Finishing - May-June 2022

12 POWDER COATINGS
Increasing output
Baker Perkins has developed a new extruder increases output from a smaller machine
Baker Perkins has developed a new range
of High Power twin-screw extruders
delivering superior outputs on powder
coating and specialist chemical applications
from a smaller barrel, with reduced cost of
ownership and machine down time.
Increased power and speed are the key
attributes of the new HPX 45 extruder,
achieved by full utilisation of an 83kW motor
through torque stability provided by the
patented MAX³ feed system, and increased
thrust capacity of the solid-shaft drive train.
The HPX45 provides an average output of
750kg/hour, rising to 1,200 kg/hour on
specific applications – typically 20% higher
than an MPX50 machine. A full range of
HPX extruders is being developed; the MPX
series will be retained for powder coating
applications requiring through shaft cooling.
The HPX45 extruder handles a full range of
powder coatings and toners including the
most intensive formulations; it is
aimed at the small to medium
batch market producing 300-800
kg/hr of product, ideally suiting
100kg to 1,500kg batches.
The HPX retains all the latest
features of the MPX range. As
well as the MAX³ feed system
these include a hi-cool barrel
increasing efficiency and allowing
lower melt temperatures; a split
stuffing box for
increased
access; a
pivoting
main feeder
for easier
calibration
and
emptying; and
purge feeders
for quicker
turnaround
between batches. Noise
is minimised by using water
cooled main drive motors; a hi-cool
discharge adaptor and non-stick coating
minimise product hang-up at discharge.
MAX³ benefits
The MAX³ feed system incorporates a
fundamental re-design of the intake feed port
and screws. It improves the flow of material
into the extruder barrel and air out of it to
eliminate material build up in the extruder
infeed that leads to restricted output and
torque surges.
The system brings proven 40 to100%
throughput benefits; top feeding creates
improvements in operation that significantly
reduce cost-of-ownership.
Side feeders force product into the screws,
causing high levels of wear and the frequent
cost of replacement . The process creates
heat which can affect quality through pre-melt
of resin on the screws, which causes loss of
conveying capacity and is also a quality issue.
In contrast, top feeding directs material into
the process section of the extruder, without
pressure. There is minimal screw wear, no
heat build up, no pre-melt and no quality
problems. A major benefit is that lightweight,
low density materials are now handled more
efficiently.
State-of-the-art controls
State-of-the-art control features a touchscreen
HMI developed specifically for the
complete range of Baker Perkins extruders.
This provides clear, at-a-glance visualisation of
the process, including current status of all
major components and parameters. Options
include systems integration of upstream and
downstream equipment into a single control
point for the line.
All Baker Perkins equipment is supplied
Industry 4.0 Ready. This harnesses data
from all the machines, devices and sensors in
any manufacturing operation and enables
them to communicate with each other via the
Internet to make informed and timely
decisions. Alarm management and date
gathering are included.
Complete line capability
In addition to the extruder, a complete
process line comprises ingredient weighing
and feeding before, and cooling, flaking and
grinding after the extruder. Baker Perkins
works with a number of different partner
companies who can supply all the pieces of
equipment required to put together a full
process line. Each of our partner companies
specializes in their particular technology so
customers are assured of excellent
performance throughout the process.
Finishing - May/June 2022