Key Millmerran staff have unique experience in the field of sheet extrusion and a dedicated facility with 3 different sized extrusion lines has been set up for this purpose.
Sheets from 75mm to 900mm in width can be produced to order in a variety of materials with thicknesses ranging from 0.5m to 3mm.
Multi-layer co-extrusions in different materials are possible to achieve specific properties, as are embossed patterns and laminated surface finishes.
Experimental work and pilot-scale production is also undertaken on behalf of clients, very often in combination with Millmerran material compounding input.
To complement existing laboratory-scale sheet and film manufacturing equipment, Millmerran has now made a massive investment in a full size sheet extrusion line so that projects can be more effectively scaled up.
Offering the capacity of widths up to 900mm and thicknesses from 0.5mm to 2mm, the new line will enable an immense advance in processing capability, in house.
Millmerran Technical Director, Rob Mann, observed – “Our laboratory sheet line continues to serve us very well and has solved many a problem both for clients and in furthering our own product development. The new equipment incorporates the very latest in processing screw design and precision operational control systems, so will not only offer greater R&D scope but will immediately bring two of our major projects into commercial realization.”
Further endorsing Labtech’s commitment to purpose built machinery, we are pleased to advise details of a laboratory chill roll line has been developed for a particular application.
The line was purpose-designed and built for a customer in America and is to be used for production under clean-room conditions of an embossed and laminated thick film for use in the electronic industry.
It comprises a front 3-roll stack where the top roll is covered with silicone rubber and the centre steel roll is engraved with the embossing pattern. A second two roll stack is used for lamination. One of the main requirements for the customer was to have the centre roll easily exchangeable to enable the use of other embossing patterns. Labtech duly obliged with a unique system that allows the rolls to be changed over in less than an hour.
Labtech has launched a new 12mm co-rotating twin screw micro-compounder designed to be used with polymers in powder or micro pellets form with an approximate maximum granule diameter of 1.5mm. It is suitable for processing of minute polymer quantities for research applications but can also produce larger quantities having a maximum output of around 4 kg/hr.
The extruder is supplied complete with a stainless steel volumetric hopper feeder with a spiral type screw and with a stirring arm (agitator) above the feeding screw. The hopper feeder can optionally also be equipped with twin screws.
Inside the clam shell barrel are segmented screws where each segment can be placed anywhere on the hexagonal screw core shaft for optimum flexibility of screw configurations. The kneading elements are supplied as single sectors which can be placed against each other in various angles enabling numerous kneading and shearing functions.
Each barrel zone is equipped with both water cooling and electric cartridge heating which allows for complete process control at each zone of the barrel. Water cooling coupled with the high wattage heating enables fast temperature changes of each zone when changing processing conditions from one compound to another. The water cooling is achieved from fine channels inside each barrel module and regulated with individual solenoid valves from its designated temperature controller.
With an L/D extruder ratio of 36:1, the extruder is supplied as standard with an atmospheric venting zone on one of the barrel modules. This can optionally be equipped with a stainless steel vacuum housing, sight glass and manometer, connected to a dedicated extractor pump.
The extruder is designed with a sturdy sub-cabinet containing all electric and electronic components in compartments completely separated from the vacuum pump assembly. The control panel is mounted onto the body of the extruder and contains programmable pressure controller with digital indication of the screw tip pressure, digital RPM indicators for main screws speed and feeder screw speeds and clear warning lamps for any overloads or temperature problems.
Millmerran Research and Manufacturing Ltd is the UK agent for the Labtech range of laboratory processing equipment. These machines are based on over 30 years experience and are built with a modern and pleasing design and a multitude of advanced features and safety standards in accordance with CE and other international norms, and every machine has the design, build quality and finish that have become recognised as the Labtech hallmark.
Complementing the existing range of co-extrusion cast film lines, Labtech Engineering presents the world’s smallest co-ex chill roll line of its kind.
The line features two conical extruders that can use regular plastic pellet sizes due to the 18mm diameter infeed gradually reducing to 8mm at the screw tip. The section feed block divides the flow into layers A+B+A and ensures an even thickness which is regulated by the extruder speeds, driven by infinitely variable speed servo motors. The flat die is a coat hanger type with adjustment screws so that the lip gap can be set from 0.1mm to 0.3mm.
The three rolls in the rolling stack are double walled for internal heating and cooling, and connected to a built-in water tank with circulating pump. The sub-cabinet contains the custom-built tank which, due to its size, can be used for several hours without the need for an external supply of cold water. The sub-cabinet also contains all the electrical components which comply fully with CE and other safety standards.
All the functions on the Ultra Micro co-ex chill roll line are controlled with a touch-screen computer with clear and easy to understand graphics.
Millmerran Research and Manufacturing Ltd is the exclusive UK agent for the Labtech range of laboratory processing equipment. These machines are based on over 30 years experience and are built with a modern and pleasing design and a multitude of advanced features and safety standards in accordance with CE and other international norms, and every machine has the design, build quality and finish that have become recognised as the Labtech hallmark. To download the full press release, please click the link Ultra Micro cast film line
Complementing the existing range, Labtech has now designed a new 36mm co-rotating twin screw extruder for heavy duty compound production. Following customer demand for a larger machine, the standard 36mm option can give outputs of 150-200 kg/h using a medium to high density compound. Alternatively it can be upgraded to the Maxi36Compounder which is equipped with a 90kW induction motor or water cooled motor drive. This gives a maximum RPM of 1200 and increases the output to 200-250kg/h.
The entire barrel on this machine is covered with modular high polished stainless steel panels for ease of cleaning. Each module can be removed individually to allow fast access to the barrel and to mount additional top or side feeders.
The modular sectional barrel has thick barrel lining inserts made from very high wear resistant PM-HIP steel which enables compounding of very abrasive materials. High corrosion resistant versions are also available for the processing of Fluor plastics and other resin types which develop aggressive acids during processing.
The screws are built up from individual element mounted on the splined hardened shafts. Several screw configurations are possible due to the variety of feeding and kneading elements available.
Downstream equipment has also been designed to complement the larger extruder.
The LW-300 3 metre long water bath can process up to 24 strands and output 400kg/hr.
The LZ-200 strand pelletizer has a speed range up to 1000 RPM, strand feeder speed between 20-80 m/min.
The LCL-80 classifier ensures all long, oversized particles and dust are efficiently removed and only perfect pellets drop into the container. The oversized particles are discharged separately and can be recycled.
Complementing the existing range of co-extrusion blown film lines, Labtech Engineering will be launching their Ultra Micro version at the NPE show, Orlando, in March 2015.
This line features three conical extruders that all use regular plastic pellet sizes. This is due to the18mm
diameter infeed which gradually reduces to 8mm at the screw tip. These extruders allow for a true 3-layer A+B+C configuration. The line uses a pancake type die and a new air ring made especially for co-ex films. It also has a fully functional oscillating film haul-off which will rotate 360° and a two station wind up.
All the functions on the Ultra Micro co-ex blown film line are controlled with a touch-screen computer with clear and easy to understand graphics.
