the profilers 03-2009 - Greiner Extrusions Technik

Information oF Greiner Extrusion
3/2009
PRODUCTION
COMPETENCE
Edition 4
LOOKING FOR A LINK?
WE CAN CONNECT YOU!
Greiner Extrusion brings in two tuning kits for PowerTooling: A steel base plate offers central connections for
vacuum and water supply as well as compatibility to the closed water circulation. A component for retrofitting
assures at existing tooling a closed water circulation.
Greiner Extrusion has developed a solution for
tooling water and vacuum supply that is possible
with no change needed to the mounting height
using a steel base plate.
The retrofitting is simple to implement. All that
needs to be done is to replace the dry calibration
base plate with a plate providing a central connection
possibility. The existing dry calibration can be
set directly on the 45 millimeter dimension plate
with no further changes.
Well prepared with fewer connections
Each separate dry calibration block is equipped
as a standard with numerous water and vacuum
connections. The new dry calibration base plate
(that can also be retrofitted) reduces the large
number of pipe connections to three for vacuum
and two for water. There can be a nominal
variation in the number of the connections depending
on the number of dry calibration units that are
connected.
Faster retooling in production changes is now possible
thanks to the fewer central water and vacuum
connections. Furthermore water recirculation is
taken care of centrally with max. five central connections.
This provides the possibility of returning
the water to the tanks and using it again on a selfcontained
basis with the Greiner Extrusion patented
closed water circulation system.
Component for water circulation
The retrofitting water-out recycling adapter means
existing tooling (at PowerTooling) can benefit from
use of the closed water circulation system. This
adapter is located on the underside of the dry
calibration and can easily be retrofitted for fully
enclosed circuit operation using two screws. The
component can naturally be used for both conventional
and turned operating modes.
The component has no central water or vacuum
connection. The number of water and vacuum
connections is unchanged in this case. The effort
required for retooling in production changes stays
the same with this tooling. This retrofitting kit will
be available shortly from our Service Department.
No particles and lower energy consumption
The water in our patented closed water circulation
is protected from any contact with the outside
environment as we already reported in issue one
of “The Profilers”. This stops particle intrusion in
the cooling water. The big benefit here is stopping
the scratch hazard in the production process. This
again improves the plastic surface quality. What is
more energy consumption is slashed and susceptibility
to pipe faults is much lower.
Standard plate
Retrofit kit for standard plate
Standard plate
Option: Base plate with central connection for water and / or vacuum
March 2009
Information OF Greiner Extrusion
Retrofit kit or standard? Greiner Extrusion offers the optimal solution.
Proprietor / Publisher Greiner Extrusion GmbH Responsible for the content Greiner Extrusion, Friedrich-Schiedel-Strasse 1, 4542 Nussbach, Austria, www.greiner-extrusion.at Company headquarters Krems münster,
District court of Steyr, Austria Commercial register no. FN 285487 i UID ATU 62967347 Design / Concept / Layout seso media group gmbh Photos Greiner Extrusion GmbH Text Kommhaus Media Enterprise,
www.mediaenterprise.at Printing Bösmüller Publication 6 times annually Total circulation 700
Pioneer for biological materials (page 2)
Simply fast (page 3)
Looking for a link? We can connect you (page 4)

Information oF Greiner Extrusion
3/2009
3/2009
Edition 4
focus Wood-Plastic-Composites INSIDE PARTNERSHIP
Edition 4
Information oF Greiner Extrusion
PIONEER FOR BIO-
LOGICAL MATERIALS
HIGH PROFILE
CONTACTS
Simply Fast
The new spare parts catalog for machines and tooling.
NEW
THRUST
FOR OUR
INDUSTRY!
Success record with 10 years of WPC extrusion technology.
Greiner Extrusion is working in the front rank on
the development of production technologies for
WPC (wood-plastic-composites) and other fiber
composite materials. Greiner Extrusion, the global
technology leader from Austria, has implemented
a complete extrusion line as a major project for the
European market in cooperation with a number
of partners. This largest WPC plant from Greiner
Extrusion to date is now in the start-up process.
Comprehensive technical know-how soon resulted
in the WPC innovation taking a firm place
in the Greiner Extrusion product range. “We see
ourselves as a stable partner in this growth market
and we are well equipped to implement the
entire range of ideas our customers are generating”,
Harald Schicklgruber, manager of the WPC
department commented.
Future markets in sight.
Dubai, Kiev, Moscow and New Delhi. Those were
the first trade exhibition stop-overs for Greiner
Extrusion so far this year. We encountered a confident
mood everywhere. Following on from our successful
start in Dubai, we scored plenty of points
in both Kiev and Moscow with our competent
service senior technician Oliver Schürrer. We took
part in numerous top level discussions covering
our technologies and services. Our two sales and
distribution people for Eastern and South Eastern
Europe experienced their first big trade exhibitions
with Greiner Extrusion. Wolfgang Haberleitner
had his premiere in Kiev and Christoph Denk in
Moscow. A financing plan for a major new project
was signed as a major highlight for us at Interplastica
in Moscow. The pleasing storm of visitors
in New Delhi left no doubt about the significance of
India as a future market. Wood-plastic-composites
were the issue that captured the audience globally
at every single trade exhibition.
The two new digital catalogs for machines and
tooling contain some 2700 products on 96 and
161 pages. They are illustrated and cover the
delivery schedule for all standard parts. The
catalogs are in the two languages German and
English throughout. Each thematic section of the
catalog is presented parallel in both language
versions. This means there is no need for complex
searches.
Clear and informative
The user has easy orientation in the catalog
using two logically structured category levels.
This means zero-error article identification is as
good as certain. The components are clearly
arranged by functional areas such as: pneumatics,
electricals, mechanics, pumps, motors, connecting
parts and many more. In addition to the
systematic structure, the user can also make a
search by article number to find the article needed
without wasting time. The newly edited spare
parts catalogs for machines and tooling were
completed in January 2009. The previous ver-
sion has proved itself to be of outstanding value
in practice since it appeared in 2006. You can
obtain the new catalogs free of charge on CD by
post or e-mail from our Service Department. We
will be pleased if you order the catalogs from us
under service@greiner-extrusion.at.
Reliable and fast
The Greiner spare parts service supports frictionfree
production and the operational readiness of
your plant. As the global leader Greiner Extrusion
has a powerful and efficient logistics service plus
the personnel and technical capacities required to
assure you the fastest of spare parts services. Standard
parts for tooling and machines can largely be
delivered direct from our Nussbach warehouse. Urgently
needed spare parts are sent out immediately
by express courier. Customer-specific spare parts
for tooling are produced swiftly and inexpensively
in the Greiner manufacturing network. Moreover urgent
work can be carried out at once in the Greiner
technical centre and pilot plant. This also applies
for tooling changes, repairs and revisions.
Dear Business Partner,
The year is some months old now, yet it is still
not possible to forecast a great deal about how
things are going to continue. There is no mistaking
the fact that we are in hard times, there
is also going to be a time after this though. We
want to contribute to this plain view of things with
some realistic optimism to make sure no one now
switches off the light at the end of the tunnel.
“The worst thing about the crisis is fear of the
crisis” – the phrase is as plain as it is true. Inspire
positive thinking and impart energy – this is exactly
what we now need in our industry.
The experience we have brought back from our
trade exhibition participations in recent weeks has
put us in a thoroughly positive frame of mind. We
noted in particular the powerful buzz of interest in
WPC – a future-oriented product, which we take a
closer look in this edition.
A trend is emerging in high-performance extrusion
with our customers achieving a clear competitive
advantage through higher productivity. We will also
report what is going on here in this number.
I wish us all plenty of pep as we thrust forwards
together and meanwhile have fun reading our
latest issue.
Best Wishes,
Yours,
Robert Grieshofer
CEO
WPC offers higher rigidity plus a lower thermal coefficient of expansion compared with full plastic materials.
Milestone
Greiner Extrusion is leading the race in the
development and manufacture of extrusion
tooling for WPC. In the decking area WPC highperformance
twin strand extrusion tooling for
handling 2.5 meters of profile a minute are
already being built. Greiner Extrusion has set
a milestone with the co-extrusion of colored
and non-colored WPC based on its years of
experience in the window profile tooling core
business. The advantage of co-extruded profiles
is that a WPC natural is colored only on the
outer layer, thus slashing up to 20 percent off
material costs. “We are proud of the high production
stability we have achieved – and this
also in the high-performance area”, Harald
Schicklgruber said.
Growth market with a future
The development of various process technologies
in the fiber composite field began some 10 years
ago. Success was achieved both in the overall
process and in the tooling area.
Outstanding material properties
WPC is a composite material that has rapidly
taken giant development strides since the
1990s – above all in the USA. Development in
Europe has been limping a little behind. But the
global trend is increasingly on the up and up.
In some countries such as Germany or China,
annual growth rates have reached over 30 percent.
The advantages of this biological material
compared with pure wood are the three-dimensional
plastic moldability, longer service life,
better weather resistance and greater resistance
to damp this outstanding environmentally
friendly material offers. Fiber composites consist
of plastic with an 80 percent mix of wood fibers.
They are very largely recycling suitable. WPC
mixtures of polyolefins with 60 percent wood,
and also WPC mixtures with PVC and 50 percent
wood have established themselves in external
use. When polyolefins are used as the additive
with the wood fibers, then the product can not
only be recycled, but can also go into the
furnace for thermal use.
Specialist visitors in Dubai obtain information at the Greiner Extrusion
stand.
Greiner Extrusion boosts energy efficiency (COP
value) with a new chiller series. A new energy
optimized control software that coordinates the
entire chiller circuit even more effectively, plus
cutting-edge compressor technology are making
significant energy savings possible. Energy consumption
has been cut back by some 20 percent
compared with the chilling plant available until
now.
“What we are aiming to do here is to continue
our path of sensible energy savings for extruder
plant also in the peripheral units to be able
to offer optimal solutions for our customers”,
Thomas Balak, Director Sales at Greiner
Extrusion explained.
Chill out for electricity costs
The energy savings for the new chilling plant are
achieved above all as a result of the improved
screw compressors and the strategy of a
When in doubt customers can save time and stress by leaving the search work to our Service Department experts by quoting the machine
number and giving a partial description of the parts they need.
NEW CHILLER SAVES ENERGY
The boosted effectiveness we have achieved for chilling plant reduces energy consumption by about 20 percent.
single compressor per chilling circuit. Until
now six compressors each of 15.6 kW nominal
output in three chilling circuit levels were required
to achieve a chiller output of 380 kW.
The new chiller provides an overall chilling output
of 400 kW with four chiller circuits and four
compressors of 17.6 kW each.
Control to real chiller requirements
A finely tuned compressor connection and shutoff
for the chilling requirement further minimizes
consumption. This ensures that the exact
chilling capacity needed is achieved with the
lowest possible energy consumption levels.
Phased connection of the separate compressors
prevents consumption peaks from occurring,
because peak electricity is the most expensive.
Energy saving as a program
The feasibility of further energy-efficiency opti-
mizing is being continuously checked out.
Vacuum pumps, for example, that are among
the big energy users in the extrusion process,
could bring about a significant saving potential.
Vacuum pumps can be supplied with a much
higher chilled water temperature, of up to 35°C,
or operated as extruder plant at 15°C.
By this means it is possible to use free chillers
for applications in this area in particular. Free
chillers require only 20 percent of a current
chiller electrical connection.
The primary pressure in the chilled water pipeline
supply system for the extruder plant can also be
kept constant with controlled pumps and the
electricity costs simultaneously kept low by the
speed-adjusted pump rating.
In case of any questions regarding to the new
chiller serie do not hesistate to contact your
sales person.