Davis-Standard Thermatic® Extruders Support Maxi-Blast Expansion

 

Longtime Davis-Standard customer Maxi-Blast, Inc. recently installed six Davis-Standard Thermatic® extruders at its new 40,000 square foot facility in St. Petersburg, Florida. This is the latest extruder addition for Maxi-Blast, whose chairman and CEO Robert Donaldson has been purchasing Davis-Standard extruders since founding the company in 1981. Donaldson built Maxi-Blast into the global leader it is today by supplying both cleaning/deflashing equipment and blasting media to support customers in the construction, electrical, rubber and automotive industries among others. The Davis-Standard extruders process nylon and polycarbonate pellets used in the company’s propriety line of cabinets for cleaning screws and molds and deflashing parts.

“From the time I started the company, I felt Davis-Standard built the best extruders,” said Donaldson. “They build a lot of the components in-house, their service is excellent and they are a well-run organization. I am constantly striving to upgrade technology and stay current, so I’ve been replacing my Davis-Standard extruders every 15 years. Not only have I gotten excellent production out of these machines, but I sell the used ones on the secondary market. Used Davis-Standard extruders are always in demand because they are so well-built.”

Davis-Standard’s extruder and feedscrew technology have been instrumental in Maxi-Blast’s quest to make the perfect pellet for their process. Pellets are manufactured in a variety of sizes, shapes, colors and formulations depending on application. As Donaldson explained, pellet geometry is especially important when the material is used as blasting medium so it doesn’t damage the part. Maxi-Blast technology is not only used to clean screws and molds, but it is capable of deflashing rubber, phenolic and die-cast metal parts. The company is so astute at what they do, that the recent facility expansion is 25,000 square feet larger than the old facility.

Donaldson appreciates Davis-Standard’s Thermatic extruder because it is built for the most demanding processing requirements. Customers often describe this model as an “industry workhorse” because of its durability, minimal maintenance, and quiet operation for multiple processing requirements and applications. Another advantage is the Thermatic’s availability with a wide range of feedscrews and control systems. Sizes range from 1 ½ to 10 inches (40 to 250mm) with L/D’s from 12:1 to 40:1. According to Donaldson, the Thermatic is the best extruder out there and he believes it’s worth the investment because of the quality it delivers.

“Maxi-Blast is all about quality. The facility expansion, the new extruders and other equipment upgrades are all part of our ongoing investment strategy to support customers by making the best product possible,” Donaldson explained. “Our new Thermatic extruders are giving us 20 percent more product in the same amount of hours, which is essential to meeting production goals. We tell our customers we’re in this for long-haul and it’s good to know we can rely on Davis-Standard’s technology along the way.”

To inquire about a Davis-Standard Thermatic® extruder, please contact us.

For more information about Maxi-Blast, visit www.maxiblast.com.

 

Oracle Packaging Finds Immediate Success with Davis-Standard Line

 

2016, June 16

A new Davis-Standard extrusion coating line at Oracle Packaging is exceeding throughput expectations, enabling Oracle to get products to market more quickly than anticipated. The installation, completed in December, supports Oracle’s manufacturing of aluminum foil based products. Applications include custom lid stock, pouch stock, cable armouring, and products with specific barrier and sealant properties. The versatile and expandable design of the Davis-Standard line is fundamental to Oracle’s marketplace growth strategy.

“We researched several global manufacturers and Davis-Standard had the best combination of delivering a total solution for our critical and precise specifications,” said Chris Payne, Oracle’s vice president of sales and marketing. “In addition to addressing machine performance requirements, we were pleased with the installation. There are always challenges with big projects and Davis-Standard met each roadblock head-on. They collaborated with our project team and managed their direct and sub-contracted installers well. We are surpassing throughput estimates, which is giving us a head-start in delivering several products to market .”

The line was customized for Oracle’s processes, including coextrusion capabilities and winding equipment. Davis-Standard’s extrusion coating equipment offers advantages such as superior melt quality, automatic profile control (APC), deckle and die options, multi-coating capacity, web handling and flexible designs based on desired speed or automation. Oracle appreciates that Davis-Standard’s technology combined with their material science is providing a platform to deliver truly innovative products to consumer and pharmaceutical markets.

“This technology investment is key in helping us achieve 10 percent growth per year for the next three years,” said Payne. “As such, we appreciate that Davis-Standard has been comfortable with all of our requests. The outstanding performance of the line is validation of their technology and service-oriented approach.”

For more information about Davis-Standard’s extrusion coating capabilities, contact Rick Keller rkeller@davis-standard.com or visit www.davis-standard.com.

Davis-Standard’s New Barrel Temperature Control Simplifies Energy Efficiency

 

When smart engineering turns a simple concept into reality, good things happen. That is what Davis-Standard has done with its new energy efficient barrel temperature control shroud. The first of its kind in the extrusion industry, this patented heater/cooler barrel shroud increases the energy efficiency of single screw extruders temperature control system by up to 50 percent. This is especially beneficial for higher temperature applications such as extrusion coating, cast film and tubing processes.

“We have essentially created a thermal blanket designed with top or side venting to reduce convective and radiant heat loss,” explained John Christiano, Davis-Standard’s Vice President of Technology. “The shroud fits right over the barrel to create a thermal layer preventing radiant heat losses while a valve system that is pressure activated prevents convective losses. When we tested the temperature control in the lab, we saw efficiency improvements around 30 percent. Field tests have shown even greater improvements up to 50 percent. It’s a simple approach with payback for most applications within 12 months.”

Davis-Standard has already sold several barrel shrouds on new extruders and many customers have requested retrofits. Retrofits are straightforward on most extruders due to the simple design of the heater insulation package. Unless the extruder has to be disassembled, the retrofit time is minimal. The shroud is broken up into parts that fit over each barrel zone, joined together with a stainless steel adjustable fastener. Shroud cut-outs accommodate barrel wiring, and top or side venting options support maximum cooling efficiency depending on process. The added insulation reduces the energy required to maintain the barrel set-point, resulting in significant cost savings.

Christiano added, “I recommend this shroud for all single screw extrusion processes because it’s an easy way to improve efficiency. It is especially economical for higher temperature applications where energy efficiency is paramount to gaining a competitive advantage.”

For more information about Davis-Standard’s barrel temperature control shroud, contact John Christiano at jchristiano@davis-standard.com.

Davis-Standard Expanding Manufacturing Facility in Pawcatuck

 

Davis-Standard, LLC (www.davis-standard.com), the leading manufacturer of extrusion machinery in North America, is expanding its primary facility at its headquarters in Pawcatuck, Conn. With the support of the State of Connecticut Department of Economic Community Development and local government, Davis-Standard will be adding 15,000 square feet of manufacturing space and over 30 jobs in the next two years to its largest global site, which currently employs over 400 people. The facility will house the manufacturing and precision machining of advanced multi-layer blown film dies. It also enables Davis-Standard to move all blown film manufacturing for its Gloucester Engineering product line from Gloucester, Massachusetts, to Pawcatuck. The addition is slated for completion later this fall.

“As the largest extrusion machinery manufacturer in North America, this expansion is a necessity for our business,” said Jim Murphy, Davis-Standard President and CEO. “Last fall we acquired Gloucester Engineering, which greatly strengthened our blown film product line through resources in sales, engineering and service. Bringing Gloucester’s manufacturing capabilities to our Connecticut site makes sense for several reasons. One of those reasons is to integrate technology; together we are now the largest manufacturer of seven to 11-layer blown film dies. These dies are used for making highly technical multi-layer films used in packaging and pharmaceutical applications. To that regard, this expansion aligns with our mission of offering customers excellent quality, value and customer service. The larger facility will allow us to do that.”

Davis-Standard has operated in Southeast Connecticut since 1848 and is one of the oldest and largest employers in the Southeast Connecticut/Southwest Rhode Island region. The expansion of the Pawcatuck site reinforces the company’s commitment to the local region. Through its long-standing position as a market leader, it is considered the “Center for Excellence” for Connecticut’s extrusion technology sector. In addition to the Pawcatuck facility, Davis-Standard has manufacturing facilities and subsidiaries in the U.S., Europe and Asia.

“We are pleased that a global leader like Davis-Standard is continuing to expand operations in our area,” said Diana Urban, Connecticut State Representative for North Stonington and Stonington. “Davis-Standard has a long-standing history of employment and profitability that is both unique and valuable to our local economy. We wish them well in this venture and appreciate their continued investment in our community.”

Davis-Standard would like to thank the following people for their support of this project: Catherine Smith, Department of Economic Community Development (DECD) Commissioner; Diana Urban, Connecticut State Representative; Paul Formica, Connecticut State Senator; and Robert Simmons, Stonington First Selectman.

For more information about the expansion, contact Debbie Crowley at (860) 599-6237.

Davis-Standard at MD&M East

 

Davis-Standard will highlight the company’s latest medical tubing capabilities at booth #567 during MD&M East in New York City on June 14-16. Specifically, the company will promote its new MEDD Extruder (Medical Direct Drive Extruder) for tight tolerance tubing. Also, Davis-Standard will promote its medical tubing lab line and dedicated cleanroom located in its Technical Center in Pawcatuck, Conn. Medical tubing continues to be a growth area for Davis-Standard in the U.S. and abroad.

The MEDD offers processors greater materials flexibility in a compact design. It features a replaceable feed section liner, interchangeable barrel assembly and a Windows® based HMI & PLC control system. Davis-Standard has already sold several MEDD extruders to various medical tubing manufacturers and the machine has been very well received. The medical tubing lab line in the Pawcatuck facility includes two MEDD extruders and associated downstream equipment located in a climate-controlled “clean room” environment. Customers are able to test new resins, make parts for proof-of-concept, and conduct downstream R&D prior to making large capital equipment investments. The line also incorporates Davis-Standard’s patented Alternate Polymer® technology with all components monitored and controlled by the EPIC III® control system.

For more information about Davis-Standard’s Global Advantage™ in medical tubing applications, visit www.davis-standard.com or contact Kevin Dipollino at kdipollino@davis-standard.com.

Davis-Standard Sells PLLA Tubing Line to Start-Up in China

 

As the market for polymeric and antineoplastic devices for internal drug delivery continues to grow, so does manufacturing of micro-bore tubing made from PLLA (Poly-L-Lactide). Davis-Standard recently sold a PLLA tubing line to a medical start-up in Tianjin, China. The line, installed last year, has exceeded customer expectations by successfully producing products ranging from 1.7mm to 2.0mm OD with a tolerance of +/-20µ.

“PLLA is a bio-absorbable resin ideal for applications that require a polymer to reside in the body for a controlled length of time before safely degrading and being absorbed internally,” explained Glenn Beasley, Senior Sales Engineer for Davis-Standard. “Very few companies process this material due to the high resin cost and difficulty in achieving a quality end result.”

Beasley continued, “To ensure immediate success, the customer relied on us to address their requirement of tight OD/ID tolerances and a smooth, gel-free tube surface when processing PLLA. The high cost of this material requires a fast start-up and no room for error during processing to keep costs reasonable.”

The line is capable of processing tubing from PLA and PLLA as well as a variety of other thermoplastic resins at rates up to 50 meters per minute (164 fpm). Davis-Standard supplied the entire line, including a flood cooling tank. Beasley noted this type of cooling has traditionally been problematic for PLLA. However, recent developments in formulations permit water cooling for a limited residence time without compromising the tube surface.

The medical tubing sector continues to be a strong market for Davis-Standard in China. The company has a subsidiary in Suzhou with a lab line capable of demonstrating PLLA technology among other processes. Depending on application, Davis-Standard’s turn-key medical tubing systems can support extruder outputs up to 700 pounds per hour (315kg/hr) and line speeds up to 800 feet per minute (240 mpm). The material range includes PLA, PEEK, FPVC, polyurethane, nylon, PEBAX and FEP. Extruder options are available depending on process and application and engineered for a fast delivery and competitive pricing. Advantages include line control with data acquisition, precision vacuum sizing, closed loop ID/OD control, ultrasonic gauging, puller/cutter systems and more.

For more information about Davis-Standard’s tubing systems for medical applications, contact Joe Wnuk, Davis-Standard Vice President of Elastomer and Profile Systems, at jwnuk@davis-standard.com.

Scott Gardner Joins Davis-Standard as Regional Sales Manager, Elastomer and Profile

 

Davis-Standard, LLC is pleased to announce the appointment of Scott Gardner as Regional Sales Manager for elastomer and profile systems. In his new role, Gardner will manage and direct Davis-Standard’s sales efforts for elastomer and profile product lines in Ohio, Indiana, Michigan, Western Pennsylvania, Kentucky and West Virginia. Prior to joining Davis-Standard, he was business development manager for ESI-Extrusion Systems in Akron, Ohio. He also worked as a technical specialist for Carlisle Syntec in Pennsylvania where he was responsible for product sales and customer training programs throughout the U.S.

“Scott brings outstanding extrusion experience and knowledge to our team,” said Joe Wnuk, Davis-Standard Vice President of Elastomer and Profile Systems. “His knowledge of business development, sustainable sales growth and customer service will serve us well. We welcome him to Davis-Standard.”

Rotuba’s Global Profile Business Thrives with Davis-Standard Super Blue® Extruders

 

Profitability in the extrusion business largely depends on finding the right equipment. For Rotuba Extruders, Inc. of Linden, N.J., the right piece of equipment has been Davis-Standard’s Super Blue® extruder. Rotuba, an industry leader in the extrusion of LED lighting, point-of-purchase displays and specialty applications, purchased its first Super Blue in 2005 shortly after the machine’s introduction. Since then, Rotuba has added six more Super Blue’s while experiencing robust growth of 400 percent in just over 10 years. The company will add five more extruders this calendar year and look to Davis-Standard for even more extruders to outfit the company’s facility expansion within the next two to three years.

“When we purchased our first Super Blue, our salesman Larry Giammarco told us he could deliver it in two weeks with everything we needed. I was a little hesitant, but decided to go for it,” said Gil Carmichael, Project Manager for Rotuba’s Extrusion Division. “It was delivered in one week and the performance has been outstanding. The reliability of this extruder and Davis-Standard’s responsiveness has been ideal for our business. This is why we have come to solely rely on Davis-Standard for extruders.”

The collaborative nature of Davis-Standard’s sales team has been a big plus for Rotuba. Whenever they need anything, Carmichael contacts Giammarco who investigates Rotuba’s needs and provides guidance on additional options and new technology depending on requirements. This type of cooperation is essential since Rotuba addresses a variety of applications and specific client needs on routinely short timelines. The spare part service, ease of maintenance, and functionality of the Super Blue are also appreciated.

“Maintenance is minimal and the knowledge of Davis-Standard’s sales staff and parts department is excellent. They always seem to have everything in stock and many spare parts are interchangeable. This helps our bottom line by keeping inventory costs low,” explained Carmichael. “From an operator perspective, the functionality of the TPC touchscreen controls is a big advantage. We also have flexibility with different Davis-Standard feedscrews. The screws are engineered to fit any Super Blue, which makes production scheduling much easier.”

Pat McEvoy, Vice President of Sales, added that one of Rotuba’s primary market advantages is their solution-based approach as a specification extrusion company; another reason the versatile Super Blue is a good fit. Just as Rotuba seeks collaboration with Davis-Standard, the company seeks collaboration with clients as early as

possible within the design cycle. Jointly with clients, Rotuba reviews product designs and designates a project manager. The manager reviews all aspects of the project to ensure optimal performance, quantitative process repeatability, lowest cost manufacturing and fast delivery.

“Our main advantage is that we house engineering, tooling design, machining, specialized quantitative measuring and production all in one location. This is what has led to us being recognized as the North American leader in new product development for LED lighting. Our dexterity to utilize all of these resources in a fast and highly efficient manner enables us to realize new products for clients,” stated McEvoy.

To support a wide range of applications, the Super Blue Product line is available in 2-inch (50mm), 2 1/2-inch (65mm), 75mm, 3 1/2-inch (90mm), 100mm, and 4 1/2-inch (114mm) sizes, each with the option of a 24:1 L/D ratio or 30:1 L/D ratio. The extruder is standardly equipped with preferred features including a low noise, high torque double-reduction gearbox; cast aluminum finned heaters bolted to the barrel; an AC drive and motor; and a high capacity air cooling system. Design advantages include a rigid base with structural steel construction; a wear-resistant bimetallic barrel designed for 10,000 psi operating pressure with removable barrel flange, rupture disc and pressure transducer; a modular, “inverted-L” style control panel for improved accessibility; and a gear drive reducer with heavy-wall, two-piece iron housing and single helical gearing. The Super Blue is standard with a three-year warranty and is available with a wide range of DSB® barrier screw designs.

“We have thoroughly enjoyed supporting Rotuba in their business growth,” added Larry Giammarco, Regional Sales Manager for Davis-Standard. “The short lead time and cost-efficiency of the Super Blue has worked well for them. We’ve been able to exceed expectations by completing the electrical and mechanical assembly and testing procedures in-house. When these machines are delivered, they are ready to go. We appreciate their business and look forward to future collaboration.”

For more information about Rotuba, visit www.rotuba.com. For more information about Davis-Standard, visit www.davis-standard.com.

Davis-Standard Expands Polymer Lab in Suzhou to Support Medical Tubing

 

As healthcare markets in the Asia-Pacific region have grown, so has Davis-Standard’s ability to support those markets. The company recently expanded its polymer process laboratory at its subsidiary in Suzhou to provide customers with the ability to develop new medical tubing products and test resins. In addition to development and testing, customers are able to contract small-scale production runs prior to making large capital equipment investments.

Medical OEM’s are continually forced to develop new products with smaller diameters, thinner walls, and more complex lumens to meet today’s clinical requirements. The Suzhou lab is equipped with a micro-bore extrusion line capable of single and multi-lumen tubing with up to three layers in the wall and as small as 2 French in diameter. This technology is designed for multiple applications including tubing for intravenous and micro dialysis catheters, endotracheal, tracheotomy and radio opaque products.

The line features direct drive 19mm and 24mm single screw extruders, each with a polymer melt pump, a sophisticated three-layer spiral flow tubing die, and PLC line control with data acquisition. The line provides precision vacuum tank sizing for both rigid and flexible products, closed loop ID/OD control via ultrasonic gauging, a servo controlled combination puller/cutting system, and a transport conveyor with single-zone air eject.

A single layer tubing line for the production of FPVC tubing for IV and fluid delivery applications is also available to support another growing market in China. Products ranging in size from 2mm OD to 10mm OD can be produced with an accuracy of +/- 50u at line speeds up to 100mpm. Line components include a 63mm 24:1 extruder, stainless steel tubing die, 8-meter water-cooling tank, OD gauge with closed loop feedback to a precision internal air supply, combination puller-cutter, and transport conveyor with single-zone air eject.

For more information about the lab or to schedule a trial, contact Jinsong Lin, General Manager of the Suzhou facility at +86-512-6269 5108 or via e-mail at jlin@davis-standard.com.

DS Brookes Ltd. Renamed Davis-Standard LImited

 

DS Brookes Ltd., Davis-Standard’s subsidiary in West Midlands, United Kingdom, will now be called Davis-Standard Limited. The modification is in name only, better reflecting Davis-Standard’s global market position and current activities. Davis-Standard Limited will continue supplying screws and barrels associated with the DS Brookes brand, and will remain Davis-Standard’s key supplier of extrusion systems for the EMEA (Europe, Middle East, Africa) region. This includes support of aftermarket and spare parts activities across all product platforms and heritage brands under the Davis-Standard umbrella.

“The name change better aligns with Davis-Standard’s corporate uniformity in serving customers worldwide,” said Mark Woodgate, Managing Director of Davis-Standard Limited. “In addition to this development, we are pleased to announce that our facility is Davis-Standard’s European service center for blown film, servicing the recently acquired Gloucester Engineering product range. As such, we have appointed Jon Bourne as our service center manager. He comes to us with more than 35 years’ experience with the Gloucester, Battenfeld/Gloucester and Gloenco brands.”

Davis-Standard Limited plays an integral role in Davis-Standard’s strong global presence, supporting the EMEA region with extrusion equipment, barrel and screw production, timely customer service and regional spare parts access. For more information about Davis-Standard, visit www.davis-standard.com.