the profilers 1-2013 - Greiner Extrusions Technik

4 THE PROFILERS | April 2013
to date
The benefits of the RED.TOOLING centralized plug:
So far, 14 plug connectors were required; now, with RED.TOOLING,
a single plug connector is used.
flow.control:
Significant material savings using
flow.control developed by Greiner.
keep.clean.unit:
Reduces material deposits during dry
calibration.
RED-TOOLING – Innovation details
The next-generation RED.TOOLING system is made up of
a variety of precision-tuned and complex components
proven to deliver optimum performance.
The benefits of tooling innovations
In this edition of THE PROFILERS, three individual components
are examined in depth:
centralized plug connection
low.control
keep.clean.unit
These three components also provide an additional
benefit: they can be retrofitted independently with
other existing tooling systems or with your current
RED.TOOLING system.
What are the benefits offered to an extrusion
company when using the central plug?
Dangling cables between the die and the extruders
do not comply with modern requirements in extrusion.
The centralized plug connection was developed
in cooperation with our partner, Krauss Maffei, and
the benefits are impressive. A single, centralized plug
connection between the die and extruder prevents
hazards and confusion, and in turn it provides for orderly
arrangement and a
clear overview. By using
a heater band testing
device, proper functioning
of the heating zones
can be easily and quickly
determined. As a result of
incorporating a centralized
plug, assembly and
disassembly procedures
are performed faster and
easier – it simplifies handling overall. Retrofitting on
existing extruders and dies is fairly straightforward; it
allows for rapid and incremental upgrading, thus entering
the security class.
How much material is saved when using
flow.control?
The flow.control system (material flow control) is an
in-house development by Greiner Extrusion. Firstly,
material is saved due to Co-Extrusion, and secondly,
flow.control is now the next step toward a substantial
reduction of material usage. With the development of
the flow.control system, Greiner Extrusion is setting new
standards in the control of material flow. In particular,
within seconds it allows for the precision-controlled correction
of material flow through the individual sections.
Using hot air or cold air in the smallest of quantities,
the flow in critical profile sections can be either slowed
down or accelerated. A reduction in material consumption
is achieved through the production of profiles
whose weight is kept to a minimum yet which are able
to maintain control through critical sections. In addition,
the flow.control system has the ability to compensate
for material fluctuations that occur during the course of
extruder changeover, while at the same time increasing
the production flexibility and the process window.
Example:
A wall thickness of 2.5mm (main walls) can be reduced
by 0.05mm using flow.control = 1.5% reduction in material.
How significant is the reduction of rejects when
using the keep.clean.unit?
The keep.clean.unit was also developed in-house. During
the first dry calibration process, wax-like deposits
affect the profile surface and are often the reason for
production downtime. The best remedy is prevention.
Use of the keep.clean.unit prevents the occurrence of
such material deposits. The specifically designed unit
can be retrofitted to existing toolings, preventing the
buildup of deposits during calibration.
Without KCU
With KCU
Shutdowns/annually 20 16
Production downtime intervals are reduced by 25%
when using the keep.clean.unit.
Amortization KCU ≤ ½ year
The best bet is to try it out with your extrusion company
– this provides the safest and most efficient means for
establishing your decision-making basis! During the
development of these three product solutions that were
created in-house, the issues of saving material, greater
flexibility, and easier handling were the primary considerations.
In continuation of this subject, Greiner Extrusion
will report on further benefits of RED.TOOLING in
the next edition of THE PROFILERS – i. e. dry calibration,
PDC tank, and vacuum tank. RED.TOOLING –
Highly Intricate Innovation will be continued.