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STRONG ON PERFORMANCE, VERSATILE AND HIGHLY COMPETITIVE ON COST 36D twin-screw extruders – pipe extrusion series
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STRONG ON PERFORMANCE, VERSATILE AND HIGHLY COMPETITIVE ON COST

36D twin-screw extruders – pipe extrusion series

IN PARTNERSHIP WITH INDUSTRY

KraussMaffei is a premium partner for the plastics and rubber processing industries worldwide

Whatever you aim to achieve in plastics or rubber

processing, KraussMaffei is your partner. We are

the only company with intensive expertise across

the three main engineering fields. And we have a

strong track record in integrating this expertise to

develop new processes and systems.

Ready for any challenge

Our Injection Molding Machinery Division

supplies machinery and systems from 35 to 4,000

tonnes for standard applications and for all

processing variants, together with fully automated

solutions. We have a strong customer base in all the

relevant industries worldwide.

Our Reaction Process Machinery Division supplies

machines and complete systems for processing

polyurethanes and other reactive materials.

Completing our product portfolio, Automotive

Component Systems supplies foam molds, cutters

and routers. Our customer base is wide, with a

focus on the automotive, construction and white

appliances industries.

Our Extrusion Technology Division supplies

machinery and systems for compounding, for pipe,

profile and sheet extrusion, physical foaming, and

the production of technical rubbers and inter-

mediates for tire production. Machinery from the

company’s range – from single extruders to

complete extrusion lines – is used in many

industries, including chemicals, pharmaceuticals,

automotive, construction, furniture and packaging.

People for Plastics

We are the “people for plastics”. We are your

partners from the first exploratory discussion,

through development to commissioning, servicing

and operating your system, and final disposal. At all

times, you are assured of outstanding competence

in planning and engineering, as well as reliable and

fast spare parts, service and support.

Adding value for customers

We put our expertise to work for your success.

With machine ranges engineered for modular-

ity, we can deliver application-specific solutions

based on our wide range of standard modules and

specially engineered solutions. This strategy offers

customers technical and cost advantages.

Close to customers around the world

As an international company, KraussMaffei has

a presence in all the major markets for the plastics

and rubber processing industries and employs

around 3,000 people worldwide. Our sales and

service network keeps us close to all our

customers around the world.

Electrical / ElectronicsLife SciencesConstructionWhite GoodsAutomotive

Electrical / Electronics Packaging

High throughput and top quality with 36D twin-screw extruders

Our parallel 36D series twin-screw extruders have been specifically engineered for PVC processing. Our aim is to ensure you a good return on your investment through a combination of high throughput and top product quality. The platform for our wide product range is a modular machine concept that enables customized production solutions for cost-competitive, high-performance pipe extrusion.

Look at the striking advantages. The specially designed screw concept enables very gentle and homogenous plasticizing. Long processing units ensure stable processes and very reliable production in many different applications. You profit from high output, consistently excellent product quality and an outstanding price/performance ratio – over the whole performance range.

TRANSPARENT TECHNOLOGY

Meet the machine: take a tour of a 36D twin-screw extruder

Gear lubricating unit for filtering and heating/cooling the gear oil

Choice of AC or DC drive technology

High-torque gear system

Horizontal metering unit

Gravimetric weighing

Vacuum degassing with a sturdy waste pipe and quick connection for easy cleaning

Mixer

Feed throat

36D processing unit with molybdenum-plated screws and deep-nitrided, air-cooled barrel

Vacuum degassing unit with double solids separator

Diagram showing a 36D extruder equipped for foamcore pipe extrusion

Blowing agent metering

Material hopper

Suction conveyor

DESIGN bASICS

36D twin-screw extruders with an optimized screw concept for ultra-flexible processing of PVC pipe compounds

The 36D twin-screw extruders with their HPG

(High Performance Geometry) screw concept

are ideal in every way for producing U-PVC and

M-PVC pipe, foamcore PVC pipe and PVC-O pipe.

High Performance Geometry (HPG)

The HPG screw design incorporates an effective

preheating length with an extended output and

mixing zone. The whole length of 36 L/D can

be used for processing the PVC compound. This

results in significant benefits for processors.

The long effective preheating zone means a high

degree of flexibility to process a range of material

formulations – and to deliver maximum output.

The long metering zone makes it possible to build

up a higher pressure; this makes for a very stable

process and optimal control of the melt tempera-

ture in the whole output zone. The long mixing

zone, together with the optimized geometry of

the mixer element, ensures a perfectly homog-

enous melt. They have a positive impact on the

dispersal of additives and blowing agent through

the melt. The HPG screw concept reduces process

fluctuations – for all grades of PVC pipe compound –

to an absolute minimum.

Processing zones in a 36D twin-screw

extruder screw

Technical data and dimensions 36D twin-screw extruder – pipe extrusion series

KMD 75-36 E/R KMD 90-36 E/R KMD 114-36 E/R KMD 133-36 E/R

Output range [kg/h] 210-540 300-770 480-1200 600-1550

Power output [kW] 57 75 117 166

Screw torque, max. [Nm] 9400 15 000 30 000 48 000

Screw speed, max. [min -1] 54 45.5 35.5 31

Screw length [L/D] 36 36 36 36

Screw diameter [mm] 75 90 114 133

Screw temperature system Internal Internal Internal Internal

Extrusion height [mm] 1000 1150 1150 1150

Dimensions [mm]

Length including intake 4600 5420 6680 8030

Width incl. operator console 1300 1400 1420 1700

Height incl. hopper 2420 2520 2580 2660

1 = Feed zone2 = Precompression zone3 = High compression zone

4 = Venting zone5 = Metering zone6 = Mixing zone

4466 55 22 22 22 22 11

15D15D 21D21D

33

Raw material costs can account for up to 90%

of the manufacturing cost of plastic pipe.

Material costs can be slashed by producing PVC

foamcore pipe on 36D twin-screw extruders

combined with the foamcore pipeheads developed

by KraussMaffei Berstorff. The 36D twin-screw

extruders deliver premium product quality. They

can be used as main extruders or as coextruders.

Foaming the middle layer of the 3-layer pipe

reduces its density to as low as 0.6 kilograms per

cubic decimeter. This reduces the total density of

the composite pipe by up to 30% compared with

compact PVC pipe. The use of PVC foamcore pipe

in non-pressure applications is on the increase, for

example, for waste water pipe.

CUTTING MATERIAL COSTS

PVC foamcore pipe – produced on 36D twin-screw extruders

Extruder combination for the production of PVC foamcore pipe comprising a KMD 75-36 E/R for the outer

and inner layers and a KMD 90-36 E/R to produce the foamed middle layer

Page 12 36D twin-screw extruders for pipe extrusion

DETAILED PRODUCT INFORMATION

Our modular extruder concept – the recipe for success with cost-effective, customer- specific solutions

Like all the extruders built by KraussMaffei

Berstorff, the twin-screw extruders in the

36D series are engineered to an intelligent

modular design.

The extruder concept

Starting with a universal machine frame and

a standard barrel, KraussMaffei Berstorff can

supply customized extruders closely matched to

customer requirements. A closed-loop controlled

metering unit with a conveying spiral ensures

constant specific melt throughput, even with

different formulations. The metering unit is part

of the standard system. For a fully-automated

extrusion process, we also offer the option of

gravimetric weighing. This supports a highly

consistent process and lets processors make the

most of the potential for material savings. All

KraussMaffei Berstorff twin-screw extruders are

fitted with deep-nitrided barrels, manufactured

using a nitrided steel grade which produces an

extremely hard surface in the barrel bores. The

parallel screws are armored with a patented

molybdenum layer as standard. The molybdenum

armoring on the screw flights and the nitrided

barrel are an ideal friction couple, offering very

good surface slip characteristics and keeping

wear to a minimum.

Air-cooled barrels

The air cooling unit is part of our standard

system. The system uses aluminum half shells

with cast-in heating coils and integrated cooling

fins. The temperature sensors are fitted to the

sides of the barrel between each pair of cooling

blocks so as to keep control circuits as short as

possible. The system is completely maintenance

free. There is no risk of scaling, which can occur

with copper fins, so that constant high heat transfer

is always guaranteed.

Cooling fan

Aluminum cooling blocks with cast-in heating coils

Big savings in pipe manufacturing costs through

the use of fillers or by foaming the core layer

cannot be allowed to impact on pipe quality.

Special metering unit for high filler content

In the fiercely competitive PVC pipe market,

where producers are face constantly increasing

pressure on prices, there is a strong trend towards

taking filler content as high as possible. This is

especially the case for waste water pipe, but also

increasingly for pressure pipe. Producers not only

need to increase filler content, but also to obtain

very high output and meet market demands for

perfect product quality. Formulations with high

chalk content (up to 60%) demand significantly

higher energy input to process and this is

optimally satisfied by a longer effective

preheating zone. The 36D twin-screw

extruder range meets these technical

challenges with ease. The extruder is

fitted with a horizontal-vertical metering

unit to process compounds with a high

chalk content (over 30%). An optional

metering unit for regrind can also be

integrated. The 36D design guarantees

absolutely reliable degassing for normal

and highly-filled PVC compounds.

DETAILED PRODUCT INFORMATION

Lower material consumption and constant product quality – with twin-screw extruders from our 36D series

KMD 90-36 E/R equipped to process highly-filled PVC compounds

Horizontal metering unit with corotating twin metering screws

Gravimetric metering for regrind

Color metering

Vertical metering unit

Page 10 Detailed product information

Mobile operator panel

(option)

KraussMaffei Berstorff standard operator panel:

integrated in the control cabinet

Swivel-mounted operator panel (option)

DETAILED PRODUCT INFORMATION

The C5 control – one of the most advanced control and monitoring systems in the industry

Centralized control of the extrusion line

Meeting tough specifications for product quality and

output demands a stable, reliable production process.

This is where the C5 control system scores. As one of

the most advanced systems in the industry, it offers

dependable technology and intelligent functions for

centralized control and monitoring of extrusion lines.

For the operator, the C5 ensures optimal set-up and

start-up, and a clear, consistent overview of the pro-

duction process. Monitoring and control is facilitated

by efficient visualization of the status of different

extrusion line components on a series of screen pages.

Central synchronization of the whole line, including

multiple extruders, is fast and simple. The operator

panel allows direct intervention in the operation of

all key elements in the extrusion line. The current

operating status of the whole line is always displayed,

together with a customizable selection of seven actual

parameters. Prompts and alarm messages flash up

in your chosen language. The C5 offers extensive

documentation options and easy connection to a host

computer. The standard design features an integrated

operator panel; swivel-mounted or mobile panels are

offered as options. The swivel-mounted panel, for

example, enables the operator to run the whole line

from a position near the die.

Page 15

CUSTOMER bENEFITS AND APPLICATIONS

36D twin-screw extruders – pipe extrusion series

The parallel twin-screw extruders in our

36D pipe extrusion series are specially engineered

for processing PVC dryblend and highly-filled

PVC compounds, and for production of 3-layer

PVC foamcore pipe.

Your benefits at a glance:

· Low maintenance thanks to internal screw temperature control and air-cooled barrels

· Optimal control of the melt temperature over the whole output range

· Reliable degassing – also for highly filled compounds

· Higher pressure build-up thanks to longer metering zone

· High output and perfect product quality

· More flexibility with a wide processing window for different formulations

· Optimal plasticizing and mixing, eg, of masterbatch

· Outstanding melt homogeneity

· Optimized mixer geometry for excellent mixing

· Low compression ratio in the high-compression phase

· Cost savings from extended service life for the processing unit, higher output and less load on the gear system

· Outstanding price/performance ratio

Customer benefits and applications

PVC foamcore pipe

Highly filled PVC pipes

Socketed PVC pressure pipe

PVC pipes for pressure and non- pressure applications

Rely on us for a fast and competent response to

all your service needs anywhere in the world.

Whatever you need – from troubleshooting and

training to spares or repairs – we’re on the job.

We’re dedicated to supplying service quality on a

par with the outstanding quality of our machines

and systems. We offer far more than spare parts

and hotlines. We’ll work with you to choose the

best and most cost-effective solution for your

operation. We’ll help you test new applications

and we’ll plan customized service packages.

All-round service

Our service offering is broad. We’ll configure your

system, install and commission it, train your staff,

plan measures to minimize your downtime risk and

maximize productivity, and carry out maintenance,

repairs and upgrades. You’ll find us fast, reliable

and competent. Our hotline is manned by highly-

trained and experienced service technicians.

If necessary, we’ll get a technician to you quickly.

Remote diagnosis, interfacing directly with your

machine’s control system, can be a practical

alternative. Spares for all important wear parts are

available at short notice. We’re continuously

expanding our service network to speed up spare

parts shipment. Talk to us about the right service

solution for your business.

Customer trials and prototyping in our test lab

The Extrusion Division operates a test lab fitted

with the latest machinery and equipment. We can

run trials, produce prototype parts and fine-tune

processes on your behalf. We can work with you

to test and evaluate processes, machines and

equipment in order to identify the best approach

for a particular project. Our highly-qualified

application engineers are there to help you.

Training with high hands-on content

Courses are held in our lab and training centre,

or, optionally, on your premises. We offer

clearly-structured basic and advanced training in

operation, process control and maintenance for

KraussMaffei extrusion systems. On request, we’ll

plan and hold special courses on topics of your

choice. All participants spend a high proportion

of their training working hands-on with original

KraussMaffei machines. A well-structured

training program produces skilled operators

and technicians, which will positively impact

your up-time and productivity.

SERVICE WORLDWIDE

Service, support and spare parts – when you need them, where you need them

Worldwide hotlineWorldwide hotline numbersnumbers

Extrusion Technology ServiceExtrusion Technology Service

KraussMaffei Technologies GmbHKraussMaffei Technologies GmbH

Krauss-Maffei-Str. 2Krauss-Maffei-Str. 2

80997 Munich80997 Munich

GermanyGermany

Contacting us by postContacting us by postIf you need to contact any of our

international service or spare parts teams

by post, use this address:

KraussMaffei Technologies

India Pvt. Ltd.

Pune, India

Phone: +91 20 41404610

Fax: +91 20 414046 99

Email: [email protected]

Krauss-Maffei Extrusion

Technology (Zhejiang) Co., Ltd.

Jiaxing City, China

Phone: +86 573 86973888

Fax: +86 573 86967111

Email: [email protected]

KraussMaffei Technologies GmbH

Munich, Germany

Customer Service

Phone: +49 89 8899-2273 (electrical systems)

Phone: +49 89 8899-4380 (mechanical systems)

Email: [email protected]

Application Engineering

Phone: +49 89 8899-4094

Fax: +49 89 8899-2161

Email: [email protected]

Krauss-Maffei Italiana S.r.l.

Abbiategrasso, Italy

Phone: +39 02 94963181

Fax: +39 02 94699482

Email: [email protected]

Berstorff Krauss-Maffei OOO

Moscow, Russia

Phone: +7 495 9377554

Fax: +7 495 9701731

Email: [email protected] Krauss Maffei Corporation

Florence, USA

Phone: +1 859 2834307

Fax: +1 859 2830290

Email: [email protected]

Krauss Maffei de México

S. de R.L. de C.V.

Mexico City, México

Phone: +52 55 53082383

Fax: +52 55 53081727

Email: [email protected]

Krauss Maffei do Brasil Ltda

São Paulo, Brazil

Phone: +55 11 46129171

Fax: +55 11 46128366

Email: [email protected]

Krauss-Maffei (U.K.) Ltd.

Warrington, UK

Phone: +44 1925 644100

Fax: +44 1925 234284

Email: [email protected]

KraussMaffei Technologies GmbH

Krauss-Maffei-Strasse 2 ··· 80997 MunichPhone +49 89 8899-2546 ··· Fax +49 89 8899 - 4043www.kraussmaffei.com

KraussMaffei is a premium partner for the plastics and rubber processing

industries worldwide. KraussMaffei machines and systems are used wherever

plastics and rubber are converted into products. As a knowledge-driven

technology company, we build on many decades of experience and a strong

commitment to research and development.

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Our 36D twin-screw extruders have been engineered specifically for optimal processing of PVC formulations and for an outstanding cost-benefit ratio. With a wide product portfolio, based on our modular machine concept, we can offer application-specific production solutions which are high-performance and extremely cost-effective. Your decisive benefits include the specially engineered screw concept for very gentle, homogenous material processing. Long processing units increase the stability of the process and ensure a highly reliable production system across a wide range of applications. You profit from high output, constant product quality over the whole output range and an outstanding price/performance ratio.


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