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Archive for November, 2009

Rail Car Unloading

Posted in: Blending, Process Control Corpration, Projects, Rail Car Unloading by Tony on November 27, 2009

Our Rail Car Unloading Systems have been design for optimizing the unloading of rail cars into resin storage silos and/or storage bins. PCC systems have been designed with the proper balance of maximizing the unloading rate and still maintaining the raw material integrity. Many years of experience in plastic processing enable our Project Engineers to accurately size each system to provide the most reliable and cost effective solution.

VP Series Vacuum-Pressure Power Unit

As the most cost effective solution for conveying bulk materials, the VP series uses a single pump design in which the same blower is used for both vacuum and pressure and incorporates a central transfer station. This series is used in applications where conveying distances are generally shorter and the conveying rates required are not as demanding.

Printable Specifications

VL Series Vacuum Power Unit

The VL Series vacuum pump is the first part of a two-pump design rail car or truck unloading system. The VL Series is typically used in more demanding bulk conveying applications where the conveying distances are longer and the conveying rates are higher. This series is used in conjunction with CH Series Transfer stations and P Series Pressure Power Units.

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P Series Pressure Power Unit

The P Series pressure power unit is the second part of a two-pump design rail car or truck unloading system. The two-pump design is typically specified when the single pump system cannot meet the desired conveying rates at the specified conveying distances. This series is used in conjunction with the CH Series Transfer stations and the VL Series vacuum power unit.

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Rail Car Hardware and Accessories

Along with the Tubing and Hardware, these components complete your bulk rail car unloading system.

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T Series Transfer Station

The T Series Transfer Station is designed for use with a dual blower conveying system.

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Popularity: 77% [?]

Material Handling

Posted in: Blending, Material Handling, Process Control Corpration, Projects by Tony on

Material Handling – Complete conveying, bulk storage, and installation. Everything from single units to complete turnkey installations.

Our Material Handling Systems have been designed for the distribution of raw materials. Many years of experience in the plastics processing industry enable PCC engineers to accurately size conveying systems for reliable, cost-effective loading of any gravimetric or in-plant distribution system. Whether pressure conveying or vacuum conveying, from simple self-contained vacuum loaders to complete in-plant distribution systems, we have the equipment and expertise to fit any need.

VE Series Vacuum Power Units

The power unit offers a dependable and economical performance for a wide variety of conveying rates, distances, and materials. PCC precisely sizes each unit to meet your requirements.

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VB Series Vacuum Power Units

Designed for low to moderate rates in material conveying. With continuous operation, this system runs quietly while improving the efficiency of your plastics processing.

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Director Series Control Panels

The brains of a vacuum conveying system. It works to control the sequencing of vacuum receivers, vacuum pump, dust collector, and a continuous run valve.

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RN Series Vacuum Receiver - Receivers for Pellets

Receivers can be mounted at any point where resin delivery is needed. The incorporated screen prevents the carry-over of pellet material back to the vacuum pump.

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RP Series Vacuum Receivers

for Dusty Materials

For use in the vacuum conveying of regrinds and/or dusty materials. The RP Series filter bags prevents carry-over of dust back to the vacuum power unit.

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LC Series Self-Contained

Compressed-Air Loaders

The LC Series vacuum loader is a space efficient, self-contained unit which uses compressed air to convey raw materials at rates up to 800 PPH.

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AFV Series Precision Additive Feeders

The AFV Series is a simple, easy to operate additive feeder designed to inject color concentrates or other additive-type materials directly into a material stream at the feed throat of an extruder or molding machine.

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RD Series Dust Collectors

Works to remove any fines acquired during a fill cycle. Through a Director Sequencing Controller, the dust collector back flushes the bags for a clean operating system, preventing the dust from getting back to the central vacuum pump.

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Hardware Components
Quality components to complete your material conveying system.

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PT Series Pneumatic Tilters

The PT Series Pneumatic Box tilter offers smooth tilt action with easy on & off placement.

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HS Series Surge Hoppers

The HS Series Surge Hoppers from Process Control are ideal for in-plant storage of both raw materials and finished product.

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Popularity: 59% [?]

Powder Feeders

Posted in: Blending, Powder Feeders, Process Control Corpration by Tony on

Powder Feeders

Stand alone Powder Feeder for Individual Applications

Constructed completely of stainless steel, Process Control Powder Feeders can be used as either a stand-alone type feeder or as part of a continuous blending system for blending both powder and pellet materials together.

They utilize a single spiral hollow shaft auger actuated by a PWM type drive which uses a DC gearmotor with an encoder that delivers accurate motor speed feedback and allows the system to maintain a consistent RPM. The weighing system is designed with our new DSP (digital signal processing) technology (patent pending) to effectively filter out unwanted noise and vibration. The agitator within the powder feeder prevents material from bridging or clumping. Both the auger drive gearmotor and the agitator drive gearmotor are latched onto the hopper using quick-disconnect plugs so they can be quickly removed from the feeder for easy clean-out and material changeover.

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Continuous Blender Powder Feeder

Continuous Blender Powder Feeder Designs

Process Control Corporation of Atlanta, GA is pleased to announce the release of a new continuous gravimetric blending system. The new design incorporates the PF Series powder feeders for use with non free-flowing materials. This new blender allows gravimetric blending of non-free-flowing powder materials with free-flowing powder and pellet materials.

The powder feeders allow feed rates as low as 0.2 PPH and as high as 3,000 PPH. The drive system of all blender components utilizes a PWM drive with a DC gearmotor and encoder for accurate motor speed feedback. This allows each of the individual feeders to maintain a constant RPM and weight throughput. The entire weighing system is designed with our new DSP (digital signal processing) technology (patent pending) to filter out unwanted noise and vibration which can wreak havoc with any feeding system, especially at very low feed rates.

This new gravimetric blending system has been designed to blend both free-flowing and non-flowing materials at unprecedented metering and mixing accuracy.

The X Series Powder Blender is also available in food grade stainless steel – consult factory for specific details!

Guardian® Series Powder Blender

Powder Feeders for Gravimetric Blenders

Process Control Corporation has incorporated the popular PF Series powder feeder into our line of Guardian ^® gravimetric batch blending systems.

The Guardian ^® blender is ideal for applications requiring agitation mixing for complete dispersion and coating of the powder/pellet/regrind mixture. The powder feeder is an auger type, which is ideal for feeding non-flowable powder materials such as talc and blowing agents. This feeder allows processors to accurately meter and blend non-flowable materials with standard pellets and regrinds at a very economical price. The powder feeder element is constructed of polished stainless steel and incorporates two drive systems. The first accurately meters the powder material into the Guardian ^® weigh hopper while the second agitates the powder above the feed screw to prevent material bridging and rat-holing in the hopper.

The powder feeder element can be easily removed from the blender for quick clean-out and material changeover. It can be incorporated into all four sizes of the Guardian ^® blender family (1.25 kg, 2.5 kg, 5 kg and 12 kg) for throughputs up to 4,000 PPH and a maximum of 12 components per blender.

Popularity: 58% [?]

Dryer Hoppers

Posted in: Blending, Dryer Hopper, Process Control Corpration, Projects by Tony on

HDA Dryer Hopper
The HDA Series Dryer Hopper is engineered to efficiently and completely dry hygroscopic materials. The dryer hopper is a critical component in resin drying systems, affecting both drying performance and energy efficiency. Poor hopper performance can result in wasted energy and incomplete drying of material. To sufficiently dry hygroscopic materials, every initially moist pellet must be subjected to a prescribed temperature and dewpoint atmosphere for a fixed time. This controlled environment lowers the moisture to a level suitable for processing.

Popularity: 65% [?]

Extrusion Control

Posted in: Blending, Extrusion Control, Process Control Corpration, Projects by Tony on

For complete control of mono or co-extrusion lines, PCC offers the Gravitrol^® System. The Gravitrol^® system takes the guess work out of extrusion control by continuously monitoring the mass throughput and adjusting the extruder screw speeds to maintain constant output by weight. With co-extrusion lines, Gravitrol^® adjusts each extruder’s throughput to precisely control the percentages of each layer in the end product. With the addition of the Gravitrol^® line speed device, the system can be further configured to control and maintain consistent weight per length of product.

	EXB Central Operator Station As the main component of the Gravitrol^® system, the EXB operator station communicates with the HGB weigh hoppers and the EXD/EXL drive modules over a high speed serial interface. The EXB is the primary operator interface control panel where the recipes are entered and the complete system is controlled. Printable Specifications
	HGB Series Weigh Hoppers Precisely and continuously monitoring the amount of material consumed by the extruder, the HGB Series weigh hopper, in essence, turns the extruder into a gravimetric metering device. The HGB sends a continuous stream of weight loss readings to the EXB central operator station for processing. Printable Specifications
	EXD Drive Speed Control / EXL Line Speed Control The EXD card provides the interface between the Gravitrol^® system and the extruder drive. The EXL is used to control the take-off device by providing a pulse generator to measure line speed accurately for closed loop control. Printable Specifications
	EXT Operator Station Touch Screen Using the PCCWeb^® to monitor and control software, the EXT Series provides a central operator control point to all Process Control computer managed products. The EXT communicates over a highspeed EtherNet interface and provides instant access for recipe entry, system monitoring, and operation. Printable Specifications
	Gravimetric Extrusion Control for X Series Blenders Equipped with the Gravitrol^® extrusion control software, the X-Series continuous gravimetric blender is able to control both the extruder drive (for constant throughput), as well as, the take-off device (for constant weight per length) with the same accuracy and precision as an HGB Gravitrol weigh hopper. Printable Specifications
	Gravifluff^TM The Gravifluff^TM system is designed to meter ground scrap back into the extrusion process by weight, while maintaining complete gravimetric control. Combined with the benefits of automatic scrap recycling system and the Gravitrol^® system, Gravifluff^TM gives complete control of extrusion lines. Printable Specifications

Popularity: 100% [?]

Scrap Recovery

Posted in: Blending, Process Control Corpration, Projects, Scrap Recovery by Tony on

Recovery of scrap generated by film, tape, extrusion coating and other extrusion processes is a key element in reducing the overall manufacturing costs. Without the expense of re-pelletizing, the System will recycle all scrap materials in-line and turn your scrap into direct profit. By re-processing the scrap in-line, the benefits include maintaining high product quality, no additional heat history, and prevent the possibility of contamination.

RMX Series Refeed Machine
The RMX Refeed Machine is designed to feed the extruder with a consistent scrap to virgin material ratio. This consistent feed eliminates extruder surge or starvation. Scrap refeed capability is limited only by the extruder’s screw design and the products scrap tolerance.

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GF Series Film Scrap Grinder
A GF Series Grinder provides efficient, uniform grinding of film scrap. The angled scissor cut design of the rotor produces ground scrap with the highest bulk density and the best ability to flow. The grinder can accommodate edge and bleed trim scrap, off-spec roll scrap, and loose hand fed scrap.

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IN Series Trim Removal Inducers
The IN Series is designed to pick up and convey edge and/or bleed trims produced on a film production line. Continuous trims are then conveyed from the line by suction created from the inducers venturi section and blown to a GF series film grinder or off-line box.

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Popularity: 61% [?]

Gravimetric Batch Blender

Posted in: Blending, Gravimetric Batch Blender, Process Control Corpration by Tony on

Guardian^® Series Gravimetric Batch Blender

– A world class blender to meet world class requirements –

The Guardian^® Series Gravimetric batch blenders provide an efficient and cost-effective alternative to feeding raw materials to your plastic process. The Series, which includes five sizes (1.25 kg, 2.5 kg, 5 kg, 12 kg, 18kg and 25kg batch size), is designed to produce a higher quality product at a lower cost. The Guardian^® blender has been designed to meter the individual ingredients, in the desired proportions, into one main weighed hopper.

Each individual material is measured and controlled, by weight, to an accuracy of +/- 0.02% for each and every batch. After being weighed, the materials are dropped into an agitated mixing chamber where the blend is thoroughly homogenized prior to entering the plastic process. The tight control methods used allow processors to reduce the excess amount of raw material used, resulting in savings with every batch made.

Popularity: 68% [?]

Thermoforming Sheet Lines

Posted in: Projects, Thermoforming Sheet Lines by Tony on November 21, 2009

Lines for polished / thermoforming sheets – versatile, economic, indispensable

Thermoforming sheet lines

Thanks to the wide scope of possible applications, thermoforming sheets made of high-quality raw materials such as polystyrene, polypropylene or polyester have become an integral part of everyday life. For many decades, thermoforming sheet lines have been a standard feature of Reifenhäuser’s product program. In addition to the versatility and profitability of our technical developments, their main target and tasks are meeting the product demands of our customers.

Modules

Technology

Type overview


Thermoforming sheet line - A module-by-module explanation. > Interactive line demo	An overview of the innovative technologies > Technology showroom	The modular product range with all specifications. > Type overview

Areas of application

Everybody comes across thermoforming sheet products regularly on the shelves of the supermarket. Whether in the form of yoghurt or icecream cups, margarine or milk containers, or as trays for TV or microwave meals or as blister packs, thermoforming sheets have become indispensable for transport and protection of foodstuffs and drinks. This is not the only place where we daily meet polished sheet products – they also abound in the office and especially in our cars. The automotive industry in particular uses thermoforming sheet with smooth or embossed surfaces for high-quality inner panelling.

Popularity: 29% [?]

Cast Film Lines

Posted in: Cast Film, Cast Film Extrusion, Projects by Tony on

Cast film lines – the highest level of quality

Cast film line

Cast films produced on chillroll lines have become an indispensable product in the packaging industry. They provide both versatile and high-quality options for safe and economic packaging of everyday products. With the development of advanced line concepts, Reifenhäuser has conquered a leading position on the market for cast films.

Modules

Technology

Type overview


A typical cast film line - A module-by-module explanation. > Interactive line demo	An overview of the innovative technologies > Technology showroom	The modular product range with all specifications. > Type overview

Areas of application

Cast films are extremely versatile and are used to package a wide variety of products. Whether as single- or multi-layer version, depending on the special requirements, they play a decisive role in packaging of foodstuffs, pharmaceutical products and sanitary products. They have become indispensable for organising offices and in textile packaging. Everybody is familiar with cast films as decorative packaging for flowers, and other florist products.

Popularity: 60% [?]

Multi-Layer Blown Film Lines

Posted in: Blown Film, Blown Film Extrusion, Projects by Tony on

The Reifenhäuser family enterprise, with its “Extrusioneers®”, is your competent partner for realising highest demands in the field of packaging for consumer goods and industrial use.

With the FILMTEC® product series, all customer requirements can be met, from sack film to agricultural films and dump liner sheeting, from single-layer lines up to 7-(9-) layer barrier film lines.

Our lead in technology and expertise is secured by Reitorque, our sizing basket design, contactless reversing bar technology and new winder technology.

These lines are characterised by economy, reliability and excellent quality.

With our worldwide service branches and a 24-hour hotline, you have the full support of the parent company in Troisdorf at your disposal.

Type overview

3layer blown film line FILMTEC 3-1700 IBC for laminating film

3 gearless Reitorque extruders of space- and energy-saving configuration
Compact 3-layer film-blowing die-head, which can produce a broad range of complex film structures with good basic tolerances
Sizing basket in a new version with air conduction bush for contactless film guiding by means of an air cushion, fed by compressed air without using blowers
Stable reversion system with microporous reversing bars that are powered by compressed air and ensure contactless, streak-free film guiding
UFA III winder with special gap winding for dull and sticky films, for producing optimal film reels

3-Layer blown film line FILMTEC 3-5000-IBC for agricultural film (greenhouse, tunnel, mulching films)

3 extruders Ø 150 mm, Ø 200 mm, Ø 150 mm with a plasticising capacity of > 2500 kg/h
3-layer blown film die-head with die insert of 2200 mm diameter
High-performance air cooling ring for >2000 kg/h production capacity
5000 mm line width and 35 metres construction height
4-ply folding unit (C-type folding) for a circumference of max. 18,500 mm
FAC 5000 short-yardage winder with centre winding, without winding shafts, suitable for automatic reel change and adhesive-less web lay-on, for films up to 200 µm thickness and max. 8-ply folding

3-Layer blown film line FILMTEC 3-1000-IBC-FFS for heavy-duty sack production

3 gearless Reitorque extruders of space- and energy saving design
Compact 3-layer blown film die-head which can produce a broad range of complex film structures with good basic tolerances
High-performance air cooling ring for >300 kg/h production capacity
6-roll haul-off unit including 4 cooling rolls for highest folding seam strength
SFA winder for film reels of up to 1500 mm

7-Layer blown film line FILMTEC 7-1700-IBC for barrier films (foodstuff and healthcare packaging)

7 extruders for processing of polyolefins, EVOH and PA without the need for a tightest change
Compact HDS 7-layer die-head (Horizontal Distribution System) for lowest basic tolerances of individual and total layer thicknesses in different, very complex composites
Reicoflow II thickness control system for lowest thickness tolerances
Very stable and exact film guidance for highest requirements
(e.g. stiff and thick film structures including EVOH and PA)