Foam Extrusion Systems - Davis

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Davis-Standard Business Areas
Aftermarket Services
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Pelletizing Systems
Pipe, Profile and Tubing Systems
Process Control Systems
Recycle/Reclaim Systems
Sheet Systems
Twin Screw Systems
Unwinding and Winding Systems
Wire and Cable Systems
#1 Extrusion Drive | Pawcatuck, CT 06379-2313 USA | Tel: +860-599-1010 | Fax: +860-599-6258 | www.davis-standard.com
Room 6717, Apollo Building
1440 Yan An Road (M)
Shanghai 200040 P.R. CHINA
Tel: +86-21-6103 1713
Fax: +86-21-6133 1866
www.davis-standard.com
© 2008 Davis-Standard, LLC. All Rights Reserved.
18A Brewins Way, Hurst Business Park
Brierley Hill, West Midlands
DY5 1UF UNITED KINGDOM
Tel: +44 (0) 1384 471930
Fax: +44 (0) 1384 671734
www.davis-standard.com
46 North First Street
Fulton, NY 13069-1297
USA
Tel: +315-598-7121
Fax: +315-593-0396
www.bc-egan.com
36 South Adamsville Road
Bridgewater, NJ 08807
USA
Tel: +908-722-6000
Fax: +908-722-6444
www.bc-egan.com
Mettmanner Strasse 51
D-40699 Erkrath/Düsseldorf
GERMANY
Tel: +49-211-2404-0
Fax: +49-211-2404-281
www.er-we-pa.de
JWRP5K1007
DAVIS-STANDARD FOAM SHEET SYSTEMS
1)
Primary Extruders
• Single or twin screw Thermatic® series extruders
• Patented screws designs for foam
• Dual T/C temperature control
2)
Gas Injection Systems
• Hydrocarbon & atmospheric blowing agents
• Mass flow meter flow control
• Dual gas blending systems
3) Screen Changers
• Slide plate and continuous styles available
4) Melt Transfer Pipe
• Built for 10,000 psi (680 bar) operation
• Spherical joints for thermal expansion
Cooling Extruders
• Thermatic® series extruders
• Self starting polymer sealing system
• Spiral wrap barrels for extra cooling
• Dual pass heater coolers
• Low torque high output screws
SECTION 1
twin screw arrangements. Extruders are available 2 1/2- to 16-inch (64 - 400mm) diameters with L/D
solid sheet applications are also available.
Foam End Products
More Than 40 Years of Foam Extrusion
Experience at Work
We believe that experience is the key to understanding our customers and their needs. Our reputation is
built on our ability to be able to supply you with the type of equipment and processing features that you
need to run a more efficient and more cost-effective business. Production of high quality foam products
with the best equipment in the industry is our goal.
SYSTEMS FOR MANY APPLICATIONS
• Packaging: Meat trays, egg cartons, cups, plates, anti-slip mats, protective wrapping
• Automotive: Custom profiles, seals and gaskets, interior furniture padding
• Industrial: Ceiling tiles, insulation board, pipe insulation, furniture padding
• Graphic Arts: Point-of-purchase displays, poster board, signage
SECTION 1
SECTION 2
Air & Water Cooling Rings
• Internal & external air rings
• Compressed air & blower type available
• Water rings available for product flatness
10) S-Wrap Pull Roll
• Single & dual sheet arrangements
• Cantilevered designs available
• Tension control loop coordinated with winder
injection foam systems are available in single screw tandem designs, as well as counter- or co-rotating
ratios of 30:1 and higher. Coextrusion systems, turnkey equipment, and weight reduction solutions for
8)
SECTION 3
See Above for Descriptions 1 - 6
7) Board Die
8) Board Calibration Unit
9) Primary Haul-off Unit
10) Cooling Transport Conveyor
11) Secondary Puller
12) Edge Profile Station
13) Process Controls
• Epic III™ and Mesa III process control systems
• Allen-Bradley PLC or Siemens control systems
• Complete line integration with touch screen computer
• Recipe storage & production reporting & troubleshooting
• Discrete controls available on request
14) Cross Cutting Machine
15) Board Stacker
16) Packing Unit
17) Control Station
SECTION 3
packaging, automotive, industrial, and graphic arts markets. Versatile, high performance, direct gas
Annular Foam Die
• Spider & spiderless designs
• “On the fly” gap adjustment
• Monolayer & coextrusion available
9) Sizing Mandrel
• Cast or machined aluminum construction
• Single, dual or triple slitting arrangements
DAVIS-STANDARD
FOAM BOARD SYSTEMS
Davis-Standard’s foam systems are used in R&D and production applications by industry leaders in the
7)
SECTION 2
5)
6) Closed Loop Cooling System
• Two closed loop temperature control systems
• Designed for 100˚ F (38˚ C) plant cooling water
11) Web Guide Systems
• Optional driven & manual edge guide systems
12)Winders
• Dual cantilevered design or pneumatic push-offs
• Surface winder designs for PE foams
• Accumulators for high output lines
13) Process Controls
• Epic III™ and Mesa III process control systems
• Allen-Bradley PLC or Siemens control systems
• Complete line integration with touch screen computer
• Recipe storage & production reporting & troubleshooting
• Discrete controls available on request
PS FOAM SHEET LINES
SPECIALTY DIE OFFERINGS
We supply PS foam sheet systems for thermoformed and flexible packaging applications. These systems
are available with tandem single screw extruders with gas injection, or with twin screw extruders with
gas injection.
Davis-Standard supplies flat die and calibration systems for the continuous extrusion and shaping of
foam boards used for temperature insulation. Adjustment features are incorporated within the die and
calibration unit to maintain uniform thickness with minimal edge trim.
Sheet Die:
• On-the-fly remote die lip adjustment
• Adjustable choke distribution ring
• For open cell absorbing foam
• Mono and coextrusion dies available
• Die sizes from 1/2-inch (13mm) to 12-inch (300mm) lips
Board Die:
• Die for 24” (600mm) to 48” (1200mm) wide board
PE FOAM SHEET LINES
BLOWING AGENTS
PE foam sheet systems for processing the protective material used in packaging fragile items and for
insulation are available with tandem single screw extruders or twin screw extruders with gas injection.
• Hydrocarbon
• Atmospheric
• Blends
PS FOAM BOARD LINES
Flat Die Forming Box assembly for Foam Board
PP FOAM SHEET LINES
These systems, primarily used for thermoforming food containers and for producing automotive parts, are
available in both tandem single screw and twin extruder arrangements based on application.
TANDEM EXTRUDER SIZES AND NOMINAL OUTPUT CHART
XPS Shaping System
XPS Haul Off
PS
PE/PP
Extruder Sizes
kg/hr
lb/hr
kg/hr
lb/hr
2 ½ - 3 ½ in.
125 - 150
275 - 330
110 - 130
240 - 285
3 ½ - 4 ½ in.
225 - 275
500 - 600
200 - 250
440 - 550
100 - 130mm
250 - 320
550 - 700
225 - 285
500 - 625
120 - 165mm
500 - 600
1,100 - 1,300
450 - 540
990 - 1,200
130 - 165mm
550 - 650
1,200 - 1,450
500 - 585
1,100 - 1,285
6 - 8 in.
600 - 750
1,300 - 1,650
540 - 675
1,200 - 1,485
165 - 225mm
680 - 900
1,500 - 2,000
600 - 800
1,320 - 1,760
8 - 10 in.
900 - 1,000
2,000 - 2,200
800 - 900
1,760 - 1,980
8 - 12 in.
1,100 - 1,350
2,400 - 3,000
990 - 1,200
2,200 - 2,640
250 - 400mm
1,400 - 1,600
3,100 - 3,600
1,260 - 1,440
2,800 - 3,700
Get to Know Us
Davis-Standard has set the standard in foam equipment
and systems. We hope you will take the time to get to
know us. Our capabilities go far beyond our equipment.
They extend to our professional training experts,
laboratory personnel, design engineers, and hands-on field
engineers who will work with you every step of the way.
XPS Calibration Unit
165-225mm with Annular Foam Die
MATERIALS
• PS
• LDPE
• PET
• PP
• Others
SPECIALTY MANDREL AUXILIARY COOLING EQUIPMENT
• Machined aluminum construction
• Segmented nose cooling
• Specialty non-slip coatings
• Auxiliary air cooling blowers
• Close approach and standard blow-up air ring designs for skin surface effect
• Designed for quick mandrel changes
Cooling Mandrel, Stand with External Sheet Cooler
LABORATORY CAPABILITIES
• R&D facility in Pawcatuck, Connecticut
• Equipment available for developing/testing new blowing agents, screws, and die designs
• Customer demonstrations and specialty product developments
Quality Components Built To Last
Investing in the right foam extrusion system is an important decision and involves a significant financial
commitment. We strive to provide you with the greatest return on your investment by supplying
equipment that meets demanding production requirements while providing you with many years of
reliable operation. We also take pride in being able to supply you with complete systems
equipped with the best components available in the industry.
PRIMARY EXTRUDERS
• Single or twin screw Davis-Standard Thermatic® series extruders
• Patented screw designs for foam
• Dual T/C temperature control
Cooling Mandrel with Dual Slitting Arrangement
INJECTION SYSTEMS
WEB GUIDE SYSTEMS
• Hydrocarbon and atmospheric blowing agents
• Mass flow meter flow control
• Multi-gas and/or blending systems
• Optional driven and manual edge guide system
• Slide plate and continuous styles
• Dual cantilevered design with pneumatic push-offs
• Surface winder designs for PE foams
• Accumulators for high output lines
MELT TRANSFER PIPE
PROCESS CONTROLS
• EPIC III™ and Mesa III process control systems
• Allen-Bradley PLC or Siemens control systems
• Complete line integration with touch screen computer
• Recipe storage and production reporting and troubleshooting
• Discrete controls available on request
SCREEN CHANGERS
Gas Injection System
• Built for 10,000 psi (680 bar) operation
• Spherical joints for thermal expansion
• Static mixer
• Melt pump
COOLING EXTRUDERS
• Davis-Standard Thermatic® series extruders
• Self-starting polymer sealing system
• Wet barrels for 30% more cooling
• Dual pass heater coolers
• Low torque high output screws
CLOSED LOOP COOLING SYSTEM
• Multiple closed loop temperature control systems
• Designed for 100ºF (38ºC) plant cooling water
ANNULAR FOAM DIE
Annular Foam Coextrusion Die
• Spider and spiderless designs
• “On the fly” gap adjustment
• Mono-layer and coextrusion available
AIR & WATER COOLING RINGS
• Internal and external air rings
• Compressed air and blower type available
• Water rings available for product flatness
Technology is what sets extrusion equipment apart in performance and quality. We have a dedicated
Technology Center that focuses on finding ways to make existing equipment and processes better.
From feedscrews to die designs, we always want to stay on the cutting edge of technology, so that our
customers have the best tools available.
AB COEXTRUSION DIE
• 4-to-1 blow-up/stretch ratio
• Requires use of fewer blowing agents to achieve a high density product
• Capable of processing rigid and foam structures simultaneously
• AB, ABA, and ABC coextrusion designs ideal for barrier packaging, absorbent
foam technology, and food tray processing
Two Dual Cantilevered Sheet Winders
HIGH-OUTPUT FEEDSCREWS
• System outputs up to 3,600 pounds (1630 kg) per hour
• Dynamic seal design prevents gas from leaking in tandem arrangement
• Minimal shear while providing efficient cooling and mixing
Name the Application – We Have a Solution
• Cast or machined aluminum construction
• Single, dual or multiple slitting arrangements
FLEXIBLE SHEET ON A ROLL
• Single and dual sheet arrangements
• Cantilevered designs available
• Tension control loop coordinated with winder
Dual Cantilevered Sheet S-Wrap
Advanced Technology
SIZING MANDREL
S-WRAP PULL ROLL
Dual Sheet S-Wrap
WINDERS
We supply both PS and PE winding equipment for flexible sheet applications.
RIGID BOARD
We supply equipment for foam board from 3/4-inch to 6 inches (20 to 150mm) thick, cut to size at
any length. We work with several leading companies to integrate technology for cooling, conveying,
printing, finishing, sizing, and shaping of board material products.
Dual Cantilevered Sheet Winder
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