.

“The acquisition of Schenck Process FPM in 2023 has been an essential step for the development of Coperion toward a more diversified company and an expanded footprint. With the transition of the FPM brand name under Coperion, we take the next step in our journey,” said Ulrich Bartel, President of Coperion.

“Aligning more closely with Coperion reflects a significant opportunity for us to combine our strengths and offer customers access to a broader portfolio of solutions, technologies and services,” said Matthew Craig, Vice President and General Manager, Schenck Process FPM. “This wider range of complementary technologies and increased scale makes us even more capable of delivering value.”

The evolution to the Coperion name and brand begins with the schenckprocessfpm.com digital domain shifting to coperion.com. The company’s website and emails, including those from technology brands such as Baker Perkins, will change.

www.coperion.com

www.Hillenbrand.com

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Direct Dosing of Chalk Supports Sustainable Extrusion Process

Without Premixing to the Highly Filled PVC Pipe

Flexibility, process stability and minimized wear are only some of the advantages resulting from the production of PVC pipes with high filler content using the solution currently being presented by battenfeld-cincinnati. At its booth W3161, the extrusion specialist is showcasing the twinEX 93-34 parallel twin screw extruder model for processing up to 100 parts of chalk without premixing.

High proportions of filler chalk make PVC pipes, which are primarily used as sewer pipes, not only cheaper, but also reduce the use of fossil resources. At the NPE 2024, battenfeld-cincinnati is presenting the ideal solution for manufacturing PVC pipes with a high filler content. A basic PVC formulation and the filler material are fed separately to the production line. The individual components are then put together in a collection hopper and subsequently blended with each other in the cold mixer connected to it. After mixing, the finished formulation is passed on to the feed opening of the extruder via a vertical dosing unit. Both the mixing ratio and the entire material throughput are gravimetrically monitored and controlled. All containers along the chalk transport and chalk dosing line are equipped with agitators. Thus, the filler material is kept in motion along the entire route to prevent bridging. A twinEX 93-34 parallel twin screw extruder serves as processing unit for the PVC formulation. The processing unit features a specially adapted screw geometry with anti-wear protection to transport and plasticize the blend evenly and homogeneously. The advantage of this solution is its chalk content variability ranging from 30 to 100 parts, which can be easily adjusted at any time and at short notice to the formulation required for the specific product. A further benefit of direct gravimetric chalk dosing is the enormous process stability, which ensures a high-quality end product. Finally, the process eliminates the need for premixing of PVC and chalk in a heating/cooling mixer. This process change involves several benefits. Central heating/cooling mixers can be kept smaller in size, or any mixing capacities which become free can be made

available to other production lines. De-mixing during material transport can be prevented, since the filler material is fed to the production line directly after transport.

With the combination of an extruder and a gravimetric metering unit shown at the fair, solid PVC pipes with filler content can be produced using a mono-layer pipe die. For 3-layer pipes with a filled middle layer and external layers without filler content, battenfeld-cincinnati offers the appropriate three-layer pipe dies and conical co-extruders. In this way, pipes up to 15.7 inches in diameter can be produced economically and resource-efficiently, which of course can also be recycled after the end of their service life.

www.battenfeld-cincinnati.com

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Large-Diameter Pipe Line Expertise From Battenfeld-Cincinnati is Unique

Two record lines sold

Giant pipes with a diameter of 106 inches can be produced with the extrusion lines recently sold to north-east Africa. With its foray into the new dimension of 106 inches large PE pipes, the extrusion line manufacturer battenfeld-cincinnati has set a new record. These are the first complete lines capable of producing pipes of this size and quality. The design incorporates both the company’s unique overall system expertise, which intelligently combines the individual components from the material dosing system to the cutting unit without interface problems, and its decades of experience in the construction of large-diameter pipe systems. Continuous optimization to reduce sagging and thus increase pipe quality speaks for itself, as do mechanical engineering aspects that simplify the transport and assembly of the large components.

With the new lines, the two customers will expand their product range to include large pipes with an enormous diameter of 106 inches and thus meet the increasing demand for high-performance fresh water and wastewater systems. Plastic pipes play a major role here, as they are easier to install due to their lower weight compared to concrete pipes, are resistant to corrosion and chemicals and cannot be damaged by tree roots in the ground. In other words, they are functional and durable

In order to be able to produce pipes in these dimensions, high-performance extruders that can homogeneously plasticize the melt material are required. For some years now, battenfeld-cincinnati has been relying on the solEX NG series, which achieves up to 25 % higher output compared to previous versions. Thanks to the process engineering design with an internally grooved barrel and matching screw and grooved bushing geometry, the extruders operate with a reduced axial pressure profile, which ensures low wear. At the same time, high specific output rates at low screw speeds and temperatures reduced by around 10 °C guarantee effective but gentle melt processing. The OptiMelt static mixer, which is installed between the extruder and the die, achieves a further 10 °C reduction in temperature. The tool itself is a helix pipe head, which, with its two-stage concept, ensures optimum melt distribution with low pressure build-up. Finally, the effective internal pipe cooling supports the stable outlet of the melt from the die. The entire unit thus ensures minimized sagging effects, which is particularly important for large pipes and their logically high weight in order to guarantee optimum wall thickness distribution without ovality.

Needless to say, that the downstream components are also designed for the large dimensions and also meet the requirements for low energy consumption. The vacuum and spray baths work solely with frequency-controlled vacuum pumps, which consume around 50 % less energy than conventional systems. At the same time, a closed water circuit in the complete calibration system ensures minimized water consumption of just 4.41 gpm.

A brand new feature is that all downstream components are now only 4 m long, meaning that they can be easily transported to their destination and only need to be joined together.

At the booth W3161, the team of experts will be providing information about the specific advantages of large-diameter pipe systems and, if requested, will be presenting the Fast Dimension Change (FDC) system, which can be integrated into any pipe line and allows the pipe dimension to be changed automatically during ongoing operation. FDC systems give the pipe manufacturer maximum flexibility and therefore cost-effectiveness.

www.battenfeld-cincinnati.com

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The high-speed extruder celebrates its 20th birthday

The New Extruder Generation Comes of Age

This year marks a special anniversary. Developed in 2003 and continuously refined since, the new generation of extruders, also known as Highspeed Extruders, is now globally recognized as a proven solution in the production of thermoforming sheet from PP or PS. Moreover, this type of extruder has found applications in the production of industrial boards or in the furniture industry, extending to the feeding of pyrolysis reactors for recycling post-consumer waste.

True to the motto “One size fits all,” today, 6 types of extruders with the optimal screw diameter of 3 inches (75 mm) are built, differing only in screw speed and drive power. This ensures a wide range of applications, serving as a high-performance primary extruder or a suitable co-extruder, typically ranging from 400 to 4,000 lbs/h in output.

Since the drive power input directly translates to the melting of plastics during extrusion, no additional external heating is required. Thus, this extruder significantly and sustainably contributes to energy savings and the reduction of the carbon footprint in film production.

Operators particularly appreciate the ease of use, short start-up or changeover times, as well as simple maintenance. Despite its comparatively small size, this machine efficiently operates even at higher outputs without requiring additional floor space.

Visitors to NPE2024 are welcome to congratulate the now matured birthday celebrant, showcased at Booth W3161.

www.battenfeld-cincinnati.com

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Battenfeld-Cincinnati Adds Small Model to Complete its Solex NG Series

Successful Extruder Now Also Available in Size 45

Next-generation extruders from battenfeld-cincinnati have long since established themselves in the market. High output rates at low screw speeds, effective melting performance with low melt temperatures plus a reduced pressure profile and consequently less wear on machines – these are the benefits provided by the high-speed solEX NG series. At NPE 2024 , the extruder specialist is now rounding off this series downwards by adding a new solEX NG 45 to the four existing models solEX NG 60, 75, 90 and 120 .

This latest and smallest model, solEX NG 45, just like the larger models of the series, has a processing unit consisting of an internally grooved barrel combined with a matching screw geometry. The process technology advantages resulting from this combination ensure an extra-high-quality standard for the extruded semi-finished product. When processing HDPE, these extruders also achieve a 25 % higher output  and for PP even of up to 40 %. And in addition to that with reduced melt temperatures of about 50 °F below those in conventional extruders.

Another advantage resulting from the innovative processing unit of the NG series is the reduction in energy consumption, which is around 15 % lower than the previous solEX series. Consequently, this successful series offers advantages not only in terms of process technology, but in terms of higher energy efficiency as well.

www.battenfeld-cincinnati.com

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Husky Launches Hypet 6e Platform at NPE 2024 – Engineered to Set Unprecedented New Standards in Sustainable Molding

Husky Technologies, a pioneering technology provider enabling the delivery of essential needs to the global community, today announced the launch of its next generation HyPET 6e platform. Building upon the industry-leading technology of the company’s flagship PET preform injection molding system, HyPET 6e is the ideal combination of proven technology and innovation engineered to work together to deliver new, unprecedented standards in sustainable molding.

“The plastics industry is at a pivotal moment and as industry leaders we must deliver by proactively developing circular solutions to address plastic waste management,” said Robert Domodossola, Husky’s President of Systems and Tooling. “Our new HyPET 6e platform meets this need as it’s designed so that all system components are integrated to work together to deliver on the unique requirements of sustainable molding, including superior rPET capability, enhanced energy efficiency, and closed-loop quality control, while simplifying operation and still delivering the lowest total production cost.”

The evolution of sustainable molding

Visitors to Husky’s booth at NPE 2024, located in the West Hall , will be the first to see the company’s new HyPET 6e technology in action. Engineered to be the market’s fastest system with unprecedented integration of machine, mold, auxiliary, and real-time remote monitoring, HyPET 6e achieves the ideal balance between high throughputs and quality without compromise

Running at the show all week, a HyPET HPP6e 400 system is producing a lightweight 5.89 gram, 100 percent rPET preform at a 4.5 second cycle time on a 144-cavity, 45-pitch mold – a configuration designed to enable up to double the production output. The system’s industry-leading performance and integration enables this preform to be blown into the market’s lightest, functional, industrializable 20oz (591ml) Factor 101 bottle, which is the evolution of the 2016 lab scale Factor 100 concept.

Superior rPET capability

A number of improvements have been made to enable the new HyPET 6e platform to optimize processing of lightweight preforms made from up to 100% rPET. An integrated drying solution enables accurate material blending, metal contaminant removal, and consistent material preparation when running up to 100% rPET. A high throughput screw design is optimized to deliver superior rPET melt quality while optimized melt delivery enables uniform melt flow for lightweight applications. To reduce rPET color variability, an integrated, self-adjusting, real-time inspection system enables closed-loop color correction and automatic color adjustments.

Industry-leading energy consumption

HyPET 6e has been designed with regenerative, system level energy management that delivers on demand performance. This enables the system to intuitively reduce energy consumption, resulting in a considerable decrease in operating costs for producers. At the heart of the platform is intelligent, adaptive technology that uses feedback from pressure and actuator sensors to determine the optimum pressure required to effectively and efficiently mold every application. This adaptive system monitors and automatically adjusts for optimal energy consumption without impacting system capability, cycle time or part quality.

Simplified operation to maximize efficiency

To simplify operation, HyPET 6e has adopted additional features so that operators of all skill levels are able to achieve maximum productivity and part consistency. Intelligent, connected mold features yield advanced, real-time monitoring, extended mold life and support increased levels of rPET while maximizing uptime. Uniform preform cooling minimizes cycle time and yields superior preform quality. Simplified machine greasing performed during operation reduces maintenance time, enhanced conveyor features ensure gentle part handling to minimize defects, and automated preform sampling supports enhanced quality inspection. All systems are equipped with Advantage+Elite remote connectivity for real-time, proactive, predictive, transparent monitoring and the introduction of a new online Husky Complete Portal delivers instant access to on-demand maintenance videos, posters, manuals, and OEM parts resources.

www.husky.co

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SABIC, a global leader in the chemical industry, is reporting here at NPE2024 test results that underline the high potential of thermoplastic-based thermal runaway barrier solutions to help prevent fire spread in electric vehicle (EV) batteries. The SABIC sub-system level test series showed that a battery module box made from the company’s STAMAX 30YH570 long glass fiber polypropylene (PP) resin with intercellular thickness as low as 1mm has a potential to act as an effective thermal barrier solution by preventing thermal runaway propagation in 18650 cylindrical cells. It provides the necessary thermal insulation and flame resistance to reduce the chances of cell-to-cell propagation in a thermal runaway scenario and thus mitigate the risks of a catastrophic safety incident. This material in combination with compressible foams also has shown promising results to contain thermal runaway propagation in prismatic and pouch cells.

Visitors to SABIC’s NPE booth  can view the tested thermoplastic battery module box in a display area dedicated to BLUEHERO, an initiative designed to help the automotive industry shift to electric power and a low-carbon future. They can also explore other EV battery components made with SABIC’s materials, such as module enclosures, busbars and end plates, on display at the booth.

The new results build upon previous independent evaluations of SABIC’s STAMAX 30YH570 resin. In 2023, the product earned the UL Verified Mark from Underwriters Laboratories for effective flame delay performance. The assessment was based on UL 2596, the Test Method for Thermal and Mechanical Performance of Battery Enclosure Materials, using the thermal runaway box test.

“We are pleased to share this additional validation of our thermoplastic solutions’ strong potential for use in EV battery components and systems,” Fahad Al-Harthi, global director, Automotive, SABIC Polymers, said “Our portfolio of flame-retardant materials, combined with our expertise in application design and fire-polymer interaction, can help enable new thermal runaway barrier approaches. We look forward to continued collaboration across the automotive value chain to help improve the safety, efficiency and performance of EV battery systems.”

Thermal Runaway Barrier Testing

The thermal runaway propagation tests, highlighted here at NPE, are performed using a cluster of 15 commercial 18650 and 11 21700 lithium-ion battery cells enclosed in a steel chamber, with and without injection-molded STAMAX 30YH570 resin blocks serving as a thermal barrier.

Initiating cells were thermally abused by heating them through an electrical tape to begin thermal runaway. In tests without the thermal barrier in place, the electric and chemical energies stored in these cells were discharged in the form of high-temperature gas, open flame, high-speed particles, and a sudden increase of pressure inside and around the test chamber. The thermal runaway immediately propagated to all neighboring cells due to the uncontrolled heat transfer, creating fire hazards and severe damage to the EV battery pack.

Conversely, in the tests using the thermal barrier made from STAMAX 30YH570 resin, heat transfer and thermal propagation from thermal abuse of initiating cells were effectively suppressed, and all remaining cells remained safe and intact.

This flame-retardant material changes phase from solid to liquid and gas and removes heat via latent heat and intumescent capabilities during severe thermal events, allowing it to act as an effective thermal shield to mitigate heat transfer and fire spread.

Potential Solutions for EV Batteries and More Automotive Applications

SABIC is also highlighting at NPE EV battery applications that successfully use the company’s advanced thermoplastics. One is the battery module from the 2023 Hyundai IONIQ 6. This application uses SABIC polypropylene compound H1030 for module enclosures. This is a 30 percent glass fiber-reinforced, non-halogenated flame-retardant material that meets China’s GB/T 41467.3-2015 fire safety regulation for EVs surviving five minutes at 1,000°C.

Additional EV battery components on display, such as enclosures, end plates and busbars, either in production or developed as prototypes, help demonstrate various performance advantages of thermoplastics over conventional metals for these applications. They include weight and cost reduction, increased functional integration, and enhanced electrical and thermal insulation.

SABIC has a display zone in its booth dedicated to automotive thermoplastic solutions. In addition to materials well suited for use in EV battery components, the company is highlighting technologies and expertise to support possible/potential solutions for automotive structural applications such as tailgates, lighting and smart panels.

An additional display zone in the booth focuses on SABIC’s capabilities to support customers’ product development efforts. Included in this space is a small-scale model of an EV battery pack enclosure with a cover and tray. Visitors can learn how the company developed this part, which includes integrated thermal runaway barrier features to support fire suppression and temperature management.

www.sabic.com

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