1. Efficient colour compounding
New Technologies and Possibilities for
Flexible and High Efficient Production
www.roc-gmbh.com © 2015 ROC GmbH

2. Efficient colour compounding
Ø Efficiency
Ø Quality
Ø Monitoring
Flexible and Efficient Compounding© 2013 ROC GmbH 2

3. Efficiency
Ø Maximum usage of production capacity
Ø Less downtime
Ø Fast colour changes
Flexible and Efficient Compounding© 2013 ROC GmbH 3

4. Quality
Ø Less customer complaints
Ø Less off-spec production
Ø Operator awareness
Flexible and Efficient Compounding© 2013 ROC GmbH 4

5. Monitoring
Ø Continously monitoring of the production
Ø Continously monitoring of the process
Ø Immediate reaction possible
Flexible and Efficient Compounding© 2013 ROC GmbH 5

6. How can we achieve this while
the production is running?
Flexible and Efficient Compounding© 2013 ROC GmbH 6

7. Flexible and Efficient Compounding© 2013 ROC GmbH
Fast Color Corrections with
ROC-ColorControl
CIE-Lab/Spectrum
ROC-QualityReport
ROC-ValueAddProgram
M
Dryer Classifier
Pelletizer
Extruder
ROC-ColorDosage:
6 dosage units per line
M
ROC-ColorControl
Precision color measurement
on pellets in 2.5 minutes ROC-ContiSampling
Full automatic sample taking and transport
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8. Flexible and Efficient Compounding© 2013 ROC GmbH
ROC-ColorControl
Color Measurement on Pellets
Ø High precision color measure-
ment: CIE-Lab & Spectrum.
Ø Cutting defects and stress
whitening at pellet edges do not
disturb color measurement.
Ø Spectroscopic image processing.
Ø Full automatic operation.
Ø Self calibrating. Self monitoring.
Ø Sample temperature control.
Ø Fast: 25 measurements/hour.
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9. Flexible and Efficient Compounding© 2013 ROC GmbH
ROC-ColorControl: Repeat Accuracy Results
(25 repetitions with pellet position changes)
Sample L a b Segmentation Image
Yellow PC 76.32 15.00 69.96
Standard deviation 0.017 0.029 0.042
Green ABS 41.02 -27.84 13.12
Standard deviation 0.016 0.038 0.039
Red PA GF30 45.11 43.80 23.94
Standard deviation 0.059 0.045 0.051
White PVC 91.29 -1.16 3.12
Standard deviation 0.018 0.009 0.021
Blue PC 45.78 -9.84 -36.66
Standard deviation 0.015 0.015 0.015
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10. Flexible and Efficient Compounding© 2013 ROC GmbH
ROC-ColorControl: Repeat Accuracy Results
(25 repetitions with pellet position changes)
Sample L a b Segmentation Image
Mid Grey PP 01 47.13 0.93 1.46
Standard deviation 0.028 0.005 0.008
Black PP 02 25.69 -0.18 -0.71
Standard deviation 0.045 0.005 0.010
Mid Grey PP 02 48.34 0.91 4.96
Standard deviation 0.032 0.000 0.006
Black PP 03 26.63 -0.22 -0.94
Standard deviation 0.019 0.003 0.008
Mid Grey PP 03 43.43 -2.87 -2.58
Standard deviation 0.033 0.005 0.005
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11. ROC-ContiSampling
Full Automatic Pellet Sampling
Ø Sampling duration
60s up to 20min
Ø Up to 6 lines
Ø Immediate sampling possible
at any time
Ø Flexible sampling point
Ø Per line one carrier (no cross
contamination possible)
Ø No loss of material
Flexible and Efficient Compounding© 2013 ROC GmbH 11

12. © 2013 ROC GmbH
ROC ColorDosage for Shading
Single Pigment
Concentrates (SPCs)
ROC-ColorDosage
6 Gravimetric
Dosage Feeders
Extruder Inlet
Flexible and Efficient Compounding
Existing
Feeders
Only small quantities needed
for shading: 0.2 – 3 kg/h
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13. © 2013 ROC GmbH
ROC ColorDosage for Flexibility
Single Pigment
Concentrates (SPCs)
ROC ColorDosage
6 Gravimetric
Dosage Feeders
Extruder Inlet
Flexible and Efficient Compounding
Existing
Feeders
Typical dosage quantity:
2 - 4% of extruder throughput
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14. Ø Option:
flight conveying =
continuous pellet transport
© 2013 ROC GmbH
ROC ColorDosage System
Flexible and Efficient Compounding
Ø 6 gravimetric
dosage units
Ø Tool-free
cleaning
Ø Automatic
refilling
Ø For online
shading and
flexible
production
more yellow
more red
darker
more green
more blue
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15. 15© 2013 ROC GmbH
Fast Color Corrections: 28 Minutes, in Spec.
1. Too blue: Add yellow shading
2. Now too green: add red shading
3. Reduce yellow
ü
Off-spec In-spec
Confirmation with color
laboratory plaque: o
ü
ü
Shading
quantity
Extruder
capacity

16. Flexible and Efficient Compounding© 2013 ROC GmbH 16
Fast Color Changes: 3 Grey Shades: A-B-C-A
Changeover Duration: 5-8 Minutes

17. Online Color Changeover
Ø Color changeover from dark to light with running
machine in < 15 minutes possible.
Ø No cleaning needed for modern underwater pelletising
systems.
Ø Simple reworking of transition pellets.
Flexible und effiziente Compoundierung© 2013 ROC GmbH 17

18. Benefits
Ø Efficiency
w Increase of the production capacity
w Less downtime
w Fast Color Changes
Ø Quality
w Less customer complaints
w Less off-spec
w Operator awareness
Flexible and Efficient Compounding© 2013 ROC GmbH 18

19. Benefits
Ø Monitoring
w Continously monitoring of the production
w Immediate reactions possible
w Continously monitoring of the process
Ø Possibility to produce smaller lots
Flexible and Efficient Compounding© 2013 ROC GmbH 19

20. Flexible and Efficient Compounding© 2013 ROC GmbH
Higher Efficiency
Example order: 3000 kg, 500 kg/h
0 1 2 3 4 5 6 7 8 9
0 1 2 3 4 5 6 7 8 9 10
hours
hours
10
Color Plaque
Production in specification: 6h * 500kg/h = 3000kg
Pellet Color Meas.
Color Plaque
Dosage Correction
Premix Correction
10
6,7
Standard Process
ROC Shading Correction Process
Time savingProduction in specification: 6h * 500kg/h = 3000kg
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21. Thank you for listening!
Contact:
Business & Technology Consulting
Dipl.-Eng. Manfred H. Buechel
+4915256824345
ManfredBuechel@me.com
Flexible and Efficient Compounding© 2013 ROC GmbH 21