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PolyLab PolyLab SystemSystem

• Twin Screw Extruders :

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Twin-screw extruders CTW100 and PTW25Twin-screw extruders CTW100 and PTW25

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Feeding of material into Feeding of material into twin-screw extruderstwin-screw extruders

Co-rotatingCo-rotating Counter-rotatingCounter-rotating

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Twinscrew ExtruderTwinscrew Extruder

Counter-rotating Rheomex Twinscrew Extruders:Counter-rotating Rheomex Twinscrew Extruders:- Defined residence time (good for i.e.rigid PVC)- Selfcleaning- No controlled feeding needed- High shearing- High pressure builtup

Co-rotating Rheomex Twinscrew ExtrudersCo-rotating Rheomex Twinscrew Extruders::- Mixing of shear sensitive material (i.e. Polyolefins)- Compounding, Masterbatch production- Venting- Controlled shearing- Flexible screw design- Controlled feeding necessary

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Conical TwinConical Twin S Screw Extrudercrew ExtruderRheomex CTW100pRheomex CTW100p

• conical design of barrel and screws:mechanical stability / easy cleaning

• counter rotating screws:defined resident time / forced material transportselfcleaning

• 6 sensor ports:exact examination of sample behaviourdosing via sensor ports possible

• venting opening:easy venting with venting screws

• 3 different screw geometries:- intensive mixing screws- standard screws- venting screws

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Rheomex CTW100pRheomex CTW100p

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Rheomex CTW100pRheomex CTW100p

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Rheomex CTW100pRheomex CTW100p

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Screw geometries for CTW100p extruderScrew geometries for CTW100p extruder

Venting screw

Intensive mixing screw

Standard screw

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Rheomex CTW100pRheomex CTW100p

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Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 11

• Plasticising

• Mixing

• Homogenising

• Cooking

• Gelling

• Degassing of momomers, oligomers, solvents etc.

• Concentrating of polymer solutions

• Modifying by incorporation of plasticizers, cross-linking agents, flame retardants,

UV-stabilisers, etc.

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• Incorporation of fillers and reinforcing agents such as: wood flour, talc, glass fibres etc.

• Alloying of polymers

• Polycondensation, Polyaddition and Polymerization of polymers

• Chemical reactions

• Dispersing of pigments and additives

• Breaking down of high molecular particles

Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWProcessing tasks -Processing tasks - 2 2

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Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWExamples of Examples of applicationapplication

• Polyethylene (LLDPE/LDPE/HDPE)

• Nanocomposites (Clay, MWCT)

• Polypropylene (PP)

• ABS

• Polystyrene (PS)

• PVC (soft)

• Polyester

• Polyamide

• Polyformaldehyde

• Cellulose ester

• Polyuretthane (PU)

• Polycarbonate (PC)

• Food

• Starch

• Polyphenylene oxide (PPO)

• Polysulphone (PSU)

• Polyacrylonitrile

• Toner

• Masterbatch

• Powder coating materials

• curing moulding compounds

• Ceramic materials

• Pharmaceutical products

• Polymethylmethacrylate (PMMA)

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New PTW16 XLNew PTW16 XL for PolyLab OS

• Horizontal split, with a lift-off top to be opened for ease of cleaning, simple removal of the screws and visualisation of the melting process.

• The segmented top barrel part is built with 4D modules to be easily reconfigured by the user.

• Barrel segments are available for cooling feeding solids, liquids and for venting.

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... Screw design ...... Screw design ...

... Feed ports...... Feed ports...

... Split Barrel... Split Barrel

Maximum flexibility…Maximum flexibility…

... Lenght ...... Lenght ...

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flexible screw configurationflexible screw configuration

Rheomex PTW16Rheomex PTW16

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PTW16 OS - Maximum flexibility…PTW16 OS - Maximum flexibility…

... Split Barrel... Split Barrel

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PTW16 OS - Maximum flexibility…PTW16 OS - Maximum flexibility…

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PTW16 OS - Maximum flexibility…PTW16 OS - Maximum flexibility…

25 L/D25 L/D

++

15 L/D15 L/D

==

40 L/D40 L/D

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PTW16 XL: 25 + 15D extendable

“what is the right length for my application: L/D 25, or better L/D 40?

… Why don´t you buy two compounders!”

• Flexible Length: not for all applications a long extruder is useful, as shear sensitive materials can degrade and 25D is long enough for basic applications.

• Optional 15D barrel extension to enhance e.g. residence time (for reactive extrusion) or multiple feed ports, easy to use (< 15 min by operator!)

• Software recognizes the Extension unit

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Example: CompoundingExample: Compounding

• Metering Feeder Metering Feeder for PEEK Pelletsfor PEEK Pellets

•Cabon Fiber Cabon Fiber Roving (endless)Roving (endless)

•Pelletiser VaricutPelletiser Varicut

•T = 380°CT = 380°C

•20-40% C-Fiber 20-40% C-Fiber (wt/wt) (wt/wt)

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Screws:

• Segmented, with slip-on elements, allowing variable configuration

• Screw diameter: 16 mm• Corotating, intermeshing

screws• Screw shafts:

– Design: hexagonal– Material: Heat treated,

abrasion resistant

Technical SpecificationsTechnical Specifications

Rheomex PTW16Rheomex PTW16

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Rheomex PTW16pRheomex PTW16p

Screw elements:Screw elements:

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Rheomex PTWRheomex PTW2424pp

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New Twin Screws PTW24/28pNew Twin Screws PTW24/28p

2 modular Models 28D and 40D up to 1100 rpm

... Happy customers

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Economic PTW24 modelsEconomic PTW24 modelscomparison to 24 „HC“ typecomparison to 24 „HC“ type

Vacuum venting

Side feed 2 Side feed

main secondary feed

Venting toAtmosphere

Or option Liquid feed

PTW24/40p (HC) PTW24/40p (HC) 4D modular 4D modular ElementsElements

PTW24/30p (TC)PTW24/30p (TC)

PTW24/25p (TC)PTW24/25p (TC)

Side feed option

main secondary feed

Vacuum venting

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• Speed range: 0 - 500 rpm(optional 0-1000 rpm)

• Pressure range: 100 bar (150 bar optional)

• Temperature range: max. 300 °C (400°C optional)

• Screw diameter: 24 mm• Barrel length (L/D) : 28:1 to 40:1 (using the

optional barrel extension unit)

Technical SpecificationsTechnical Specifications

Rheomex PTWRheomex PTW2424

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Rheomex PTW24Rheomex PTW24

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SidefeedingSidefeeding

Segmented screw Segmented screw

Extruder barrel: segmented and hingedExtruder barrel: segmented and hinged

Rheomex PTW24 – Advantages:Rheomex PTW24 – Advantages:

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Bore diameter:

24 mmScrew Centres:

18.75 mmChannel Depth:

5.2 mmClearance:

0.2 mmTotal barrel length:

672 mm.

(28:1 L/D, in 4:1 modules)

Barrel extendable to 40:1 length

with optional barrel extension Feed Zone:

Water Cooled Processing Zones:

Electrically Heated / Water cooledExtrusion Die:

Electrically heated

Technical Details:Technical Details:

Rheomex PTW24Rheomex PTW24

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Rheomex PTWRheomex PTW2424pp

Screw elements:Screw elements:

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Rheomex PTW25Rheomex PTW25

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Rheomex PTW25 withRheomex PTW25 with PolyLab PolyLab SystemSystem

MasterSlaveHeat-exchanger

PolyLab System

Rheomex PTW25

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Parallel twin-screw extruder Rheomex PTW25Parallel twin-screw extruder Rheomex PTW25TTechnical data -echnical data - 11

Drive: PolyLab RC 300p Extruder: segmented barrel Length: 18 - 48 D Screws: segmented screw elements Outer screw diameter: 25 mm Core diameter: 17 mm Centre distance: 21.5 mm Max screw speed: 400 rpm Screw elements: Conveying elements

Kneading blocksToothed blocks

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• Max. barrel temperature: 400 °C

• Max. melt pressure: 300 bar

• Barrel segments:

Open barrel 4D Venting, feedingClosed barrel 4DCombi barrel 6D Side feeding and ventingMetering barrel 4DClosed barrel 6DOpen barrel 6D Venting, feedingMeasuring disk 1.5D Measurement of melt-

temperature or -pressure

Parallel twin-screw extruder Rheomex PTW25Parallel twin-screw extruder Rheomex PTW25TTechnical data -echnical data - 2 2

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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTWPTWScrew ElementsScrew Elements

• Profiles with open chambers are used:

- in the feeding sections - for melt exchange (longitudinal mixing)- for degassing (venting)

• Profiles with closed chambers are used:

- for high pressure built up- in front of kneading elements

Conveying elementsConveying elements::

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Parallel twin-screw extruder Rheomex Parallel twin-screw extruder Rheomex PTWPTWScrew ElementsScrew Elements

Conveying elementsConveying elements::

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Rheomex PTW – Conveying ElementsRheomex PTW – Conveying Elements

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• Mixing Elements are used to introduce shear energy to the extruded materials.

• The disks are arranged in different offset angles used for:

- plasticizing- mixing

- dispersing

Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWScrew ElementsScrew Elements

Mixing Elements Mixing Elements ::

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Parallel twin-screw extruder Rheomex PTWParallel twin-screw extruder Rheomex PTWScrew ElementsScrew Elements

Mixing Elements Mixing Elements ::

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Mixing elementsMixing elements

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• Toothed blocks are special mixing elements, used for the distribution of even small quantities of additives.

• The shearing energy introduced to the polymer is significantly lower than that of the kneading elements.

• The open worked flights of the mixing discshave a special asymmetric design.

Parallel twin-screw extruder Rheomex PTW25Parallel twin-screw extruder Rheomex PTW25Screw ElementsScrew Elements

Toothed blocks Toothed blocks ::

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Parallel twin-screw extruder Rheomex PTW25Parallel twin-screw extruder Rheomex PTW25Screw ElementsScrew Elements

Toothed blocks Toothed blocks ::

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Application:

Feeding of glass fibres, fillers or other

additives into the molten polymer.

Venting of the introduced air.

Requirement:

2 separate feeders necessary for side feeding.

One side stuffer with constant (high) dosing speed to press the

material into the barrel.

One feeder to controll the feeding rate.

For constant feeding ratio between polymer and additives

gravimetric controlled feeders can be used.

Rheomex PTW Rheomex PTW Side-feedingSide-feeding

VentingVenting

Flow directionFlow directionSide feedingSide feeding

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557- 5001 Rheomex PTW 25 x 20D557- 5001 Rheomex PTW 25 x 20D

Barrel segments:

Feeding barrel 4DClosed barrel 6DOpen barrel 6DMeasuring barrel 4D

Application:

Melting of polymersVenting

FeedingVenting

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Barrel segments:

Feeding barrel 4DClosed barrel 6DCombi barrel 4DClosed barrel 4DOpen barrel 6DOpen barrel 4DMeasuring barrel 4D

Rheomex PTW 25 x 32DRheomex PTW 25 x 32DPProduction of roduction of MMasterbatchasterbatch

M a t e r i a l S h a p e Q u a n t i t y i n%

P P , P E , P E T ,P C , P A , e t c .

p o w d e r o rg r a n u l a t e s

6 0 - 8 0

p i g m e n t s p o w d e r 2 0 - 4 0

Side-feeding (pigments)

Venting(vacuum)

Venting(atmosphere)

Venting(atmosphere)

Feeding(polymer)

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Screw configuration Rheomex PTW25/38Screw configuration Rheomex PTW25/38

FFor typical food extrusionor typical food extrusion

25/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

25/1/2

25/1/2

25/1/2

ZB

-37.5

25/1/2

25/1/2

E-K

B-25/L

I

25/1/2

25/1/2

E-K

B-25/L

I

25/1/2

25/1/2

E-K

B-37.5/L

I

25/1/2

25/1/2

E-K

B-37.5/L

I

E-K

B-37.5/L

I

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

37.5/1/2

25/1/2

25/1/2

25/1/2

Screw

tip

Dry-BlendLiquidsSteam

FeedingMixing/HydrationCookingVentingCooling

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Masterbatch productionMasterbatch production

Vac

uu

m

Pre

mix

Atm

osp

her

e

Parallel twin-screwWater bath Pelletizer