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Cost Reduction Considerations for Extrusion Coating
Extrusion Coating and Laminating - Developments in Machinery and Techniques
Internal Deckled Extrusion Dies
Auditing Your Extrusion Coating or Cast Film Line
MDOs can "Stretch" Film Yield and Boost Properties
Fundamentals of Cast Film and its Potential Effects
Coater Application Selection Guide
The Fine Art of Remoisturization- Steam Humidification for Remoisturization and Flatness Control
Gravure Coating Technology and Techniques for Adhesives
Winding & Unwinding
Challenges in Winding Flexible Packaging
Continuous Splicing Techniques for Turret Unwinds
Converting to Shaftless Winding Boosts Efficiency at Slitter Winder
Cost Justification of Regenerative Tension Control on Slitter Winders
Developing Roll Hardness on Center-Surface Winders
Developing Roll Hardness on Center Winders
Flextronic Rider Roll Control
Guidelines for Rolls Used in Web Handling
Guidelines for Selecting Proper Web Handling Idler Rolls
Guidelines for Web Conveyance and Winding Tensions
Meeting Today's Productivity and Profitability Challenges
New Developments in Stretch Film Winding
Practical Applications for Unwind Systems for Converting Slitter Rewinders
Stationary Knife Changer has Received Worldwide Recognition
The Art of Winding Good Rolls
Supervisory Controls for Today's Converting Machines
Line Installations: Who's Best for the Job?
Modern Converting Equipment and Controls for Source and Waste Reduction
How to Get the Most From Your Edge Bead Reduction Equipment
Measuring and Evaluating Pressure Stability in Plasticating Extruders
Coating Technology for Flexible Packaging
How to Maximize Five-Roll Transfer Coater Performance
Identifying Gravure Coaters
The Basics for Gravure Coatings
Viscosity and its Relation to Bubble Removal
How to Describe Defects in Underwater Pelletized Pellets
Is Your Underwater Pelletizer Giving You Maximum Performance?
Winding & Unwinding
Coefficient of Friction Properties Effect on Winding
Guide to Selecting the Best Winding Process
How to Get the Most From Your Web Spreader
Pros and Cons of Inline Slitting
Shear Slitters (Metric)
Web Tension (Metric)
When to Use Center-Surface Winding
When to Use Center-Surface Winding (Metric)
- dsX Product Line™
- History of Firsts
- Lab Trial Opportunities
- Technical Papers
- Technical Center Developments
Product Line for a Competitive Advantage
- Competitively priced for a fast return on investment
- Less risk with industry-leading design, engineering, construction and support
- Consistent high quality distinguishes products from the competition
- Optimized production efficiencies with greater up time, increased productivity, and less waste
First wax paper machine manufactured
Extruder #1 manufactured for the wire and cable industry
First cast film line produced
First underwater pelletizer
First turn-key installation of a coating line
First internally deckled extrusion coating die for North American and European markets
Introduced patented TailTaper splicing system
World's first seven-layer cast stretch film line
Unveiling of a MicroLayer Feedback for ultra used in cast film and extrusion
Introduction of the dsX™ brand worldwide including the dsX flex-pack™, dsX med-tube™ and dsX s-tretch™
To keep up with the latest product developments in the plastics processing, rubber, and flexible web converting industries, there is great value in understanding your own production capabilities. In our fully equipped research and technical centers, our process engineers work with you to develop new production processes, formulas and applications. Each of our five laboratory facilities serves as a testing ground for new products, technologies and machine capabilities. Whatever it takes to ensure that you have a superior end product, is what we'll strive to do.
- Extruder “A”: 3.5” (89 mm) Diameter, 30:1 L/D with 100 HP (75 KW) DC Drive
- Extruder “B”: 4.5” (114 mm) Diameter, 13:1 L/D with 30 (22 KW) HP AC Drive
- Extruder “C”: 2.0” (51 mm) Diameter, 17:1 L/D with 25 (19 KW) HP Hydraulic Drive
- Sytron: Vibratory Tray Feeder
- Gravimetric Hopper Blending System: Three compartment
- Conair Automatic Hopper Loaders: Three Dustbeater Hopper Loaders are available. Maximum rate is 500 pounds/hr
- Resin Blending: Patterson Kelley Twin Shell Batch type
- Drying Capabilities: 2 Conair units - 800lbs. and 4000lbs. capacity (363 kg and 1814 kg)
- Feed Screws: A variety of high performance feed screws. These include single and two-stage single flighted and dual flighted screws as well as barrier type screws. Mixing sections include, but are not limited to, Maddox, twisted spiral, pins or blister ring. Many screws have removable tips for interchanging or removing mixing sections.
- Valved Adaptor: For extruder head
- Gear Pump
- Feed Pipe: Connections from three extruders or a dedicated pipe from extruder A directly to the pelletizer
- Underwater / Water or Air Ring Pelletizer: Black Clawson Model 0.5
- Spin Dryer / Water System: 50 gpm recirculation loop capable of holding less than 3°F (-16°C) variation across the pelletizer under full load conditions at temperatures between 55°F to 180°F. Trane microprocessor controlled 60 ton chiller. In-line 15KW temperature controlled heater for fast start-ups on above room temperature processes.
- Hot Oil Heating System: 100KW for pelletizer body and die plate.
- Process Control System: Offers line control. Displays include temperature control and line conditions.
Take your process to the next level in our Continuous Unwind and Winding Lab where our pilot line is available to evaluate different methods of unwinding, rewinding, and automatic transfer. In the unwinding section, you'll find the Accutail III, which delivers high-speed splicing up to a maximum line speed of 3000 fpm (915 mpm). The Accutail III is capable of tracking the splice as it leaves the unwind, opening nips, and initiating the winder transfer sequence at appropriate times.
In the winding section, you'll see technology that delivers efficient and cost-effective roll changes, dual direction winding capabilities, and our patented stationary knife roll changer. This is the only system that allows for continuous, safe roll changes at regular operating speeds while reducing or eliminating fold-back at the core.
- Maximum Cast Film Width: 54 inches finished (1372mm)
- Maximum Extrusion Coating Width: 50inches finished (1270mm)
- Extruder “A”: 3.5-inch diameter (89mm), 30:1 L/D with 150 HP Eurothem DC Drive
- Extruder “B”: 3.5-inch diameter (89mm), 30:1 L/D with 150 HP Eurotherm DC Drive
- Extruder “C”: 2.0-inch diameter (51mm), 17:1 L/D with 25 HP Hydraulic DC Drive
- Conair Automatic Hopper Loaders: Three dustbeater hopper loaders are available. Maximum rate is 500 lbs/hr (227 kg/hr)
- Resin Blending: BC off-line tumble blender
- Drying Capabilities: 2 Conair units with 800 lbs. and 4000 lbs. capacity (363 kg and 1814 kg)
- Feedscrews: A variety of high performance feedscrews for both extrusion coating and cast film
- Valved Adapter: On each 3.5-inch (89mm) extruder head
- Feed Pipe: Connections from three extruders to feedblock or a dedicated pipe from extruder A directly to the die
- Cloeren 5-layer Dual Plane Co-Extrusion Feedblock: Offers up to five-layer structures with up to three distinct polymers (including AAAAA, BBBBB, AAAAC, AAABB, AAACB, ABCBA, ABBBC and BAAAC)
- EDI 60-inch Autoflex H-40 Cast Film Contour Die: Die deckles down to 20 inches (508 mm)
- Cloeren 48-inch and 60-inch EBR Extrusion Coating Dies: Dies deckle down to 24 inches and 32 inches respectively (210 mm and 813 mm).
- BC Model 300XL 60-inch Coathanger Die: Die deckles down to 20 inches (508 mm)
- Jyohoku 47-inch Die: Die deckles down to 12 inches (305 mm)
- Casting Section/Extrusion Coater/Laminator: Two chill rolls; 18 inches diameter x 60 inches wide (457mm x 1524mm), double-shell, spiral-fluted, 60 rms matte finish and 2 rms high gloss; stripper roll and plate-out roll for cast film; web paths for extrusion coating and laminating; single-position auxiliary air brake unwind mounted to extrusion coater frame
- Multiple Nip Rolls: Extrusion coating lamination nip, silicone, rubber, Teflon, large diameter single nip roll or small nip roll with back up pressure roll
- Cooling System: 300 gpm chill roll recirculation loop capable of holding less than 3°F (-16°C) variation across the chill roll face under full load conditions at temperatures between 55°F to 180°F (13°C to 82°C); Trane microprocessor controlled 60 ton chiller; in-line 15 kw temperature controlled heater for fast start-ups on above room temperature processes
- Air Knife: Features 60-inch (1524 mm) slot width
- Vaccum Box: Features 60-inch (1524 mm) width
- EnerconTreater: 15 kw bare roll treater and 2 kw Ozone generator
- Integrator™ Process Control System: Offers distributive line control; displays include temperature control, line conditions, winder conditions, historical trending, diagnostics, and more; features PLC interface, drive interface, miscellaneous I/O and printer
- NDC Gauge: Thickness measuring gauge with automatic profile control, IR and Beta heads
- Robotic Winder/Roll Changer: Offers 1200 lb. maximum roll capacity; 72-inch (1829 mm) maximum demonstration width from single position unwind only or 54-inch (1372 mm) through entire extrusion line; 3-inch and 6-inch (76 mm and 152mm) auto air inflated core shafts; stationary, static, enveloper, and bump & cut automatic transfer systems; three models of winding, including center with taper, center/surface tension, and center/surface draw; light nip and firm nip programmable lay-on roll loading systems; in-line slitting down to 2 inches (51 mm) widths, with or without bleed trims
- Auxiliary Unwinds: For extrusion coating and lamination; 24-inch maximum diameter; air brake tension control; 3-inch & 6-inch (76 mm and 152 mm) core chucks; 1000 lb. (454 kg) roll weight; mounted directly to extrusion coater
- Primary Unwind: 3-inch and 6-inch (76 mm and 152 mm) core shafts; air brake tension control 10 to 150 lbs. (4.5-68 kg); 72-inch (1829 mm) maximum roll diameter; 5000 lb. (2268 kg) roll weight; 600 fpm (183 mpm) into extrusion process or 1200 fpm (366 mpm) directly into winder
- SteamexRemoisturizer: Process steam applied to both sides of the web or either side independently
- Multifunctional Cooling Section with Laminating Nip: Cools the web after the dryer, and for laminating (or interleave) a second web from an auxiliary single position unwind, capable of 140 PLI
- Auxiliary Single Position Unwind: Features manual side-lay and squaring, air-cooled pneumatic operated disc brake; mounted on a movable base so it may also be positioned for wet-bond laminations
- Turret Winder Roll Changer: Two-direction machine with stationary knife has center, surface, and surface with center assist winding
- Differential Offset Winding: Features slitting capabilities
- SurfaStart 1000 Winder: Pneumatic loading of secondary arms permits the operator to control the hardness of the finished roll
- Integrator PRO Process Control System: Supervisory control system provides monitoring and data logging of all critical operating parameters
- Coating Techniques: Many configurations available including doctor blade, rod, variations of offset gravure, variations of reverse gravure, variations of direct gravure, slot die, contact die, 2-roll smooth, 3-roll smooth, flex bar, hot melt (slot die) and many more.
- Primary Turret Unwind: Features arm pedestal design, regenerative motor braking or pneumatic brakes
- Splicer: Single direction with speed compensated controlled tail length, lap splice with core detection and splice tracking, zero-tail length (butt splice) capability
- Corona Treater: Single side treatment, maximum power 15 kw
- Pull Rolls: Provides tension isolation
- Universal Coater: (Series 4000) Cartridge-style machine that can be configured into multiple coater configurations through the use of quick-change roll out carts
- Dryer: The 60-foot (18.3 m) convection dryer is composed of (3) 20-foot (6.1 m) zones. Each zone has independent top and bottom air-flow and temperature control. Direct fired natural gas burners provide the heat source. A wide range of drying nozzle configurations can be demonstrated. The dryer is designed for solvent and aqueous coatings. Critical process parameters such as an air temperature, air-flow, solvent concentration, and web temperature are monitored and recorded in our Integrator PRO.
- Ultraviolet Curing Station: Allows for curing via photo initiation
- Cooling Pull Roll & Web Guide: Used to cool and guide the web prior to the remoisturizer
- AC Vector Drives
- 40 inches wide and equipped to run a wide range of product thickness
- 3.5-inch, 2.5-inch and two, 1.5-inch extruders
- Capability to use a shear for rigid thick products that cannot be wound
- Cantilever winder capable of producing xyz inch diameter rolls
- 18-inch, three-roll vertical down stack
- Water heated/cooled
- Roll skewing for thin gauge sheet
- Hands free roll gap adjustment
- Individual roll drives
- Primary fabric unwind
- D-S cantilevered winder
- Dancer and load cell control
- Vulcan shear
- Conair gravimetric blending stations with inline drying
- Co-extrusion capabilities with EDI co-extrusion feed block (micro-layer technology also available)
- Thin gauge capability with roll stand skewing
- Protective film unwind stations at the pull roll
- NDC X-Ray Backscatter gauging technology
- Xaloy melt pump and screen changers
- EPIC III™ control system
- Scan Tech X-ray thickness gauge
- Razor and Anvil Slitters
- Solution coater
- Top and bottom unwinds at pull roll
- Desiccant driers for hydroscopic materials
- Multi component blenders
- Two direct drive interchangeable-barrel MEDD extruders, 3/4 and 1-inch (19mm and 25mm), 24:1 L/D
- EPIC III™ supervisory control system
- Capability to process high temperature polymers including Fluoropolymers
- Enclosed, ventilated and air-conditioned space
- Davis-Standard melt pumps with servo drives
- Desiccant drying capabilities, up to three resins simultaneously
- Mono and coextrusion capabilities
- Vacuum sizing capabilities
- Multi-lumen capabilities
- Laser and ultrasonic gauging including trim control
- Dual servo belt puller capable of 250 fpm
- 6-foot belt conveyor for sample collection
- Space for customer-supplied equipment (coiler, payoff)
Products targeted for development include microbore, multi-lumen and catheter tubing.
This facility is used for new product development, product testing and extrusion systems trials for systems up to and over 140 feet (43 meters) long. The following extruder sizes are available for design development:
Smooth Bore L/D
2.5-inch (64mm) 24:1 and 30:1
4.5-inch (114mm) 24:1, 30:1, 34:1
Groove Feed L/D
3.5-inch (90mm) 24:1, 30:1, 34:1
Other extruders available for development work in the Technical Center include:
- 2.5-inch (64mm) 40:1 L/D high speed extruder
- 0.75-inch (19mm) 24:1 L/D high temperature corrosion resistant for FEP
- 24:1 L/D high temperature corrosion resistant for FEP
- 2.5-inch (64mm) 24:1 and 30:1 L/D, vented and non-vented
- 3.5-inch (90mm) groove feed 28:1, 33:1, 40:1 L/D configurations
- 4.5-inch (114mm) 24:1, 30:1, 34:1 L/D vented and non-vented
We have an extensive inventory of industry-leading screw design technology for process development and customer project development.
Davis-Standard’s success in implementing extrusion and converting technology has been paramount to the company’s ability to help our customer’s produce successful products. Extensive R&D capabilities, including a range of comprehensive extrusion and converting pilot lines for testing and proving new applications, enable us to work side-by-side with customers. Davis-Standard’s engineering team is focused on technology that improves efficiency, reduces energy and minimizes scrap. Specifically, the company has excelled in proven market-driven solutions.
Components of major extrusion lines are readily tailored to address customer needs. This can be as simple as combining existing design elements in a unique way or developing a new solution to enhance existing capabilities.
Davis-Standard has mastered the art of working with progressive customers and industry partners to break old paradigms and develop extrusion and converting product platforms that excel in the marketplace.
From concept to reality, experienced engineering teams turn specific objectives into high performance manufacturing. Well-equipped extrusion pilot facilities enable customers to test and prototype concepts, building a foundation of confidence.
By consistently reviewing technology fundamental to the extrusion and converting industry, Davis-Standard addresses major initiatives such as lowering energy consumption. In some instances, this involves partnerships with other industry-leading suppliers.
The results speak for themselves:
- A cast stretch film winder with the fastest cycle time in the industry
- A scrapless winder that eliminates scrap during winder indexing
- A high efficiency dryer for priming applications
- Environmentally friendly pelletizer technology for recycling
- Use of bioresins for flexible and rigid packaging
- Expanded medical tubing extrusion capabilities
- High-speed extruders to improve return on investment
- Direct drive extruders for better power transmission
- New screw designs to boost productivity
- More efficient heating and cooling systems
- Energy saving barrel heaters
- Green solutions for battery separator, solar and electronics applications
Davis-Standard’s groove feed extruder technology and patented DSB® barrier screw design offer processors a fully engineered solution for high-output applications. These high-performance extruders are based on Davis-Standard’s popular Thermatic® design. Davis-Standard has made significant advancements in groove feed bushing design and barrier screw design for processing high-output, low melt temperature, improved mixing and homogenization, and linear output.
At A Glance
- Rugged, wear resistant, unitized groove feed housing with a removable and replaceable groove feed bushing
- Groove feed technology for pipe and profile applications
- Extruders available in sizes from 2 to 6 inches (50 to 150mm) in 38:1 L/D sizes
Multiple groove designs are available for processing a range of thermoplastic materials including PP, PVC, polyolefins and various engineered resins.
Our ability to design and manufacture some of the industry’s top-performing feedscrews is one reason we have been an extrusion leader for nearly 60 years. With our R&D facilities and team of experienced polymer process engineers, we offer world-class screw designs and technical capabilities. Several types of barrier screw technologies are available based on the polymer(s) used and application. These include the DSB® I, DSB II, DSB III, DSB V, DSB VI, DSBM-T™ and Sterlex® designs.
Screws For Every Application
Screw sizes range from 3/4-inch (20mm) to 12-inches (305mm) for single screw, 40mm to 140mm for counter-rotating twin screw, and 32mm to 130mm for co-rotating fully intermeshing twin screw extruders. Screws, including smooth and groove feed designs, can be customized for specific applications.
The DSB® barrier screw typically consists of feed, barrier and metering sections with a dispersive or distributive mixer. This design introduces an additional flight over the transition section of the screw known as the barrier flight. This is advantageous because:
- The barrier flight creates a physical barrier between the solid bed and the melt pool, so that the depth of each channel varies independently.
- The barrier flight is undercut to allow molten material to pass from the solids channel (S/C) to the melt channel (M/C).
- The melt channel becomes progressively wider and deeper along the barrier section to accommodate the accumulating molten material.
- This geometry makes the melting process more efficient and improves stability.
Distributive And Dispersive Mixing
Our technology optimizes two types of mixing to achieve excellent melt quality – distributing mixing and dispersive mixing.
- Distributive mixing occurs between compatible materials by the simple splitting and recombination of flow streams. The mixing mechanism is important to achieve uniform temperature distribution across the melt stream to uniformly incorporate minor phase components such as master-batches for color, UV stabilizers, and slip and anti-block.
- Dispersive or intensive mixing is energy intensive and uses shear stress as a driving force when processing blends of different components. This breaks down agglomerated components or incorporates a semi-compatible minor phase component into a major component.
Manufacturing Methods And Materials
Our screws are engineered in CAD format and transferred to manufacturing using a CAD/CAM system. They are then milled and ground on CNC machines to the highest industry standards. This CAD/CAM system ensures accuracy, repeatability, and efficiency.
A wide range of raw materials and wear resistant technology is available for the full range of extrusion applications. Our engineers evaluate your application and recommend the best metallurgy for barrel, screw and flight surfaces.
Davis-Standard offers a complete range of energy efficient ECOTRUDERS. Our direct drive system is based on a Permanent Magnet Synchronous Motor (PMSM) technology that offers several advantages over conventional extruder drive and motor gear reducer systems.
The direct drive system eliminates the gear reducer, simplifying the extruder mechanical design. These motors provide very high torque densities compared to conventional AC and DC motors and produce high levels of torque at low operating speeds.
At A Glance
- No gear oils
- Energy efficient
- Quiet operation
- Small footprint
- Low maintenance
- Medical clean room friendly
- Available sizes: 0.75-inch (20mm) to 5-inch (130mm) diameter extruders
Comparison Of Different Solutions
- Up to 15 percent energy savings may be realized versus a conventional AC drive with gear reducer systems. A 2 1/2-inch (64mm) 30:1 extruder processing HDPE materials at 100 screw RPM will consume 10 percent less energy than a conventional AC drive with a gear reducer. The same 2 1/2-inch (64mm) 30:1 extruder processing PP materials at 100 screw RPM will consume 15 percent less energy than a conventional AC drive with a gear reducer.
- Up to 25 percent energy savings may be realized versus a conventional DC drive with gear reducer systems. A 2 1/2-inch (65mm) 30:1 extruder processing HDPE materials at 100 screw RPM will consume 25 percent less energy than a conventional DC drive with a gear reducer. The same 2 1/2-inch (65mm) 30:1 extruder processing PP materials at 100 screw RPM will consume 25 percent less energy than a conventional DC drive with a gear reducer.
• Noise emission caused by gearcase
• Noise emission caused by motor fan,
especially with higher powered motors
Direct Drive Solution
• Quiet operation:
– No gear reducer
– Less than 80 dBA
• Motor gear reducer combination requires
Direct Drive Solution
• Compact extruder configuration
for coextrusion applications
|Service & Maintenance:|
• Regular maintenance required:
– Gear reducer (oil changes)
– DC motors (brush replacement)
• Oil leaks possible
Direct Drive Solution
• Low maintenance
• Longer lifetime of motor
• Oil free system possible