NIPA Cost Saving Workshop

Screw Design & Smart Heat

21/03/14

What costs should we reduce ?

Cost per Kg of output.

Cost per part produced.

Factors Include:

Kg or parts per hour

But good parts – minimize scrap.

Energy costs.

Output vs Screw Wear

.10 .20 .30 .40 .50 .60 .70 .80 .90 1.000

20

40

60

80

100

120

140

160

180

200

Screw Diameter = 120 mm. 130 RPM.

CLEARANCE PER SIDE in mm

GR

AM

/SE

C

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31118.20

118.40

118.60

118.80

119.00

119.20

119.40

119.60

119.80

120.00

Plot of Screw Diameter:

Measured

Max OD

Min OD

SC

RE

W D

IAM

ET

ER

mm

Special Coatings:X830 Hardfacing

Base Material

X8000TM Carbide CoatingStandard Surface Finish: (60 Ra)

Polished Surface Finish: Ra = 0.2 (16-32 Ra)

RATE OVER TIME

00

20

40

60

80

100

120

140

160

180

200

Screw 120 mm

TIME

RA

TE

GR

AM

/SE

C

____ = 4140/C56/Cr

____ =4140/X830/X-8000

Most Machines have ‘GP’ Screws

(‘General Purpose’)

(Or ‘Generally Poor’ ?)

(Or ‘No Purpose’)

Mixing Screw Illustration (Pulsar Mixer)

POLYCARBONATE LENS PROJECT

RESIN: PC (TYP 740-4) CLEAR 100% CHECK ON BLACK SPECS PROBLEM: SCRAP RATE ~ 20%

DEMAG 200-840 SCREW DIAMETER 45 MM L/D RATIO 22:1 SHOTWEIGHT: 50 Grams CYCLE TIME: 23 Sec.

TARGET:

IMPROVE PRODUCT QUALITY REDUCE SCRAP RATE

44,8044,85 39,60

39,58

43,0 39

,7

44,4

-0,0

5-0

,1

258

240

159

100

DIA 38,0

12,010,2

59,0-0,1-0,2

± 0,5

STAMP:“ SN-XXXXX” “17-4PH+ST12-L1

2 x 30°

SPLINESOD= 44,4 -0,05/-0,1CD= 40,0 -0,05/-0,1NUMBER OF TOOTH = 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 drawingor information therein and the usethereof for making other drawings or for making apparatus therefrom are prohibetedwithout priar written consent of NordsonXaloy-Europe GmbH.

• DISTRIBUTIVE MIXER• LOW SHEAR • LOW MELT TEMPERATURE• SUITABLE FOR SHEAR SENSITIVE

RESINS

POLYCARBONATE LENS PROJECT

RESULTS:

CYCLE TIME REDUCTION: 3 seconds

SCRAP RATE REDUCED FROM 20 % to 1.5%

BASED UPON 6000 hrs: productivity improvement 625000 pcs = 41%

TOTAL INVESTMENT € 5000 (screw only)

ROI: 21 days

POLYCARBONATE LENS PROJECT

NIPA Cost Saving Workshop

Screw Design & Smart Heat

21/03/14

AUTOMOTIVE PROJECT

I.M.M. BATTENFELD HM 19000 - 2700

SCREW DIAMETER 130 MM

L/D RATIO 26:1

SCREWSPEED MAX: 120 RPM

GOAL:

PROCESS PP + 40% LGF

SHOTWEIGHT: 4400 Grams

OVERALL CYCLE TIME: 70 Sec.

IMPROVE PRODUCT QUALITY

SN-#

4765 O.A.L.

395

1285

119,8119,7

STAMP -

NOTE: STAMP NUMBERS SO THEY CAN

SPLINES ACC. DIN 5480

BE SEEN BY OPERATOR

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 drawingor information therein and the usethereof for making other drawings or for making apparatus therefrom are prohibetedwithout priar written consent of NordsonXaloy-Europe GmbH.

• DISTRIBUTIVE MIXER• LOW SHEAR • LOW MELT TEMPERATURE• SUITABLE FOR SHEAR

SENSITIVE RESINS

AUTOMOTIVE PROJECT

RESULTS:

CYCLE TIME DEDUCTION: 4 sec = 5.7%

BASED UPON 6000 hrs: productivity improvement 18702 pcs = 6%

INCREASE IMPACT STRENGTH 10%

TOTAL INVESTMENT USD 88500 (screw,barrel,valve)

ROI: 270 days

AUTOMOTIVE PROJECT

Product: Bucket: 10 Ltr.Resin: PP MFI: 8Shot-weight: 584 GRScrew diameter: 98mm with LD = 25

OE solution 32,9 gr/revXALOY solution 35,5 gr/rev

Our design: MeltPro Barrier + Z-MixerInvestment: 7500 EUR

Benefit:• Cycle time reduction by 7.5%• ROI: 40 days

PACKAGING

TWINSHOT

The TWINSHOT® Co-Injection Technology enables a conventional machine with a single barrel and screw to inject two materials in a single shot with one material totally enclosing the other.

Twinshot loop-c.exe

SKIN RESIN: PP+20%CaCO2

CORE RESIN: Regrind PP+CaCo2+blowing agent

SHOTWEIGHT: 3800 Gr.

INVESTMENT: 117500

ROI: 160 days

TWINSHOT EXAMPLE

Nordson XALOY

PRESENTATION

Integrated BarrelHeating Technology

Sustainability requires True Innovation

nXheat®Induction heating

Mica band-heaters

Ceramic band-heaters

Infrared heater systems

Insulating blankets

SmartHeatTM

IntegratedMelt-Stream Heating

1950

1960

1970

20032006

2011

Melt-Stream Heating Evolutionary Timeline

Introducing

, a heating coating for barrelsA barrel heating technology that offers the:

Best process control

Most energy efficient

Most reliable

Most compact

Safest …barrel heating system on the market today

What is ? Plasma sprayed metallized-ceramic heater

coating

Pure resistive heating

Simple retrofit of existing heater bands

Eliminates exposed wires for maximum safety

Supplied with thermal insulation

Plasma heater layer

Integrated heating technology

Easy to thoroughly insulate

Benefits

• Improved Process Control Less Scrap – Higher Yield

• Superior Energy Savings Reduces your costs & saves money

• Safer Operation Less operator injury risk or fire potential

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)

Te

mp

era

ture

(oC

)

32

96

160

224

288

352

416

480

544

608

672

736

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)

Tem

pera

ture

(oC

)

32

96

160

224

288

352

416

480

544

608

672

736

Improved Process Control

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

De

via

ito

n f

rom

Me

an

(g

ram

s)

Conventional Barrel

New Barrel Band Heaters SmartHeat Barrel

Improved Process Control

Ramps to target 30% faster using 23% less energy

Response time to maintain temperature is quicker

Superior Energy Savings

30%-60% more energy efficient than band heaters

Design watt density is 60% of band heaters

(1000 watt band heater = 600 watt SmartHeat™)

Virtually eliminates heat losses to the environment

Save on A/C expense

For process temperatures up to 750oF (400oC)

Superior Energy SavingsLab Machine Trials -- Power Distribution Profile

(36 mm screw, PP, 28 sec cycle, 38 gram shot, 249oC/480oF melt)

0

200

400

600

800

1000

1200

1400

1600

Nozzle power Discharge Middle Feed

Po

wer

(w

atts

)

A) Band-heaters -- not insulated

B) SmartHeat -- not insulated

C) SmartHeat -- insulated50% Less Energy

over Heater Bands

Safer Operation

SmartHeat™ barrels are supplied with a thermal insulation wrap and straps.

The complete system provides “Cool to the Touch” operator safety and the covered

electrical connections provide for significant fire hazard safety improvements.

Safer Operation

Eliminate fire hazard from numerous wires from multiple heater bands

All wiring run under thermal insulation for safety

Elimination of all the loose wiring

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

Maintenance Free

Eliminates heater band maintenance

Simple retrofit to existing heater band wires and control

Plastic resin easily chips off

Hardened resin just pops right off

Typical ROI Southern US Southern U.S. (FL, TX, GA, AL, MS)

about 12 months air conditioning

ExampleCustomer: processor in Texas Machine: 60 mm Engel machine Utility Cost: $0.12/kWh. ROI: about 12 months 

Typical ROI Midwestern US (OH, MO, IN, CA) about 8 months air conditioning

Typical ROI Northern US (MI, MN, WI, MA)

no air conditioning

Customer Testimonial Siemon Company

55 Ton Milacron Roboshot Machine8 cavity mold running Makrolon PCElectrical Connectors

• ROI of less than 1 year

• Cut start up time by 50%

• 80% Improvement in shot to shot consistency

Customer Testimonial Piolax Corporation

50 Nissei FN4000 Machine32 cavity mold – 24 sec cycleAutomotive Interior Parts

• Energy savings of 59%

• Multiple SmartHeat being ordered

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 SmartHeat™ 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 SmartHeat™

• Less downtime when SmartHeat™ is an integrated part of the melt pipe

• Less downtime from cleaning  

on Melt Pipes

Application photos

on Melt Pipes

Application photos / Paragon Films

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  

Superior Process Control

Better Shot Consistency

Stable, Uniform Heat Profile

Maximum Energy Savings

Maintenance Free

Extremely Durable & Safe

Summary