Reifenhäuser News Issue 31 (pdf) - Reifenhäuser GmbH

REIFENHÄUSER Maschinenfabrik
REICOFIL
REIMOTEC
REILOY
POLYREMA
REIFENHÄUSER CHINA
REIFENHÄUSER GROUP
Pipe Extruder
N E W S
Midex-Winder
Issue 31

EDITORIAL
Ulrich and Klaus
Reifenhäuser
Dynamic markets require innovation
and the ability of all market
players to meet changing conditions.
Not only must Reifenhäuser
face up to progress
and innovations
in technology, but also in organisation
and structures to cope with
shifting markets in the area of plastics
machinery construction.
The process that started in the
past with the spin-off and foundation
of new companies such as
Reiloy, Polyrema, Reimotec,
Reifenhäuser China and Reifenhäuser
REICOFIL will thus be continued.
At the beginning of the new fiscal
year on July 1, 2006, we will merge
our film extrusion, extrusion component
and production divisions
into the new Reifenhäuser EXTRU-
SION GmbH & Co. KG. Thus, the
former machinery company’s old
structure will shortly be changed
into a powerful company group of
small, flexible units.
This will allow our customers to
benefit more strongly than ever
before from direct dialogue,
market-orientated research,
development and production and
from our comprehensive RQS
quality service.
The family shareholders’ commitment
to the Reifenhäuser group
ensures a successful and coordinated
operation in the future
plastics machinery construction
market.
In this
issue
5 Thermoforming
sheet extrusion
Reitruder technology for
processing PET resins
without pre-drying
EC Extrusion Center 10 The names of Kosche
and Reifenhäuser combine
for WPCs – Wood
Plastic Composites
13
REILOY Metall
Special flight armouring to
protect extruder screws
from wear and corrosion
7
11
„Reifenhäuser News” is also published in German.
Articles and illustrations may only be reproduced with our
written consent and acknowledgement of source.
Reifenhäuser News Online: This edition is also available
on the Internet for downloading in pdf format,
address: http://www.reifenhauser.com
Blown film extrusion
High-quality standard
line for a basic price
of less than one
million Euros
Reifenhäuser Quality
Service (RQS)
Upgrading of older
extrusion lines
14 POLYREMA
Formula for success in
second-hand lines
Publisher : Reifenhäuser GmbH & Co. KG
Maschinenfabrik
D-53839 Troisdorf
Editors : Ursula Reifenhäuser
Wolfgang Högemann
Design + AD DAS WERBETEAM GmbH
Production : www.ad-werbeteam.de
Issue : May 2006
2 3
9
EC Extrusion Center
Extruders and pipe dieheads
for water pipe
production in Africa
12 REICOFIL®
Teleservice – the basis for
a reliable long-term partnership
15 REIMOTEC
Multi-layer monofilaments
for the textile and artificial
grass industries
Cast film extrusion
Improved performance of 7-layer film line
through optimized winder technology
More than 50 customers invited
to attend the chill roll symposium
in February 2006, could
witness the high efficiency of a
7-layer Midex 7-2500 cast film
line. The extrusion of CPP film
was demonstrated with an output
of 800 to 1000 kg/h at a line
speed of 330 m/min.
The high speeds and the resulting
performance improvement
for the complete line could be
achieved using an optimized
winder technology for the contact
winding of cast films.
The 7-layer coextrusion line is provided
with the following components:
Extrusion
Gravimetric dosing units
3 conventional extruders with
AC drive technology, screw diameters
of 150, 90 and 80mm
4 REItorque single-screw extruders
with gearless drive technology
and 60 mm screw diameter
The advantages of REItorque
extruders, especially when used in
coextrusion, are a space-saving
design and high efficiency (energy
savings) compared with conventional
drive techniques.
Four REItorque extruders of space-saving configuration
REIcofeed II 7-layer coextrusion
block
The melt streams are combined
in the coextrusion block and
the distribution of each layer
can be adjusted by means of
segmented adjusting elements.
The layers can then also be
individually adjusted by slide
adapters to ensure optimal
tolerances in the final film.
Forming
The BSD CR04-2400 automatic
slot die-head provided with
thermobolts for flex lip adjustment
is characterized by optimal melt
flow properties. Translator bolt
control can be used as an alternative.
Excellent film qualities are ensured by
precisely controlled temperatures on
Arrangement of extruders for 7-layer cast film extrusion

1 = film reel (driven)
2 = contact roll (not driven)
3 = tension measuring roll (driving the
winding shaft)
4 = auxiliary haul-off unit (driven)
5 = tension measuring roll (driving the
auxiliary haul-off unit))
the surface of the 800 mm diameter,
2500 mm wide casting roll.
The casting section has been
adapted for production speeds
increased to over 300 m/min.
4
coex block
die
casting roll
Winding
In view of the trend towards highquality
thin films, the winder is one
of the most important components
in cast film extrusion since it
determines line performance.
The upgraded and optimized technology
of Midex rotary arm cast
film winders is able to convincingly
fulfil the performance requirements.
The patented winding system
uses two independently rotatable
shaft support arms that operate at
roll change depending on the reel
diameter. The resulting optimal
distance between film reel and the
new winding shaft ensures short
reel changing times and good reel
quality quasi up to the end of the
finished roll.
Expanded technology
The versatility of the rotary arm film
winder has been basically improved
by a modification of the
contact roll design in the film
conveying module.
The adoption of the modified
contact roll makes the use of a
pressure roll superfluous. The new
contact roll controls the film
tension and is pressed on by
means of a newly developed
system.
This winder technology has the
following advantages:
Contact winding is possible for
almost all raw materials, especially
PP film, and is no longer
limited to stretch film
Contact winding ensures
improved film guiding and
precise build-up of reel edges
Midex winder type D04 for precise build-up of reel edges
The winding quality and winding
density can be influenced
by adjustable contact pressure
and controllable winding
tension
Air inclusion layers required for
post-crystallisation shrinkage
can be better controlled by the
new design concept
The complete winding and roll
change process is done without
electrostatic charging
Corrugation problems occuring
in film conversion due to gap
winding are avoided by using
contact winding
A speed of more than 300 m/min
can be reached in the production
of 23 µ CPP film, resulting in an
increased throughput for the
complete line.
New standards have been set by
the optimized winder technology
for winding high-quality thin films.
The product range of this highperformance
cast film line comprises:
barrier film of max. 7 layers with
edge encapsulation
metallizable PP film
PP or PE laminating film
stretch film
film thicknesses ranging from
0.012 to 0.250 mm
line output up to 1000 kg/h
(depending on the product).
Thermoforming sheet extrusion
Reitruder technology for processing PET resins without pre-drying
With the introduction of PET
bottles for beverages and the
resulting amounts of PCR (postconsumer
recycling) materials and
bottle flakes, the interest in an
economically profitable method of
processing PET raw materials and
regrind has been growing.
Reifenhäuser offers a convincing
technology from a single
source for processing undried
PET raw materials using its
Reitruder co-rotating twinscrew
extruder.
The proven technology comprises
virgin material (A-PET, C-PET and
G-PET) and undried PET/PE
regrind that could not previously
be extruded. Now, it is possible to
process these materials into multilayer
thermoforming sheets.
Reitruder
The Reitruder offers essential
advantages in processing recycled
PET materials.
The two or three operating steps
compounding – pre-drying –
extrusion that are traditionally used
on conventional machines, are
combined in a single step requiring
only one heating-up cycle. The
PET material is processed by the
Reitruder without pre-drying. This
means considerable savings in
energy costs due to a reduction of
intermediate steps in the compounding
of raw materials.
Reitruder twin-screws and barrels
are divided into segments that can
be combined according to the
intended product.
For example, barrel segments with
vacuum venting and twin-screw
segments designed for melting
and homogenizing the polymer are
available.
3-layer thermoforming
sheet lines
Extrusion
Extrusion lines for production of
3-layer thermoforming sheet from
PET virgin material and regrind are
equipped with two extruders.
For production of the core layer, a
Reitruder twin-screw extruder is
used as main extruder suitable for
processing 100 % PET/PE regrind
or PCR material without predrying.
3-layer thermoforming sheet line with Reitruder
The two outer layers (7 to 10 %
layer thickness) are normally
produced from virgin PET using a
further Reitruder as coextruder.
However, a single-screw extruder
with a small drier for the virgin
material in the outer layers is
another possibility that does not
compromise product quality.
The high amount of recycled
material used in the core layer
results in a considerable reduction
of raw material costs.
Processing of different recycled
PET materials, e.g. PET/PE, on
conventional machines may lead
to problems due to adhesion and
bridging effects caused by different
melting points. These negative
phenomena are overcome by
the use of Reitruder technology.
Forming
A REIcofeed coextrusion block
with patented REIcofeed adapter
is used which enables a precise
adjustment of the layer distribution
during production for the extrusion
of 3-layer sheets.
Sheet die-heads of sophisticated
technology are used for coextrusion.
The flex lips at the die outlet can
either be adjusted manually by
means of pressure screws or
automatically by thermo bolts. The
slot width of the die can be varied
by internal or external deckling
with the line in or out of operation.
5

Polishing stacks
Polishing stacks equipped with
individual servo drives and dedicated
temperature control units
are available with vertically or
horizontally arranged rolls for
cooling and polishing the thermoforming
sheet.
MIREX S polishing stacks
designed for vertical extrusion are
preferably used for the production
of thin sheets (0.2 to 0.8 mm).
MIREX W polishing stacks for
horizontal extrusion are particularly
suitable for thick sheets up to 2.0
mm.
Downstream equipment
The line can be completed with
thickness gauges, additional
cooling rolls, antistatic baths,
longitudinal cutters and other
components for optimising sheet
quality.
Typical properties of PET sheets:
High stiffness and transparency,
especially in case of virgin
PET
Good cooling behaviour
A UK customer reporting on PET processing:
"The product ranges of our company comprise bakery, dessert
and salad trays, dual-ovenable trays for ready meals and
A-PET/PE trays for modified atmosphere packaging of red
meats.
The two main polymers used are PET and PP. Until recently all
our sheet was produced using single screw extruders with
conventional drying and crystallising when processing PET.
Special Reifenhäuser technology allows processing A-PET
without any pre-drying or crystallisation. This is achieved by
using a Reitruder co-rotating twin-screw extruder with specially
developed screw geometry and a unique venting technique.
The screw design allows processing of 100% flakes or 100%
pellets or blends without problem. The flexible technology saves
significantly on energy consumption compared with conventional
single screw extrusion with pre-drying."
Suitability for microwave, "dual
ovenable” if C-PET is used
Good barrier properties for an
extended shelf life
Blister packs for presentation of
consumer goods and cosmetic
products are further applications
Highly transparent PET films are
preferably used as protective
packaging for bakery and foodstuff
such as meat, fruit and
vegetable
PET film from coloured
recycling material find large
applications as flower and plant
pots in horticulture
Bottle flakes Thermoformed sheet products
6
Reifenhäuser offers convincing
technology for processing undried
PET raw materials into high-quality
sheet products with this extrusion
line.
Blown film extrusion
3-layer blown film line Filmtec 3-1700 IBC RHS
High-quality standard line for a basic price of less than 1 million Euros
The value of a film extrusion line
is more highly rated through its
reliable output capacity, long
service life and product quality
than by high technology.
Reifenhäuser has designed a
standard compact 3-layer blown
film line equipped with well defined
core components in the
medium output range.
Extrusion
3-layer film production is based on
3 REItorque extruders with gearless
drive technology and screw
diameters of 60 mm, 70 mm and
60 mm.
Screws and barrels made from
bimetallic materials with wearresistant
armouring alloys are
suitable for processing all polyolefins,
especially metallocenes
and other new raw materials, and
ensure a long service life for the
line.
Die-head / air ring
The standard compact 3-layer
blown film die head BKF 400 provided
with central IBC system offers
a large range of applications with
die inserts from 180 mm to 400
mm. Used in combination with a
dual-chamber air ring, good basic
tolerances are achieved with different
film structures.
Thickness control is achieved by
means of the proven REIcoflow
system which is characterised by
rapid reaction times and product
change-overs.
Sizing / film guiding
The scissor-type 8-segment sizing
cage with easy-running teflon rolls
provides stability both constructionally
and dimensionally.
Standard blown film line Filmtec 3-1700 IBC RHS
Ultrasonic sensors are used for
film bubble diameter control.
The 1700 mm wide collapsing unit
with carbon fibre rollers ensures
wrinkle free guiding of the film to
the REIcofly I turner bar. Even matt
and tacky films can have their
tolerances randomized using the
turner bar provided with REIcofly
system. Formation of wrinkles is
avoided thanks to the very uniform
air cushion between film and
turner bar.
Winding
An SFA II winder, equipped with
servo drive and Siemens S7 control,
which is suitable for contact
and centre winding is used for
winding the film.
Outputs from 300 to 400 kg/h can
be achieved with the blown film
7

1 = extruder and dosing unit
2 = blown film die head and air ring
3= sizing cage
4 = film guiding unit
5 = turner bar system
6 = line platform
7 = winder
die-head and a die insert of 300
mm, depending on the raw
materials used.
Standardized steel tower
The line components are firmly
fixed and integrated into the tower
construction.
Due to this special construction
technique, the line can be assembled
and commissioned very
quickly so that production can be
started typically 5 months after
placing the order.
The tried and tested high-quality
line components manufactured as
standard parts in the parent company
ensure a high technical level
of the complete line and excellent
operating reliability. Expensive new
designs for specially manufactured
or adapted parts are avoided so
that favourable production costs
can be obtained.
8
7
5
6
SFA II film winder
Automation
The line is equipped with a
REIcofol automation system with
touch screen for visualisation of
the respective applications.
4
2
3
1
6
The range of film applications
includes carrier bags, general
packaging, sanitary packaging and
laminating films.
The portfolio of film products is
completed by additional options,
e.g.:
stretch hood module with a
circumference of up to 3400
mm for industrial packaging
optional inclusion of a highperformance
UFA III winder
gravimetric blending unit with
suction conveyor and a special
user interface via touch screen
Worldwide distribution
Several blown film lines of this
series are already in production in
South East Asia and have set
technological standards in this
region after a short period of time.
The suitability of the line configuration
and good product quality
convinced one customer to order a
second line already.
Optimized through technical
developments and, if necessary,
optional equipment, these 3-layer
blown film lines may also be used
world-wide including Europe.
Blown film extrusion
High-performance package for increasing the output of 3-layer blown film lines
Reifenhäuser has developed a
new double-stage air cooling
system, REI2cool, to ensure
efficient cooling in 3-layer
blown film extrusion.
The highly efficient cooling
system used in combination
with a 3-layer blown film diehead
that is optimised for
back pressure and throughput,
allows an increase in the
line output of 25 %.
REI2cool air cooling system
Provided with two vertically
adjustable air rings for outside
cooling of the film
bubble, the REI2cool system
can be adapted to the uniformly
distributed air volume of the IBC
(Internal Bubble Cooling). The
highly efficient cooling, in conjunction
with the newly designed
blown film die results in through-
puts that are 25 to 30 % higher
than in standard lines.
EC Extrusion Center
pre-distribution in combination
with newly designed spiral
mandrels.
The new die-head is
characterised by a very
uniform melt distribution
at the die outlet as well as
minimized dwell times and
smooth flow channels.
The new air cooling
system is easy to handle
and offers a great flexiblity
in the production of
versatile film structures
from different raw
materials.
Visitors to the Italian plastics
show in Milan were very interested
in REI2cool as an essential
component for increasing the
capacity of 3-layer blown film
lines.
Extruders and pipe die-heads for the production of water pipes in Africa
Over the past few months,
extruders and pipe die-heads
have been manufactured at
Reifenhäuser for the production
of water pipes from HDPE
and PP.
These core components together
with the downstream equipment
for pipe cooling and finishing will
Pipe die head
3-layer blown film die with
REI2cool air cooling system
3-layer blown film die-head
The newly developed compact
design blown film die-head
features a thermally optimized melt
be supplied by a partner company
to an East African country.
In accordance with the high
requirements of pipe extrusion, the
three extruders of the RH series
with screw diameters of 120, 90
and 60 mm have been designed
for high output capacities. Special
screws ensure a low melt temperature
at high outputs.
The pipe die-heads with spiral
mandrel melt distributors (110 to
630 mm and 16 to125 mm outer
diameters) can produce different
pipe sizes and ensure a homogeneous
melting of the radial and
axial melt flows.
The extrusion units are completed
by single-screw extruders with
REItorque drive (RH 27-1-25-25 ht)
for the production of colour stripes
on the pipes.
The proven line concepts stand
for product quality and high production
reliability.
RH single-screw extruder with pipe die-head and REItorque extruder
9

EC Extrusion Center
Bitruders used for wood extrusion – The names of Kosche and Reifenhäuser
combine for WPCs - Wood Plastic Composites
The economic utilization of
wood chips for the production of
high-quality wood-plastic composites
is successfully undertaken
using a BITRUDER counter-rotating
twin-screw extruder.
The processing of plastics filled
with 30 % wood fibres was already
tested decades ago. Over the past
few years, further developments in
wood extrusion have been made
successfully and the market for the
dimensionally stable WPC
Bitruder used for wood extrusion
Decking for outdoor application
10
products has been constantly
growing.
Production of WPC
products
Generally, WPC formulations include
the following components:
thermoplastic materials such
as: PE, PP, PVC
50 to 90 % wood fibres
tie resins, e.g. MAH
additives, e.g. UV stabilizers,
colours, MAPP and other materials
such as starch
Production is possible either by
extrusion of the wood and polyolefin
compound blends or by
direct extrusion of the raw materials.
In long test runs Reifenhäuser
has developed a technology
for processing wood chips
and plastic raw materials in cooperation
with Kosche, a leading
company in the timber industry,
BITRUDER twin-screw
extruders
A key component of the extrusion
line is the BITRUDER twin-screw
extruder with counter-rotating,
intermeshing screws that offers optimal
technical solutions. Twin-screws
and barrels are divided into segments
that can be combined according to
production requirements.
The BITRUDER series has been
specificly adapted for processing
wood fibre composites and offers
essential advantages thanks to its
parallel twin-screw design:
Gentle plasticising and good
homogenisation of the raw
materials. The plasticising units
with lengths from 25 D to 36 D
can be adapted to any special
requirements.
Screw heating-cooling system
allows melt temperature control.
Long pre-heating times
ensure a good degassing so
that wood with a higher moisture
content (up to 7 %) can be
processed.
Special screw segments ensure
high pressure build-up and thus
high output capacities at low
screw speed
Controlled degassing of the raw
materials and colour components
BITRUDERS for WPC extrusion
are available in a series of sizes
ranging from 75mm to 133mm.
Dies provided with several controlled
cooling zones (water/oil)
have been designed for the production
of wood/extrusion products
(WPC profiles and angle
slats).
The partner companies Kosche
and Reifenhäuser offer a complete
solution that covers the
whole processing chain for
WPC products. That means
from compounding the wood
chips to the extrusion of the
finished profile.
Extensive know-how and a range
of services form a comprehensive
concept that is unique so far.
WPC products offer the following
advantages compared to
wood/natural products:
higher strength, no risk of splittering
and cracking
increased resistance against
fungal decay and insect attack
bacteria and dirt repellent
easily selectable colours with
low fading properties
recyclable, etc.
Advantages over plastic products:
more favourable cost structure
with respect to raw materials
and production
higher stiffness
natural appearance and more
eco-friendly
Natural wood fibres Decking
Applications
WPCs are used for indoor and
outdoor applications in the construction
industry, e.g. as
decking and fence profiles
wall panels, window sills
angle slats and door frames
This versatility is regarded as very
positive in the USA and in Europe.
Compared to 2004, the WPC market
in Germany has doubled In
2005.
Reifenhäuser-Quality-
Service (RQS)
Upgrading of older extrusion lines
The technicians of the service
department consider it their
tasks to sustain the service lives
of Reifenhäuser extrusion lines
and to improve the performance
in an economically reasonable
manner.
Many projects have already been
successfully realized, e.g. modifications
to or implementations of
drive controls
temperature controls
PLC and visualisation systems
thickness gauges
A concept will be developed together
with the customer that is
adapted to his specific product
requirements, especially with
regard to the use of new raw
materials.
Initially an analysis of the present
condition of the extrusion line will
be made by the experienced RQS
service staff. Following this the
customer will receive a detailed
inspection report and a corresponding
quotation for modernizing
or upgrading his line.
Extrusion line performance may be
considerably improved through
several projects already undertaken:
updating the winding technology
of older film winders
modification of existing mono
film lines into more efficient
coextrusion lines
modifications for wide film
extrusion lines / factory modernization
Four wide film extrusion lines have
been extensively upgraded already
creating the basis for processing
modern raw materials and improving
the line performance. From
an economic view the ROI (return
on investment) can be achieved
very rapidly through the openingup
of new markets via higher quality
film products.
Single source for all services,
from project planning to
commissioning.
Advantages for the customer:
agreed fixed downtimes required
for modification of the
respective modules until the
complete line can be re-started
high line utilisation due to a
minimisation of downtime risks
The modification and upgrading of MFA winders manufactured over
10 years ago offer advantages through:
modern drive technology, improved winding quality, increased speed,
shortening of reel changing times by up to 20 % and reduction of
scrap. Safety aspects are in accordance with CE regulations.
improved film quality
reliable spare parts supply
rapid return on investment
The advantages of new mechanical
and electronic technologies are
being implemented with great
success by the well-established
experience of Reifenhäuser Quality
Service.
11

Teleservice
Teleservice
firewall
Teleservice
firewall
Router:
separates line from
customer’s network
Customer’s line
REICOFIL ®
Teleservice – the basis for a reliable long-term partnership
Spinbonding lines successfully
developed over a 20 year period
have led to a worldwide acceptance
of REICOFIL technology.
However, prime technology is
not the only hallmark of market
leadership, it is complemented
by customer service that is
provided for production lines
installed all over the world.
The REICOFIL service department
(RQS) in co-operation with the IT
department has established a teleservice
concept. Secure internet
connections are used by means of
VPN technology (Virtual Private
Network) to enable communication
12
Hub
Hub
between customers worldwide and
Reifenhäuser REICOFIL. Thanks to
the use of the internet, there is no
need to establish expensive individual
network connections.
If a VPN teleservice is requested by
a customer, Reifenhäuser
REICOFIL supplies the VPN firewall
appliances. These are designed in
a way that a secure connection
can be established only by the
counterpart installed at Reifenhäuser
REICOFIL. The complete
data will be encrypted and transmitted
via this connection through
a so-called tunnel.
Standard
firewall
Internet service provider
Reifenhäuser
Internet service
provider customer
Standard
firewall
Standard Ethernet
Physical connection
Logical VPN
connection
Secret pair codes have been
provided on both noidal points to
secure the transmitted data.
This ensures exclusive communication
between the two correlated
VPN appliances.
A VPN connection allows the
parent company in Troisdorf to
give rapid help and advice within
the framework of remote maintenance
in order to eliminate malfunctions
of production lines or
identify defective components,
etc.
Sub-suppliers of line components
who want to use the VPN system
require Client Software that will be
supplied by Reifenhäuser
REICOFIL on demand free-ofcharge.
A virtual private network
from the sub-supplier’s terminal to
the customer’s counterpart is
established by means of this software
in compliance with the above
security mechanisms.
When it is necessary to start communication,
the component subsupplier
has to request Reifenhäuser
REICOFIL to activate the
system which will be done using
the safety system. The dialogue
between supplier and customer is
recorded.
The schematic representation of
the teleservice system shows that
the data transmission is secured
by firewalls at both end points (red
line) and that connections from the
suppliers’ service computers are
also guided through these safety
control points (yellow line).
Applications
An important spinbonding customer
in Brazil has been provided
with a teleservice system. This
allows checking and maintenance
of the line in Brazil via a service
monitor in Troisdorf within a few
minutes of the internet connection
being established.
In accordance with the customer’s
requirements, the technician at
site or the service specialist in
Troisdorf can look at the parameters
and production data and
adapt them to provide rapid
assistance.
The teleservice system also offers
the possibility for planning and
upgrading the electrical equipment
of older lines with suitable components.
Advantages of the VPN teleservice:
Travelling times of service technicians
will be reduced,
especially overseas,
Support of the operating staff at
site
The production line operability
will be improved by efficient
remote maintenance
Concentration of diagnostic
knowledge
Software updates and expertise
from a single source
VPN teleservice is the basis for
a long-term partnership with the
customer.
REILOY Metall
Special flight armouring to protect extruder screws
from wear and corrosion
For more than 30 years Reiloy
has been successfully manufacturing
bimetallic barrels and
extruder screws tailored to the
requirements of the plastics
processing industry.
The present tendency in plastics
processing shows that fillers and
reinforcing agents are often added
to the classical raw materials. This
increases the risk of wear in the
plasticising unit when producing at
high throughput rates and high
temperatures.
Because of this trend, Reiloy has
carried out material developments
in its own laboratories to create
economic alloys to be used for
screw flight armouring.
These new iron alloys with a high
vanadium-carbide content (17 %
vanadium) are typically used when
processing highly filled thermoplastic
materials.
RC3 alloy based on ironvanadium-chromium-carbon
is
generally suitable for use on all
mono screws and offers a high
hardness due to its completely
crack-free arc welding property.
Trouble-free mechanical machining
of this armouring alloy is
possible, e.g. without the risk of
edge damage when milling.
RC1-P alloy is used for arc
welding on pre-manufactured,
milled screw flights and is particularly
suitable for twin-screw
extruders and for refurbishing
worn screws.
RV26 alloy with an increased
vanadium content of 26 % offers
good resistance against extremely
high corrosive wear. This applies
especially to extruders used in
foodstuff processing and cleaned
with very corrosive agents.
These armouring alloys are applied
by plasma powder transferred arc
welding (PTA) in a single layer.
The above alloys have cost advantages
over the typically used
cobalt-nickel based hard alloys
that require 2 layer welding.
Screw blank with welded flight armouring layer
These materials were developed in
Reiloy’s in-house laboratory and
the metal powders are produced
in its own gas atomizing plant.
They are processed using lines
partly developed in-house.
Reiloy’s claim is "All from a single
source - from the raw materials to
the finished component”.
13

REILOY Metall
Large centrifugal casting plant for bimetallic barrels taken into operation
New large centrifugal casting plant
POLYREMA
Polyrema has been successfully
active in the modernization of
used extrusion lines for many
years.
In addition, Polyrema has
developed a program for
modifying the proven mono
blown film lines of type 3.45 into
3-layer lines.
Two new Reifenhäuser extruders
(50 or 60 mm screw diameter) are
the core components of this concept.
Considerably increased output
capacities can be achieved in
combination with the existing
extruder.
Excellent tolerance distribution
and product quality are ensured by
a new 3-layer blown film die with
dual port spiral mandrel melt distributor.
14
Using its well established knowhow,
Reiloy has built a new large
centrifugal casting plant to its own
design in its manufacturing facilities.
This plant with a floor plan of
approx. 10 x 15 metres is able to
centrifically cast well-proven
protective lining layers in barrel
blanks up to 6 m long and
weighing up to 10 tonnes.
The new line considerably increases
the production capacity and
offers the advantage of manufacturing
large barrels that previously
had to be welded from 2 or 3
blanks, in one piece. This results
in a significant cost saving
potential since setting up times are
reduced and welding seams are
avoided.
Formula for success in second-hand lines
The output capacity can be almost
doubled using an internal bubble
cooling system (IBC) and a patented
Peak Power air ring. It is also
possible to upgrade the line with a
gauge control system (REIcoflow).
Downstream components, such
as sizing cage, haul-off unit, turner
bar and winder will be taken from
the existing film extrusion line.
After skillful preparation and provision
of the new components, the
line will be modified at the customer
within a short period of time
and without long production
downtime.
This modification offers the customer
the possibility to use new
technologies and to extend his
The plant includes the following
new developments:
Separation of heating-up and
centrifugal casting processes
using two roll stations
Barrels are heated in a protective
gas atmosphere so that
there is no need for chroming
High electric power of up to
4000 kW is available for heating
so that the heating-up time is
reduced considerably.
The fully automatic operations in
the centrifugal casting plant, from
material feeding up to the barrel
discharge, are micro-processor
monitored and controlled.
Reiloy is well prepared for the
future through the new centrifugal
casting plant.
product range without investing
high amounts of capital.
The upgrading concept for
second-hand machines is a further
element in Polyrema’s formula for
success.
3-layer blown film die with dual port spiral
mandrel melt distributor and Peak Power air
ring
REIMOTEC
Multi-layer monofilaments for the textile and artificial grass industries
High-performance lines for the
production of top quality, hardwearing
monofilaments and
strapping tapes have formed
Reimotec’s product portfolio for
many years.
Monofilaments supplied as finished
or semi-finished products are
available as:
thin filaments for screens used
in the paper industry, sewing
yarn and fishing lines
technical filaments for industrial
fabrics, zippers, ropes, technical
textiles
thick filaments for all kinds of
bristles and coarse filters
The range of raw materials processed
includes PP, HDPE, LDPE,
PET, PA6, CoPA, TPE and PVC. It
is also possible to use other types
of raw materials.
The monofilaments range between
0.08 and 4.00 mm diameter.
New products for the
monofilament markets
As a result of new developments,
Reimotec has created lines for the
extrusion of high-quality multifilaments
from different polymers.
These include bi- and tri-component
applications.
2-layer bi-component monofilaments
are extruded from similar
PE raw materials. The core layer
and the cover layer may have different
properties that can be achieved
by using additives.
A combination with black in the
core layer and white in the outer
layer provides a ready indicator of
filament abrasion. Filaments with
outer layers from materials with
lower melting points and with
cores made from materials with
higher melting points are used
where they are to be thermally
bonded. Antiseptic properties in
the core layer or electrically
conductive bi-co monofilaments
can be achieved by adding nano
particles to the pellets.
Cost savings in raw materials are
possible if recycled PET is used for
the monofilament core and PET
pellets for the cover layer.
3-layer tri-component monofilaments
are products of a higher
technical complexity than 2-layer
monofilaments. A tie layer
between core and cover layer is
used to combine polymers that do
not adhere to each other.
This technology a patent for which
has been applied for by Reimotec
is able to achieve tri-co monofilaments
with very different effects:
good abrasion resistance
inexpensive UV protection
dirt repellent properties
Microtome cut of a bi-component
monofilament;
white core: polyamide
black coating: tie resin
yellow-red colour around: clamping unit
spring-back capacity and good
sliding friction property of artificial
grass made from monofilaments
The multi-layer bi-co and tri-co
monofilaments are mainly used for
fabrics with special end applications.
Thin filaments are a further trend
followed in monofilament development.
They are especially used in the
textile industry. The required output
capacity for these products can be
obtained through increased hauloff
speeds.
Reimotec has successfully
developed a specific line concept
that allows haul-off speeds of up to
500 m/min to be achieved even
with small diameter filaments.
Twin spinning head for tri-co monofilaments
These products provide fresh
evidence of Reimotec’s successful
developments combining technical
innovations with customer requirements.
Gearless REItorque extruders and
Reitruder co-rotating twin screw
extruders from Reifenhäuser
together with Motech line control
systems form core components of
Reimotec lines.
15

Printed in Germany • Technical modifications reserved • E 5/2006
Reifenhäuser worldwide
Reifenhäuser is represented in all the world’s major markets.
In this way, we provide our clients with rapid contact and longterm backup for their extrusion lines.
The dependability of the Reifenhäuser organisation is assured by our own marketing subsidiaries
and over 60 agencies throughout the world.
Members of the Reifenhäuser Group:
Reifenhäuser REICOFIL
GmbH & Co. KG
Spicher Straße 46-48
53844 Troisdorf
Germany
Phone +49 (0) 2241 / 93 261-0
Fax +49 (0) 2241 / 93 261-744
info@reicofil.com
www.reicofil.com
Reifenhäuser A/S
Toldbodgade 16
DK - 6000 Kolding
Denmark
Phone +45 75-52 57 33
Fax +45 75-52 56 27
reifenhauser@email.dk
Reifenhäuser GmbH & Co. KG Maschinenfabrik
Spicher Straße 46-48 · 53839 Troisdorf · Germany
Phone +49 (0) 2241 / 4810 · Fax +49 (0) 2241 / 408778
info@reifenhauser.com · www.reifenhauser.com
Polyrema GmbH & Co. KG
Hertzstraße 12
53844 Troisdorf-Bergheim
Germany
Phone +49 (0) 228 / 96390-0
Fax +49 (0) 228 / 96390-29
info@polyrema.com
www.polyrema.com
Subsidiaries and service stations
Reifenhäuser GmbH & Co.
Office Moscow
Postbox 40
109028 Moscow
Russia
Phone +7 (495) 956 75 77
Phone +7 (495) 917 54 55
Fax +7 (495) 956 47 02
info@reifenhauser.ru
Reiloy
Metall GmbH
Spicher Straße 46-48
53839 Troisdorf
Germany
Phone +49 (0) 2241 / 481-511
Fax +49 (0) 2241 / 481-510
infors@reiloy.com
www.reiloy.com
Reifenhäuser Ltd.
Reifenhäuser GmbH
Service Centre
The Peak - Unit 604
107, Alfaro Street, Salcedo Village
Makati, Metro Manila
Philippines
Phone +632 811 35 17
Fax +632 811 35 33
rhmanila@broadbandphilippines.net
Sun Street
Tewkesbury, Glos. GL20 5NX
Great Britain
Phone +44 1684-299 666
Fax +44 1684-295 098
info@reifenhauser.co.uk
Reimotec GmbH
Reifenhäuser (India)
Marketing Ltd.
229, Udyog Bhavan
Sonawala Road · Goregaon (East)
Mumbai 400 063
India
Phone +91(22) 2875 6361
Fax +91(22) 2875 6362
reifen@bom3.vsnl.net.in
Reifenhäuser Private Ltd.
Asian Pacific Headquarter
25 International Business Park
#03-103 B German Center
Singapore 609916
Phone +65-65628740
Fax +65-65628749
rhsing@pacific.net.sg
Im Steinböhl 5
69518 Ober-Abtsteinach
Germany
Phone +49 (0) 6207 / 606-400
Fax +49 (0) 6207 / 606-30
info@reimotec.com
www.reimotec.com
Reifenhäuser Plastic
Machinery (Suzhou) Co., Ltd.
Dong Hu San Lu (Road)
Wuzhong Economic Development Zone
Suzhou · P.S. Code: 215 128
P.R. of China
Phone +86(0)512 656 860 36
Fax +86(0)512 656 860 31
info@reifenhauser.com.cn
Reifenhauser Inc.
Regional Headquarter
2 Washington Street
Ipswich, MA 01938
USA
Phone +1(978)-412-97 00
Fax +1(978)-412-97 15
customer.service@
reifenhauserinc.com