Davis-Standard Turret Unwind Upgrades Boost Productivity

 

Davis-Standard’s aftermarket group offers turret unwind upgrades that significantly improve productivity and minimize downtime. An upgrade for Green Bay Packaging Inc. involved the modification of two turret unwinds on a 1200 feet-per-minute (365 mpm) pressure-sensitive adhesives (PSA) coating line. Davis-Standard changed the turret unwind operation from air brakes with a speeder motor to a fully regenerative operation, which significantly improved both efficiency and performance.

“Upgrades are an excellent way to extend the longevity of turret unwinds that are still operational,” explained Andre Icso, Vice President Global Aftermarket Sales. “It also allows them to run lighter products with significantly better tension control, less scrap, and increased energy savings. For this upgrade, the modification and re-commissioning took only two weeks enabling us to get the customer back up and running quickly.”

Icso said there are several different upgrades available, but the one for Green Bay was very straightforward. Davis-Standard’s team removed the brakes and speeder belt and installed new turret motors and mechanical power transmission to the unwinding spindles. New slip rings, spindle glue line sensors and turret position encoders were also included as well as the installation and integration of four new unwinding spindle drives.

Davis-Standard’s aftermarket group is able to upgrade PLC, drive and mechanical systems on thousands of existing installations, including non Davis-Standard brands. For more information about Davis-Standard’s aftermarket capabilities related to this article, contact Andre Icso at aicso@davis-standard.com.

Davis-Standard Limited Announces Die Rebuild and Cleaning Services

 

Davis-Standard Limited is pleased to announce the addition of blown film die rebuild and cleaning services at its facility in Brierley Hill, United Kingdom. The new services, commencing August 1, 2016, will apply to all blown film dies from Davis-Standard product lines and heritage brands, including Gloucester Engineering. Non Davis-Standard brands will be considered on a case by case basis. This regional capability further supports Davis-Standard’s large installed base of blown film equipment throughout Europe, the Middle East and Africa.

“Our service team is highly knowledgeable in the cleaning of blown film dies as well as the disassembly and assembly of various key components,” said Mark Woodgate, Managing Director of Davis-Standard Limited. “Our vigorous component inspection program ensures customers are immediately aware of any parts that may require refinishing or replacement. This can often result in great cost savings when compared to purchasing a new die. Having a die professionally rebuilt by the original equipment manufacturer using certified replacement parts also brings a level of assurance that others cannot provide.”

The rebuild services will be located within a dedicated area of the Davis-Standard Limited facility, and staffed by technicians with decades of experience in extrusion and blown film processes. Support is available both on- and off-site to ensure customer needs are addressed in a timely manner. Davis-Standard’s aftermarket team in the United Kingdom is part of a global aftermarket team that offers a full range of services including parts replacement and support, complete rebuilds for gearboxes and extruders, as well as control upgrades, drive conversions and more.

For more information about the aftermarket services at Davis-Standard Limited, contact Mark Woodgate at mwoodgate@davis-standard.com or visit www.davis-standard.com.

Davis-Standard Ships First Large-Scale Accumulator Head Machine From Fulton Facility

 

Davis-Standard is pleased to announce the shipment of its first 75-pound accumulator head machine from its new blow molding facility in Fulton, N.Y. This is the largest blow molding machine Davis-Standard has built at this facility, which opened in October of last year. Overall dimensions of the machine are 26 feet wide by 43 feet long and 28 feet tall (8 by 13 by 8.5 meters) to accommodate production of large flat panels, drums and outdoor recreational equipment. Due to the size of the applications, the machine is equipped with a press that has a clear paten area of 60 inches wide by 96 inches tall (1,500 by 2,400mm) and 250 tons of clamping force.

“We have built machines larger than this one before, but this is the first of its size to come out of Fulton,” explained Mark Panaro, Davis-Standard Product Manager, Blow Molding. “The transition to Fulton has been seamless as we continue to offer customers the full range of blow molding machine sizes and head requirements. It was exciting to get this big one out the door.”

As with all Davis-Standard accumulator head machines, this machine was wet tested prior to shipment to simplify installation. The head is equipped with a spiral diverter for efficient wall distribution and color changeovers, and features a clamp with a rollout function to facilitate mold installation and changes. A convenient remote access feature on the machine controller enables viewing of operations via an Internet connection. The total project took nine months from order placement to completion, an excellent timeframe for a machine of this size.

Davis-Standard’s versatile accumulator head systems are available for multiple applications including automotive parts, packaging and consumer products. Machinery advantages include shot-to-shot consistency, cycle-to-cycle precision, and highly accurate parison control for both polyolefins and engineered thermoplastics. Davis-Standard’s Extrusion Technical Service Group can upgrade and refurbish all makes and models of single screw continuous blow molding extruders. This includes replacement screws, process improvements, mechanical and electrical upgrades.

For more information about Davis-Standard’s blow molding capabilities or the new facility in Fulton, contact Mark Panaro at mpanaro@davis-standard.com.

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.”