Rheocord 300p + Mixer/Extruder Sensor
= PolyLab System
Mixer sensors
Rheocord 300p
Single screw
extruder sensors
Twin screw
extruder sensor
Rotors
1
Feeding
systems
Screws
Dies
Postex
PolyLab System
2
3
PolyLab System
• Laboratory Mixers :
4
Laboratory Mixers
measuring principle
Shearing of a test sample
in a heated mixing chamber
with counter rotating rotors
3
2
Test results:
 Torque
 Melt
5
temperature
Mixer - Rheogram
Temperature
Torque
Energy
6
Rotors for Rheomix mixers
Banbury rotors
Sigma rotors
Roller rotors
Cam rotors
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Mixer Test
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Application
Influence of the mixer load on PVC fusion
m: 60 g
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Application
Influence of the mixer load on PVC fusion
m: 66 g
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Change from Mixer to Extruder
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PolyLab System
• Single Screw Extruders :
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Rheomex single screw extruder
collars for heating and cooling
Feeding cooling
Screw back-pressure
sensor (optional)
13
Sensor ports
(2 standard, others optional)
Rheomex Application
Extruders are generally used to:
• transport material
• plasticize
• compress
• homogenize
• compound
• vent
• chemical reaction
• building up pressure
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Rheomex Application
Measuring of process variables:
• torque
• melt temperature
• melt pressure
• mass flow
Optimizing of process parameters:
• extruder speed
• temperature profile
• pressure
• screw design
15
Screws for single screw extruders
Conical Core
Screw
Standard
Metering
Screw
Short
Metering
Screw
Venting Screw
Mixing
Screw
16
Pressure built-up in a single screw extruder
P3
pressure
P4
P5
P2
P1
barrel - length [L/D]
0
17
11
14,5
20,5
24,5
PolyLab System
• Twin Screw Extruders :
18
Twin-screw extruders CTW100 and PTW25
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Feeding of material into
twin-screw extruders
Co-rotating
20
Counter-rotating
Rheomex CTW100p
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Rheomex CTW100p
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Screw geometries for CTW100p extruder
Venting screw
Intensive mixing screw
Standard screw
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Rheomex CTW100p
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Parallel twin-screw extruder Rheomex PTW
Processing tasks - 1
•
•
•
•
•
•
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.
25
Parallel twin-screw extruder Rheomex PTW
Processing tasks - 2
• 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
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Rheomex PTW16p
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Rheomex PTW16p
Hinged barrel for easy handling
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Rheomex PTW16p
flexible screw configuration
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Rheomex PTW16p
Applications:
Compounding + Rheology
Degassing of i.e. solvents etc.
Modifying by incorporation of plasticizers,
cross-linking agents, flame retardants,
UV-stabilisers, etc.
Incorporation of fillers and reinforcing agents such as:
wood flour, talc, glass fibres etc.
Breaking down of high molecular particles
30
Rheomex PTW16p
Technical Specifications
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
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Rheomex PTW16p
Screw elements:
32
Rheomex PTW24p
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Rheomex PTW24p
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Rheomex PTW24p – Advantages:
Extruder barrel: segmented and hinged
Segmented screw
Sidefeeding
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Rheomex PTW25
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Rheomex PTW25 with PolyLab System
PolyLab System
Rheomex PTW25
Heatexchanger
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Slave
Master
Parallel twin-screw extruder Rheomex PTW25
Screw segments 1/3
Conveying elements:
38
Parallel twin-screw extruder Rheomex PTW25
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557- 5001 Rheomex PTW 25 x 20D
Feeding
Venting
Barrel segments:
Feeding barrel
Closed barrel
Open barrel
Measuring barrel
40
Application:
4D
6D
6D
4D
Melting of polymers
Venting
557- 5031 Rheomex PTW 25 x 32D
Production of Masterbatch
Venting
(vacuum)
Venting
(atmosphere)
Venting
(atmosphere)
Side-feeding
(pigments)
Barrel segments:
Feeding barrel
Closed barrel
Combi barrel
Closed barrel
Open barrel
Open barrel
Measuring barrel
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Feeding
(polymer)
4D
6D
4D
4D
6D
4D
4D
Material
Shape
PP, PE, PET,
PC, PA,etc.
Quantity in
%
powder or 60 - 80
granulates
pigments
powder
20 - 40
Screw configuration Rheomex
PTW25/38
For 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-KB-25/LI
25/1/2
25/1/2
E-KB-25/LI
25/1/2
25/1/2
E-KB-37.5/LI
25/1/2
25/1/2
E-KB-37.5/LI
E-KB-37.5/LI
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
Screwtip
42
Feeding
Mixing/Hydration
Cooking
Venting
Cooling
Dry-Blend
Liquids
Steam
Vacuum
Atmosphere
Premix
Masterbatch production
Parallel twin-screw
Water bath
43
Pelletizer
PolyLab System
• Feeding systems :
44
Metering Feeder
Principle sketch:
Standard
Hopper
glass
window
interchangeable
feeding tube
Motor with gearbox
Metering screw
Closure for Cleaning
Extruder
45
Metering Feeder
46
Metering Feeder
Application:
•
•
•
•
•
•
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Accurate dosing of powder
Accurate dosing of pellets
Starved feeding to enable venting
Starved feeding to reduce torque
Production of masterbatches
Feeding of parallel twinscrew extruders
PolyLab System
• Extruder Application :
48
Cast film application
• Instruments:
• Application:
• Rheocord 300p
• Small production of films
• Extruder (single- or
twin-screw extruder)
• Testing the processabillity
• Screws
• Sheet & ribbon die
• Testing and optimisation of
processing conditions
• Sheet & ribbon take-off
• Results:
• Pressure sensor
• Fish-eye testing
• (Screen package)
• Pigment distribution
• (OQT 512)
• Surface quality
• Testing of additives
• Tensile testing
• Weathering
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Sheet and Ribbon Die

Die width:
25/50/100/150 mm

Die gap:
adjustable
(standard: 0.2-1.2 mm)
50

fixed die gap on request

Max. temperature: 360°C

1 measuring port
Sheet and Ribbon Take Off
adjusting the gap
polished and temperable
steel rollers
rubber rollers
Motor
waterbath
circulator
51
take-up
roller
Cast film application
PVC sheets: good & bad
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Cast film application
53
Blown film application
• Instruments:
Rheocord 300p
Extruder (single- or
twin-screw extruder)
Screws
Blown film die
Cooling ring
Blown film take-off
Pressure sensor
(Screen package)
(OQT 512)
54
• Application:
small production of films
Testing the processability of
compounds
Testing of additives
Testing and optimisation of
processing conditions
• Results:
Fish-eye testing
Pigment distribution
surface quality
557- 3175 Blown Film Die
• Ring diameter 25mm (35mm)
• Pin diameter 24mm (34mm)
• Gap width 0-0.8 mm
• Measuring ports 2
• Max. temperature 480°C
adjustable
die gap
55
Air
PolyLab blown-film combination
Blown film take-off
PolyLab System with extruder
56
PolyLab blown-film combination
57
PolyLab blown film combination
With optical testing unit OQT
Lightning Device
Blown film take off
CCD-Camera
PolyLab System with extruder
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Blown film take-off with built in camera system
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OQT- Graphical display of defects
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OQT- Graphical display of the data and defects
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OQT- Graphical display of the data
62
Compounding
• Instruments:
• PolyLab RC300p
• Rheomex twin-screw
extruder
• extruder Screw(s)
• Pressure sensor(s)
• (Screen package)
• Rod die (horizontal or
vertical) or Multistrand die
• Waterbath
• Pelletizer
63
Test results:
• Testing of the
processability of polymer
compounds
• Testing of additives
• Testing and optimisation
of processing conditions
• small production of
masterbatches
557- 3235 Horizontal rod die
• Application:
Universal die for extrusion
tests
• manufacturing of polymer
strands for the production of
pellets.
• Nozzles available from:
1mm - 6mm
• Two sensor ports for pressureand temperature-measurement
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557- 3150 Vertical rod die
• Application:
Universal die for extrusion
tests
• manufacturing of polymer
strands for the production of
pellets.
• Nozzles available from:
1mm - 6mm
• Two sensor ports for pressureand temperature-measurement
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557- 3180 Multistrand die



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Application:
Universal die for extrusion
tests with higher output
manufacturing of polymer
strands for the production of
pellets.
Strand diameter: 3 mm
(others on request)
Compounding
67