10. POLYCARBONATE LENS PROJECT
ď RESIN: PC (TYP 740-4) CLEAR
ď 100% CHECK ON BLACK SPECS
PROBLEM: SCRAP RATE ~ 20%
ď DEMAG 200-840
ď SCREW DIAMETER 45 MM
ď L/D RATIO 22:1
ď SHOTWEIGHT: 50 Grams
ď CYCLE TIME: 23 Sec.
TARGET:
ď IMPROVE PRODUCT QUALITY
ď REDUCE SCRAP RATE
11. 44,80
44,85 39,60
39,58
43,0
39,7
44,4
-0,05
-0,1
258
240
159
100
DIA 38,0
12,010,2
59,0
-0,1
-0,2
Âą 0,5
STAMP:â SN-XXXXXâ
â17-4PH+ ST12-L1
2 x 30°
SPLINES
OD= 44,4 -0,05/-0,1
CD= 40,0 -0,05/-0,1
NUMBEROFTOOTH = 21
1020
1278
45 MM SCREW
Drawn by: almh Date:
Drawingnr.: SCHR_291NOTES:REVISIONS:
5.
4.
3. MATERIAL: 17-4PH-ST12-L1
1. CUSTOMER:
2. I.M.M. DEMAG 200-560/840This drawing is the property of
NordsonXaloy-Europe GmbH. Reproduction or
disclosure of any part of this drawing
or information therein and the use
thereof for making other drawings or for
making apparatus therefrom are prohibeted
without priar written consent of NordsonXaloy-Europe GmbH.
⢠DISTRIBUTIVE MIXER
⢠LOW SHEAR
⢠LOW MELT TEMPERATURE
⢠SUITABLE FOR SHEAR SENSITIVE
RESINS
POLYCARBONATE LENS PROJECT
12. RESULTS:
ďCYCLE TIME REDUCTION: 3 seconds
ď SCRAP RATE REDUCED FROM 20 % to 1.5%
ďBASED UPON 6000 hrs:
productivity improvement 625000 pcs = 41%
ďTOTAL INVESTMENT ⏠5000 (screw only)
ďROI: 21 days
POLYCARBONATE LENS PROJECT
15. SN-#
4765 O.A.L.
395
1285
119,8
119,7
STAMP -
NOTE: STAMP NUMBERSSO THEYCAN
SPLINESACC. DIN 5480
BESEEN BYOPERATOR
130 MM SCREW FOR LGF
Drawn by: almh Date:
Drawingnr.: SCHR_458NOTES:REVISIONS:
5.
4.
3. MATERIAL:
1. CUSTOMER:
2. I.M.M.:BATTENFELD HM 19000This drawing is the property of
NordsonXaloy-Europe GmbH. Reproduction or
disclosure of any part of this drawing
or information therein and the use
thereof for making other drawings or for
making apparatus therefrom are prohibeted
without priar written consent of NordsonXaloy-Europe GmbH.
⢠DISTRIBUTIVE MIXER
⢠LOW SHEAR
⢠LOW MELT TEMPERATURE
⢠SUITABLE FOR SHEAR
SENSITIVE RESINS
AUTOMOTIVE PROJECT
23. Introducing , a heating coating
for barrels
A barrel heating technology that offers the:
ďą Best process control
ďą Most energy efficient
ďą Most reliable
ďą Most compact
ďą Safest
âŚbarrel heating system on the market today
24. What is ?
ďą Plasma sprayed metallized-ceramic heater
coating
ďą Pure resistive heating
ďą Simple retrofit of existing heater bands
ďą Eliminates exposed wires for maximum safety
ďą Supplied with thermal insulation
Plasma heater layer
Integrated heating technology
Easy to thoroughly insulate
25. Benefits
⢠Improved Process Control
ď Less Scrap â Higher Yield
⢠Superior Energy Savings
ď Reduces your costs & saves money
⢠Safer Operation
ď Less operator injury risk or fire potential
26. Improved Process Control
Non-uniform temperature distribution Uniform temperature---Fully insulated
What benefits could apply to your processes if you could rely on a 55% improvement
in temperature consistency shot to shot?
Temperature Response with Band-Heaters
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Temperature(o
C)
32
96
160
224
288
352
416
480
544
608
672
736
Temperature(o
F)
Temperature Response with SmartHeatTM
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Temperature(o
C)
32
96
160
224
288
352
416
480
544
608
672
736
Temperature(o
F)
27. Improved Process Control
ďą Uniform heat profile leads to a more stable process and
consistent part
Part Weight Variability
-0.5
-0.4
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
0.4
0.5
0 5 10 15 20 25 30
Cycle Number
DeviaitonfromMean(grams)
Conventional Barrel
New Barrel
Band Heaters
SmartHeat Barrel
28. Improved Process Control
ďą Ramps to target 30% faster using 23% less energy
ďą Response time to maintain temperature is quicker
29. Superior Energy Savings
ďą 30%-60% more energy efficient than band heaters
ďą Design watt density is 60% of band heaters
(1000 watt band heater = 600 watt SmartHeatâ˘)
ďą Virtually eliminates heat losses to the environment
ďą Save on A/C expense
ďą For process temperatures up to 750oF (400oC)
30. Superior Energy Savings
Lab Machine Trials -- Power Distribution Profile
(36 mm screw, PP, 28 sec cycle, 38 gram shot, 249o
C/480o
F melt)
0
200
400
600
800
1000
1200
1400
1600
Nozzle power Discharge Middle Feed
Power(watts)
A) Band-heaters -- not insulated
B) SmartHeat -- not insulated
C) SmartHeat -- insulated
50% Less Energy
over Heater Bands
31. Safer Operation
SmartHeat⢠barrels are supplied with a thermal insulation wrap and straps.
The complete system provides âCool to the Touchâ operator safety and the covered
electrical connections provide for significant fire hazard safety improvements.
32. Safer Operation
ďą Eliminate fire hazard from
numerous wires from multiple
heater bands
ďą All wiring run under
thermal insulation for safety
Elimination of all the loose wiring
33. Melt Pipes
SmartHeat Melt Pipe
⢠Uniform heat end to end
⢠No loose wiring (buried under the
insulation)
Conventional Heater Bands
⢠Non-uniform heat
⢠Loose wiring
34. Maintenance Free
ďą Eliminates heater band maintenance
ďą Simple retrofit to existing heater band wires and control
ďą Plastic resin easily chips off
Hardened resin just pops right off
35. Typical ROI
Southern US Southern U.S. (FL, TX, GA, AL, MS)
about 12 months air conditioning
Example
Customer: processor in Texas
Machine: 60 mm Engel machine
Utility Cost: $0.12/kWh.
ROI: about 12 months
38. Customer Testimonial
Siemon Company
55 Ton Milacron Roboshot Machine
8 cavity mold running Makrolon PC
Electrical Connectors
⢠ROI of less than 1 year
⢠Cut start up time by 50%
⢠80% Improvement in shot to shot consistency
39. Customer Testimonial
Piolax Corporation
50 Nissei FN4000 Machine
32 cavity mold â 24 sec cycle
Automotive Interior Parts
⢠Energy savings of 59%
⢠Multiple SmartHeat being ordered
40. on Melt Pipes
Features
⢠Uniform heater coating around the
melt pipe
⢠Integrated heating system with
SmartHeat⢠as part of the melt
pipe
⢠25% energy savings or more
⢠Eliminate band heaters and their
maintenance
⢠Resin will not stick to SmartHeatâ˘
coating
Benefits
⢠Consistent and uniform heating of
polymer providing a stable process and
fewer rejects
⢠Considerably less wiring creating a
safer, cleaner work environment
⢠Improved ROI using SmartHeatâ˘
⢠Less downtime when SmartHeat⢠is an
integrated part of the melt pipe
⢠Less downtime from cleaning
43. on Nozzles
Feature
⢠Eliminate nozzle band heaters and
all their maintenance
⢠Uniform heater coating around the
entire nozzle
⢠Resin will not stick to SmartHeat
coating
Benefits
⢠Less downtime when SmartHeat⢠is an
integrated part of the nozzle
⢠Consistent and uniform heating of
polymer providing a stable process and
fewer rejects
⢠Less downtime from cleaning
44. Superior Process Control
Better Shot Consistency
Stable, Uniform Heat Profile
Maximum Energy Savings
Maintenance Free
Extremely Durable & Safe
Summary