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SHEETEXTRUSION LINES
Our historyBandera was established in 1947 by Luigi Bandera and soon proved
to be a strongly expanding company, thus contributing to the actual
development of plastics processing industry in Europe.
In 1950 Bandera became a joint-stock company.
In 1960s - 1970s, company activities underwent remarkable expansion
to reach an industrial scale production, offering a wide and diversified
range of extrusion products (pipes, profiles, sheet).
In 1980s - 1990s the company was acknowledged as one of the leading
companies in extrusion line manufacturing field, in Italy and worldwide.
In 1998 Bandera received ISO 9001 Quality Certificate.
Bandera has recently focussed its product range on three main fields:
blown film, foil & sheet, and pipes (including specific technology for steel
pipe coating).
2
NewsBandera is headquartered in Busto Arsizio (VA), just a 10-minute drive
from Milan Malpensa International Airport. Bandera buildings were
recently renewed to combine industrial series production with quality
check procedures. The company is currently managed by Piero and
Franco Bandera, the founder’s sons, who are keeping investing in
technical improvements of production tools and machinery, and in the
company key source: human resources.
Please find below a brief description to better outline Bandera company:
3 production areas (100,000 sqm)
175 employees
ISO 9001 certified manufacture methods and procedures
A wide and complete range of full extrusion lines (pipes, blown film,
sheet and foil)
Engineering and R&D Depts, keeping Bandera on the cutting edge of
innovation
Bandera has recently allocated its manufacturing process in three sites:
B1: Administration and marketing offices, assembly department, test
room, and shipping department
B2: Screw, barrel, and extrusion head (CNC instrumentation)
manufacturing site
B3: R&D Department, with dedicated test rooms
Bandera is widely acknowledged as world leading manufacturer of sheet
extrusion lines.
Pushing on its broad expertise acquired over many years, its customer-
oriented philosophy and its R&D Dept efforts focussed on new applications
and technologies, Bandera is today able to satisfy the broadest range of
production needs. The configuration of the extrusion lines offered can be
arranged to suit the most demanding requirements in terms of layout,
automation, and ancillary equipment.
Best-selling standard sheet extrusion lines are outlined in this brochure.
Bandera is definitely proud of the top technical standards applied to its
extrusion lines. Any bandera extrusion line is manufactured to suit the
broadest customer needs. Perfectly tailor-made.
Sheet extrusion lines
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Process materials: ABS, HIPS, PE, PP, ASA
Standard thickness range: 1,5 mm ÷ 12 mm
Sheet width: up to 3000 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1200 Kg/h
Sheet extrusion line for shockproof products
Process materials: PS
Standard thickness range: 1,5 mm ÷ 7,0 mm
Sheet width: up to 900 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1200 Kg/h
Worldwide construction standardization of home appliances has led to
an optimization of the extrusion process size.
Finished product width ranges between 600 mm and 900 mm.
The extrusion line is equipped to provide high outputs. Production line
control is eased by sheet standardized width.
Sheet extrusion line for refrigerators
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Process materials: ABS, PS, PS-K, PMMA
Standard thickness range: 1,5 mm ÷ 12,0 mm
Sheet width: up to 3000 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1200 Kg/h
Sheet extrusion line for caravan and sanitaryware applications
Process materials: polyolefin resins
Standard thickness range: depending on finished product embossing
Sheet width: up to 3200 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 800 Kg/h
Available selection of finished product grammage, and non-wovens
coupling grammage to suit any customer requirements.
Sheet extrusion line for building and industrial applications
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Process materials: PMMA, PC, PET-G, PS-K, SAN
Standard thickness range: 1,2 mm ÷ 12,0 mm
Sheet width: up to 3000 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1000 Kg/h
The production of high quality acrylic sheet from PMMA and PC intended
for top-level prestigious architectural applications require specifically
arranged extrusion lines. Besides standard - and suitable - chemical
and physical-mechanical features, the finished product - in order to be
classified as fine optically superior product - must have outstanding
aesthetic characteristics, among others:
No blend residues
Requirement compliant hue
Brightness and transparency
Perfect blend of master batches and additives
No optical distortions
The must-have features for a valuable product.
L. Bandera has been investing in technical innovation for over 20 years to
offer superior-product manufacturing machines, focussing on high-tech
research aimed at ongoing process enhancement.
High optical quality sheet extrusion line and for acrylic products
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Estrusore bivite corotante
Process materials: ABS, PMMA, PET
Standard thickness range: 0,4 mm ÷ 12,0 mm
Sheet width: up to 2200 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1500 Kg/h
Masking unit for the application of sheet protective film
Due to optimal PET characteristics required for furniture applications,
Bandera extrusion lines feature co-rotating twin-screws - of which
Bandera is world-leading manufacturer.
The innovative corotating twin screw extruder L/D:52 grants multiple
advantages:
Outstanding venting efficiency: larger vacuum areas prevent process
material pre-treatments (drying and dehumidification process)
Quick colour switching over, due to minimized material residence time
Excellent mixing capacity
Power saving (-30% if compared to a single-screw extruder)
Multi material processing capacity obtained with standardized screw
geometry
Sheet extrusion line for furniture industry
Complete 3-layer ABS/PMMA extrusion line
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Process materials: polyolefin resins
Standard thickness range: 0,5 mm ÷ 2,5 mm
Sheet width: up to 7000 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 2000 Kg/h
Possibility of surface embossing, brushing and corrugating. The extruded
product shall guarantee weldability, resistance to atmospheric agents,
and suitable mechanical strength. The extrusion line can be designed
and manufactured to meet any customer requirements.
Sheet extrusion line for geoliners
Geomembrane extrusion line. Standard configuration layout
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3
Process materials: polyolefin resins, polyesters, glass fibres and mineral
fillers
Standard thickness range: 0.2 mm ÷ 3.0 mm
Sheet width: up to 2200 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1000 Kg/h
The line is equipped with no. 2 flat die heads.
Further to product application studies carried out by Bandera R&D Dept,
the mechanical resistance to elongation, tear, punching and drilling of
the extruded product is maximized.
Resistance to light, ozone, chemical agents, high and low temperatures,
fire (halogen and mineral filler free composition) and - needless to say
- water, is 100% guaranteed. The application range is extremely wide:
foundations, tunnels, subways, swimming pools, etc.
Sheet extrusion line for waterproofing applications
Extrusion line for waterproof applications. Standard configuration layout
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Sheet extrusion line for automotive Process materials: polyolefin resins, mineral fillers and powder stabilizers,
liquid plasticizers
Standard thickness range: 0.5 mm ÷ 3.5 mm
Sheet width: up to 2500 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 3000 Kg/h
Exclusive cutting edge technology for internal lining with both
aesthetic and functional purposes, intended for top-class vehicles
Dimensional stability even after thermoforming
High-performance soundproofing and thermal insulation
Over fifteen applicable formulations
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Process materials: polyolefin resins
Standard thickness range: depends on composite finished product to be
obtained
Sheet width: depending on composite finished product to be obtained
Sheet structure: composite, single-layer or coextruded
Hourly output: depends on composite finished product to be obtained
(coupling material grammage, and extrusion line output)
The line core feature consists in the in-line manufacture of a finished
product via “in-calender” coupling of semifinished reels (nonwovens,
paper, aluminium, etc.) with polyolefin sheet exiting the flat head.
Line accuracy and user-friendliness depends on the high level of design
and construction. The finished product, besides complying with coupling
chemical and mechanical requirements, features extremely refined
aesthetics.
Composite products obtained with coating extrusion lines have a wide
application range (from building and construction fields to food and
industry sectors).
Sheet extrusion line for coating lamination
Extrusion line for coating applications. Standard configuration layout
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Process materials: HDPE, PP (and high molecular weight resins ensuring
elevated chemical and physical-mechanical features)
Standard thickness range: 1.0 mm ÷ 40.0 mm (2 flat heads)
Sheet width: up to 3000 max
Sheet structure: single-layer or coextruded (twin-screw and/or single-screw
extruders)
Hourly output: up to 2000 Kg/h
The line is intended for semi-finished products for chemical-industrial
applications (liquid tanks), cut flatbeds, technical components (e.g.
flanges, gears, outsoles, etc.).
Being stress-cracking, and cut-, abrasion- and impact-resistant (typical
characteristic of some materials), high-thick sheet can be used in the
automotive field for external covers (e.g. pick-ups).
High-thick sheet extrusion lines outstand for their specific design.
Extremely high thicknesses require dedicated post-sizing in-calender
sheet processing and thermal stress relieving (for sheet dimensional
stability) to avoid issues at cutting and thermoforming stages.
Possibility to obtain blends with mineral fillers and straighteners
directly in line (extrusion line with co-rotating twin-screw extruders)
Calender equipped with hydraulic system for up-down displacement
(available sheet path up to down or down to up)
Movable and power-driven double roller bed. Independently
temperature controlled rollers
Multi-emission point X-ray heating system for sheet molecular
thermal stress relieving
High-thick sheet extrusion line
High-thick sheet extrusion line
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Process materials: PP, PET
Standard thickness range: 200 µm ÷ 1.2 mm
Sheet width: up to 1200 mm max
Sheet structure: single-layer or coextruded
Hourly output: up to 1200 Kg/h
Calenders in vertical, inclined or horizontal configuration, equipped with
chromium-plated (and super-finishing), satinized or embossed rollers.
Air blade systems and simple or double effect vacuum box for thin sheet.
Process materials: EVA (Ethylene Vinyl Acetate)
Standard thickness range: depends on finished product to be obtained
Sheet width: up to 2500 mm
Sheet structure: single-layer or coextruded
Hourly output depends on finished product to be obtained
The silicon photovoltaic module is normally obtained with sandwiched
together material layers - the so-called “laminated layer” - and with
other ancillary materials making the sandwich suitable for use.
As a standard, the laminated layer is made of the following materials:
Glass (4 mm thick, as a standard)
EVA - Ethylene Vinyl Acetate
Monocrystalline or polycrystalline cells
Backsheet (made of PET or glass)
Sheet extrusion lines for paper and cardboard industry
Sheet extrusion line for solar panels
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Co-rotating twin-screw extrudersSheet extrusion lines are increasingly provided with co-rotating twin-screw
extruders. A choice due to top flexibility and versatility offered by twin-screw
technology.
Co-rotating twin-screw extruders are thoroughly designed and
manufactured by Bandera. Extrusion screws are made in high
performance wear resistant XDBD steel, and extrusion barrels are made
in nitrided steel and/or bimetal alloy (screws and barrels consisting of
independent modular sections, accurately assembled).
Co-rotating twin-screw technical features - the result of R&D studies and
yearly expertise - offer the extrusion line several advantages, as follows.
Versatility and flexibility
The standardized geometry of the extrusion screws enables various
materials processing (PET, PP, PS, ABS, HDPE,LDPE, …) and ensures
no material stress, besides easing production control and schedule.
Possibility to process up to 100% ground skeleton material (industrial
waste), to manufacture products obtained by Chemical (dedicated
additives) or physical (gas injection) foaming processes, and to use
mineral filler powders, e.g. talc, calcium carbonate, titanium dioxide
(see photo here beside)
Mixing and self-cleaning
The intermeshing and co-rotating extrusion screws guarantee
minimized material residence time, together with quick and easy
colour switching, thus resulting in outstanding time and material waste
reduction - a peculiar characteristic deriving from the compounding
sector
Melt purification
The outstanding efficiency of the venting system (up to 10mBar ÷
15mBar residual vacuum, sufficient for the whole extrusion barrel)
allows for hygroscopic material processing with no need for material
pre-treatment (dehumidification, drying, crystallization, …).
Furthermore, it is undoubtedly worth mentioning that Bandera
technology is FDA approved in the food packaging sector
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Power saving
The important power saving ensured by co-rotating twin-screw extruders
is due to the reduced motor torque if compared with single-screw
extruders.
Power saving can be up to 35%, depending on process material.
Bandera twin-screw extruder production range is detailed in the table
below.
Co-rotating twin screw L:D ratio
2C 55 mm
34:1, 42:1, 52:1
2C 70 mm
2C 85 mm
2C 105 mm
2C 135 mm
2C 170 mm
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Single-screw extrudersSingle-screw extruders currently play an important role in sheet extrusion
line manufacturing. Today, Bandera offers its customers a wide range
of extruders to comply with all market needs in terms of productivity,
efficiency, and quality.
Bandera designs, manufactures and tests its machines independently
and manufactures extruders up to 380 mm in screw size.
Extrusion screws are made in nitrided steel. Possibility to apply special
wear resistant alloys onto the thread edge (Stellite or Colmonoy 56/57).
Extrusion barrels are made in nitrided steel and/or bimetal alloy.
Thanks to its long-lasting experience (Bandera single-screw extruder
No. 3 dates back to 1943 and is proudly displayed at Bandera premises)
and to several technological innovative enhancements over the years,
Bandera has always been a leading company in this field.
Sheet extrusion line production range is mainly divided into 2 categories:
Single-screw extruders for polyolefins and polyamide (PE, PP, PA, ...)
non vented (for processing non-hygroscopic materials)
Single-screw extruders for styrene and acrylic polymers (PS, ABS,
PC, PMMA, ...) vented (for processing hygroscopic materials)
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Single-screw extruders for polyolefins and polyamide (PE, PP, PA, ...)
Single-screw extruders for styrene and acrylic polymers
(PS, ABS, PC, PMMA, ...)
Single screw extruder L:D ratio
TR 35 mm
25:1, 28:1, 30:1
TR 45 mm
TR 50 mm
TR 60 mm
TR 65 mm
TR 75 mm
30:1, 35:1
TR 80 mm
TR 85 mm
TR 90 mm
TR 100 mm
TR 120 mm
TR 140 mm
TR 160 mm
TR 180 mm
TR 200 mm
Single screw extruder L:D ratio
TR 50 mm
35:1, 38:1
TR 60 mm
TR 65 mm
TR 75 mm
TR 80 mm
TR 85 mm
TR 90 mm
TR 100 mm
TR 120 mm
TR 140 mm
TR 160 mm
TR 180 mm
TR 200 mm
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Proper material loading and dosing into the extruder is undoubtedly one
of the key factors to be taken into account - in fact, it is considered the
first process variable. Single- and twin-screw extruders are equipped
with different dosing systems:
Continuous gravimetric dosing system, of the loss-in-weight type, for
co-rotating twin-screw extruders (the so-called starve-fed extruders)
Volumetric dosing system for single-screw and co-rotating twin-screw
extruders
Gravimetric dosing system of the batch type (by weights) for single-screw
extruders
Bandera designs and properly sizes various dosing systems to meet
any customer needs: the material can be dosed in different form, e.g.
granules, production waste, flakes, additives, masterbatch, filler powders
(mineral or otherwise). In case of low-density ground materials, the
single-screw extruder is completed with a force feeder to ensure utmost
process efficiency. Bandera prefers to include the above equipment into
the scope of the supply, so as to integrate full extrusion line control in the
general control desk.
Dosing and loading systems
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Melt filtering
Melt gear pump
Melt filtering is a key step of the extrusion process to ensure final product
quality. Besides, it is important to safeguard gear pump, extrusion head
and calender roller integrity, especially in case of recycled materials.
Standard filtering systems are hydraulically operated, and equipped with
filtering screen plates (2, 4, 8, …) for screen changing without production
interruption (continuous filtering) and without altering of foil/sheet
quality.
Process stability is ensured by melt pressure and temperature control,
arranged upstream and downstream of the filter.
The basic function of the melt gear pump is to grant constant melt flow
(i.e. under precise and constant pressure and output conditions) from the
extrusion head: high precision gearing is aimed at ensuring the finest
accuracy tolerances.
Gear pump dimensioning and design depend on process material
features and required outputs.
Due the integrated control system provided by Bandera control panel,
the operator can easily control production variables by regulating melt
gear pump parameters.
Process stability is ensured by melt pressure and temperature control,
arranged upstream and downstream of the pump.
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A feedblock for the production of sheet featuring A-B-A, B-A-C-D and A-B-A-C-D structure (picture and 3D layout above).
Here below, feedblocks for the production of 3- and 7-layer sheet.
Provided the very wide range of products required by the sheet sector
(raw materials, structures, thickness an width ranges, outputs, …), Ban-
dera flat heads are ad hoc designed and manufactured for each extru-
sion line. Besides, as a standard, they are equipped with a feedblock
whenever sheet structure is multi-layer.
The feedblock comprises a tempered and stabilized stainless steel case:
inner melt flow channels are superrefined and/or chrome plated.
Layer distribution is managed by interchangeable selector plugs and
apposite melt flow and orientation diverter valves.
Flow channels are designed and manufactured depending on process
material rheology and single layer output: these features are of core
importance for the utmost precise distribution of sheet layers.
Sheet extrusion line feedblocks
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An extrusion head (either single-channel or multi-channel) is made in
tempered and stabilized stainless steel: inner melt flow channels are
superrefined and/or chrome plated.
Flow channels are designed and constructed depending on material
rheology and global machine output.
Thermoregulation of head and lips is extremely accurate and involves
specifically designed high efficiency cartridge-type resistance heaters.
The extrusion head can be complete with several appliances, depending
on production needs, such as:
Internal or external decklers to easily and quickly adjust sheet width
Distribution bar to evenly distribute the melt flow over the entire sheet
width
Fast-gap adjustment system to regulate the gap by moving part of the
head body
Air blade systems and vacuum box for the production of thin sheet
In the pictures here below, manufacturing process and operation of
single-channel die head for the production of mid-thick sheet.
It is worth highlighting that in case of multi-layer sheet from different
rheology materials, the employ of extrusion heads with separate
channels is of the utmost importance for high-quality extrudate.
Multi-channel extrusion heads are more complex, besides requiring
independent thermoregulation and melt flow control.
Flat heads for sheet extrusion lines
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CalendersIn sheet extrusion and co-extrusion lines, the calender is the actual
process core, where material is sized and cooled at the extrusion head
outlet.
Calenders differentiate for several design and construction
characteristics, e.g.:
Configuration: horizontal, (15°, 30°, 45°, 60°) inclined and vertical
Roller closing system, i.e. hydraulic, pneumatic and mechanical
Roller gap adjustment, i.e. mechanical - manual, mechanical -
power-driven, pneumatic with special design valves
Width, diameter, and quantity of the cooling/calibrating rollers
Roller construction, i.e. spiral or transverse hole cooling
Roller cooling/thermoregulation, i.e. by water or by oil
Roller surface finishing, i.e. mirror polished, satinized, or embossed
Drive and electronic control
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Pushing on a number of calenders manufactured over the most recent
years and the expertise derived from a proactive cooperation with its
customers, Bandera meets the most various and demanding requests.
To continue along this positive trend and offer its customers an ongoing
professional service, Bandera has dedicated an exclusive product-
oriented staff to this series of extrusion lines. For process optimization
as well as for special production needs, Bandera calendering systems
are completed - among others - as follows:
Hydraulic system for calender vertical displacement (available sheet
path up to down or down to up)
Movable and power-driven upper and/or lower roller beds complete
with independently thermoregulated rollers
Multi-emission point X-ray heating system for sheet molecular
thermal stress relieving
Innovative cooling and polishingtechnology for composite sheet
23
Ancillary downstream equipment for semi-finished product further
processing:
Calender roller cleaning systems, power-driven, to reduce frequency
of line downtime
Idle and/or power-driven roller beds with independent thermoregulation
for calibrating high quality and high-thick sheet
Sheet ennoblement (lacquering, surface treatments…)
Infrared ray heating systems aimed at sheet thermal stress relieving
Various laminating systems for sheet ennoblement and/or composite
sheet production
Masking machine for the application of protective film on the extruded
sheet
Heavy-duty haul-off units
Multiple and combined longitudinal and transverse cutting systems
Side trim cutters and transversal sheet breakers
Blade granulators complete with granule conveying equipment
Manual stacking systems, either semi-automated or fully automated
Thin and/or flexible sheet winding systems
In-line extruded sheet quality control system, via video cameras and/
or polarized lights
Downstream ancillary equipment
Bandera ultimate machinery:
Calender roller cleaning system, by movable power-driven cart equipped with pneumatic pad and detergent solution distributor
Masking unit: installed on a longitudinally sliding roller bed. Calender roll control stations arranged underneath the roller bed
Single or multiple roller beds equipped with power-driven rollers temperature-controlled by dedicated thermoregulation stations
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Longitudinal “K” cutters with heated blades, sliding on roller bed
Transversal cutter for acrylic materials
Longitudinal cutting system with power-driven circular blades
Automatic stackers for shockproof and embossed materials
Transversal cutter for acrylic materials
Trim edge-cutting system with breaker
and belt conveyor to the blade granulator
Combined transversal cutting unit:
Guillotine-type (shear) and circular saw blade
Movable transverse cutting system with swarf exhauster
Automatic stackersfor high quality sheets
Haul-off unit and transversal cutting unit
for acrylic materials
25
Company/Factory LAN
EWon
Machine LAN
Operator Panel
Serial
PLC
PSTN, ISDN
Line control andcentralized managementThe centralized control of all extrusion line parameters has proved to be
a key factor in production management.
Markets have increasingly become sensitive about labour costs, quality
control, product traceability systems and connection to company network
(or remote connection) for production line software check and inspection.
To meet its customers’ - and prospects’ - needs, Bandera has designed a
specific software control architecture. The control system is based on an
industrial workstation for Windows operating system. The line master
PLC, interfaced with the industrial workstation, is in turn connected
with ancillary equipment PLCs and with single unit remote I/O module
via field bus. Due to the control architecture, all line parameters are
available for remote connections aimed at production control, material
management or remote assistance by Bandera technicians.
The user interface has been designed with special care - from hardware,
with a wide colour monitor to software, with intuitive synoptic graphics,
from which the operator interacts via the touch screen HMI. Bandera is
proud to mention that its customers have played a key role in Bandera
machine development: following their suggestions, today Bandera
machine quality definitely outstands on the global market.
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Bandera relies upon its specialists to support its customers with
an accurate after-sales service, both at the line start-up and
testing, and at the production stage. Cutting-edge technology is
at Bandera customers’ disposal, at any time.
In order to comply with its customers’ maintenance needs,
Bandera has established a dedicated efficient Aftersales and
Spare Parts Division.
Pushing on its high tech solutions, Bandera offers its customers
turnkey extrusion lines - from engineering and design to
construction, assistance and assembly stages. Besides, Bandera
has drawn up specific training programs dedicated to customers’
personnel - the best way to understand how to operate new
machineries and to retrofit existing ones.
Technical service
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PLASTICS MACHINERYEXTRUSION TECHNOLOGY SINCE 1947
Visit www.luigibandera.com to view Bandera complete production program
Costruzioni Meccaniche Luigi Bandera S.p.A.C.so Sempione, 120 | 21052 Busto Arsizio (VA) ITALY
Tel. +39 0331 398111 | Fax +39 0331 [email protected] | luigibandera.com
REV
3/SH
EET/
GB
/12/
11
Technical specifications provided for illustrative purpose only and subject to change without prior notice.
EXTRUDERSBLOWN FILM PIPES & COATING PELLETIZING