Firmenprsentation I 04/2006 I Page 1

Coperion Processing of PVC

Dario Savino
Sales Manager Coperion S.r.I., Ferrara (I)
Firmenprsentation I 04/2006 I Page 2

Processing of PVC
APPLICATIONS
Rigid PVC: Extrusion and Injection Moulding
Window profiles
Technical profiles
Pipes and Fittings
Sheets

Rigid and Semi-rigid PVC:

Calendering applications and Blow moulding
Rigid and
semi-rigid sheets
Packaging and
Bottles

Firmenprsentation I 04/2006 I Page 3

Processing of PVC
APPLICATIONS
Plasticised PVC: Extrusion, Injection moulding, Calendering
Cable
Film
Technical profiles
Hoses
Flooring

Plastisol
Artificial leather
Coated Textiles
Sealants
Wallcovering
Flooring
Dolls

Firmenprsentation I 04/2006 I Page 4

Coperion
Typical plant concept

Firmenprsentation I 04/2006 I Page 5

Raw Materials Receipt

Bulk delivery by tank trucks

Firmenprsentation I 04/2006 I Page 6

Raw Materials Receipt

Empting stations for 25 kg bags and jumbo bags
automatic filter
Big-Bags loading nozzle

typical Installation

Firmenprsentation I 04/2006 I Page 7

hatch for 25 kg bags

Raw Materials Receipt

Empting stations for 25 kg bags and jumbo bags
filter control unit (timer)
tipping station (overall view)

solenoid valves

filter pockets
Firmenprsentation I 04/2006 I Page 8

compressed air tank

Raw Materials Receipt

Outdoor storage silos

Firmenprsentation I 04/2006 I Page 9

Raw Materials Handling

Extraction from storage silos and hoppers

Extraction by Fluidification

Firmenprsentation I 04/2006 I Page 10

Extraction by Bin Activator

Raw materials handling

Pneumatic conveying: suction box & rotary valves

suction box with suction nozzle for PVC

rotary valves for fillers and additives
Firmenprsentation I 04/2006 I Page 11

Vacuum dosing and weighing

Suction scale

vacuum pocket filter

(side removal)
opening hatch
weighing hopper
with 3 load cells
discharging cone

Firmenprsentation I 04/2006 I Page 12

Vacuum dosing and weighing

Suction scale

upper part
opening hatch
side pocket filter
lower part with fluidizing
discharge aid

Firmenprsentation I 04/2006 I Page 13

Mixer feeding
Suction scale

suction scale

Firmenprsentation I 04/2006 I Page 14

Additives handling
Lemon hoppers: compact arrangement for the discharge stations

Firmenprsentation I 04/2006 I Page 15

Additives Handling
Discharge and Dosing Stations

Bin activators
Dosing screw

tipping
hoppers

Firmenprsentation I 04/2006 I Page 16

weighing scale

Additives handling
Dosing and weighing stations

additives dosing screws

additives scale

load cells (3)

elastic hopper of scale ensures complete discharge of weighed batch

minimization of tolerances between the batches is decisive for a constantly high quality
of the compound
Firmenprsentation I 04/2006 I Page 17

Additives handling
Dosing screws

easy detachable cover

Firmenprsentation I 04/2006 I Page 18

dosing screw easy cleaning type

Additives handling
Liquid additives dosing and weighing stations

load cell
Firmenprsentation I 04/2006 I Page 19

feeding valves

load cells

Additives handling
Pre-weighed pigments and microingredients

feeding chute

pre-weighed bags

Firmenprsentation I 04/2006 I Page 20

phase belt conveyor

Mixer feeding
suction
scale

additives
tipping
hoppers

hot mixer

dosing
feeders

cool mixer

additives
weighing
scale
pneumatic conveying line
Firmenprsentation I 04/2006 I Page 21

Heating/Cooling Mixer
Typical capacities for rigid PVC production

No. of batches per hour

7 to 8

Batch size

60 to > 1000 kg

Capacity per hour

0,5 to > 7 tons

Heating mixer end temperature

120C

Cooling mixer end temperature

45C

Firmenprsentation I 04/2006 I Page 22

Heating/Cooling Mixer
TYPICAL MIXER INLET ARRANGEMENTS

additives
scale
pinch
valve

hot mixer
cover
sealing butterfly
valve
Firmenprsentation I 04/2006 I Page 23

Heating mixer
Function principle of the heating mixer

ideal vortex for high mixing quality

excellent self-cleaning

Cross section of a high efficiency mixer

Firmenprsentation I 04/2006 I Page 24

Heating mixer
Details of the heating mixer

mixing bowl with

dosing lance
deflector
mixing tool

Firmenprsentation I 04/2006 I Page 25

Cooling mixer
Details of the cooling mixer
Usually direct feed of the dryblend from hot mixer to compounder to save energy
cooling mixer is only required in special applications: transparent and medical grades

up to 4 times size of the hot mixer

sizes from 400 to 8000 l
extremely large cooling surface
high efficiency cooling based on
perfect heat transfer

Firmenprsentation I 04/2006 I Page 26

Extruder Feeding

Firmenprsentation I 04/2006 I Page 27

Extruder Feeding
Vacumat (Vacuum conveying)

Firmenprsentation I 04/2006 I Page 28

Automation by WPC
Weighing and Mixing Process Control (WPC)

- More than 150 automated plants worldwide

- More than 20 years of experience and continuous development
- Automation system developed and designed in-house
- A lot of features already in the basic package
- Numerous useful options, individually for every plant
- Multilingual (Russian, Chinese, etc.)
- High level of standardisation
- Through the integration in overlaid process-IT functions - more than
just an automation
- The optimum automation for
PVC industry
and...in every process with mixing, dosing and conveying

Firmenprsentation I 04/2006 I Page 29

Automation by WPC
Data management and visualization

Master data management

Raw material entry and storage
including lot management
Production planning, monitoring
and production data management

Firmenprsentation I 04/2006 I Page 30

Plant operation handling by

integrated visualization system

Automation by WPC
Trend graphs: visualization of the mixing process

Firmenprsentation I 04/2006 I Page 31

Automation by WPC
Useful and innovatives adds-on

Plant maintenance cycle control system

VMI interface (Vendor Managed Inventory)
Recording of production job batch data

Firmenprsentation I 04/2006 I Page 32

Equipment for material handling

Roots type blowers: vacuum conveying assembly
vacuum blower
by-pass valve

filter (cartridge type)

vacuum Blower safety
filter (cartridge type)

Firmenprsentation I 04/2006 I Page 33

roots blower
(vacuum assembly)

Equipment for material handling

Roots type blowers
electric motor

inlet silencer
V-belt coupling

supporting frame with

shock absorbers
Firmenprsentation I 04/2006 I Page 34

overpressure
safety valve

3-lobes pump

outlet silencer

Equipment for material handling

Discharge devices / discharge aids: various types and principles

Compressed air

Vibration

Vibrating bottom

Fluidising cloth

Raker

(Pulsating compressed air)

(mechanical)

Compressed air
Compressed air

Horizontal valve

Firmenprsentation I 04/2006 I Page 35

Sinter bed for fluidisation

Fluidising nozzle

Air jet

(intermittent)

(intermittent)

Equipment for material handling

Rotary Valves program overview
Powder < 1 mm

Pellets 1-10 mm

ZXQ

ZAQ

ZXD

ZRD

ZKD

ZRO

ZVH

ZVB ZVD

ZGM

Pressure [bar]

3,5

3,5

1,5

1,5

1,5

0,1

3,5

1,5

1,5

Plastics / base
materials

General chemicals

Minerals

Food

Firmenprsentation I 04/2006 I Page 36

Equipment for material handling

Diverter valves program overview
Pellets

Pellets and powders

WEK

WET

WYK

WZK

WHT

WGV

Pressure [bar]

4,5

4/2

Plastics

Principle

General Chemicals

Minerals

Food

Firmenprsentation I 04/2006 I Page 37

Equipment for material handling

Blow-through rotary valve
ZXD Model

Blow through operation

Operation pressure max. 1,5 bar(g)
Conveying of free flowing and cohesive
powders
Characteristics:
- Circular inlet flange
- Optimised blowthrough channel

Firmenprsentation I 04/2006 I Page 38

gear motor
assembly

Equipment for material handling

Extruder feeding by vacuum and mechanical conveying

Firmenprsentation I 04/2006 I Page 39

Equipment for material handling

Long Resistance Bends for abrasive dry-blend

Firmenprsentation I 04/2006 I Page 40

Equipment for material handling

Accessories
ATI cone

repair slide

air knocker
Firmenprsentation I 04/2006 I Page 41

level switch

Equipment for material handling

Accessories

disk in SS 304

seat in Neoprene
rubber

housing in cast
aluminium

pneumatic actuator with limit

switches and solenoid valve
Firmenprsentation I 04/2006 I Page 42

Equipment for material handling

Accessories
flange connection

Morris type couplings

galvanized carbon steel

Neoprene rubber

collar in SS AISI 304

welded on pipe

Firmenprsentation I 04/2006 I Page 43

flange in cast aluminium

Equipment for material handling

Coperion R&D technical center for material handling

Firmenprsentation I 04/2006 I Page 44

Thank you very much for your attention.

Firmenprsentation I 04/2006 I Page 45