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 PVC, Cable and special compounds:
Cost-effective compounding and pelletizing as well as calender feeding.
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Frequently, a large number of product changes, small batch sizes, problematic storage and logistical tasks, or difficult processing conditions make direct extrusion of dry-blend into a finished part impossible. In these cases PVC must be compounded and pelletized in an intermediate step.
The plant diagram below shows a typical set-up of a PVC processing line – from dosing of the raw materials, through dry-blend manufacturing in the premixer, to the pellet cooling.
Coperion Werner & Pfleiderer, together with Coperion Waeschle, specializes in the designing and building of complete turn-key plants. The Coperion Werner & Pfleiderer two-stage compounding systems are equipped with a volumetric feeder, a vacuum degassing unit, and a pelletizer.
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| Hose. |
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Pipe fitting. |
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| Cable. |
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Plasticized PVC:
| - | | PVC cable: insulation, sheathing, and bedding compounds |
| - | | Shoe and shoe sole material (also PVC-P with blowing agent) |
| - | | Extrusion materials for profiles and hoses (including medical applications) |
| - | | Injection molding compounds |
| - | | Calendered film and sheets for flooring |
Rigid PVC:
| - | | Extruded profiles for interior and exterior uses |
| - | | Injection molding grades for fittings, etc. |
| - | | Blow molding grades such as bottles, containers, etc. |
| - | | Alloys and blends |
| - | | Films (calender feeding) |
Cable and special compounds:
| - | | Halogen-free, self-extinguishing formulations for cable (HFFR) |
| - | | Compounds for elastomer-based low, medium, and high tension cable |
| - | | Cross-linkable PE (incorporating peroxide) |
| Twin screw profile. |
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| Process steps |  | |
| - | | Feeding of PVC dry-blend from the hot mixer or heating-cooling mixer combination via ZS-B into the Kombiplast processing chamber or separate dosing of the components into the ZS-B |
| - | | Preheating, mixing and gelling the premix |
| - | | Possible feed of pigments (solid or liquid) directly into the processing chamber |
| - | | Degassing the compound in the transition chute, using vacuum |
| - | | Conditioning and building up pressure for pelletizing in the single-discharge screw |
| - | | Eccentric dry-cut pelletizing |
| - | | Pneumatic conveying and cooling in a fluidized bed |
| Kombiplast KP 58 Mc / 200. |
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| Kombiplast – the heart of the compounding plant | | |
Between the ordering of raw materials, the manufacture of dry-blend, and the bagging or transfer of the pellets to silos, comes the indispensable process stage of uniform shearing, homogenizing, and pelletizing the material formulations.
The Coperion Werner & Pfleiderer Kombiplast is the ideal plant for this requirement. It processes hot and cold dry-blend as well as individually dosed components to the required and desired product quality.
Example of a Kombiplast system
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Twin-screw side feeder ZS-B |
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Vacuum pump |
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Twin-screw Compounder ZSK | |
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Single screw |
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Granulation |
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Pellet cooler GFC | |
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