Agenda - Tuesday, October 13

Tuesday General Sessions

8:00am-8:30am Data Collection and Analysis in Extrusion


Presented By: Chris Rauwendaal, Rauwendaal Extrusion Engineering Current data acquisition systems tend to be expensive, difficult to use, and often present the user with an overwhelming amount of data. If a DAS is not user friendly it will not be fully utilized or not used at all. In this paper, we present a new data collection & analysis (DCA) system that is not only user-friendly but also provides the user with an analysis and interpretation of the data. This DCA system focuses on the vital signs of the extrusion process rather than all process variables. The vital signs are melt pressure, melt temperature, and motor load. In addition, the system will monitor screw speed and line speed. The customer will be able to see trend plots of the vital signs on their extrusion line and elsewhere using internet connected devices. The system will be cloud-based. The unique part of the system is that it performs in-depth analysis of the data and provides the results on this analysis to the customer. This will allow determination of the level and nature of the process variation. The DCA system can detect problems and determine when maintenance is required for certain parts of the extruder. The system will also be able to provide remote troubleshooting using the process information we collect. The system provides status reports to the customer on a regular basis. The DCA system will measure and collect data 100 times per second. At this data collection rate short-term variation can be accurately assessed. Systems that collect data once per second or slower cannot accurately determine short-term process variation over a time period less than one second. This is problematic in extrusion because every extrusion process is subject to short-term variation. Add to MyShow Planner




8:30am-9:00am How Comprehensive Real-Time Monitoring Assists Operators in Extrusion


Presented By: John Christiano, Davis-Standard Add to MyShow Planner




9:00am-9:30am What Causes Catastrophic Failures of Screws?


Presented By: Tim Womer, TWWomer & Associates Premature screw failure or breakage is, typically, not due to poor screw manufacturing but, more likely, due to incorrect processing parameters, inadequate maintenance procedures or poor screw design for the material being processed. this presentation will explain some of the reasons why screws commonly break or wear out prematurely, and some of the "Dos and Don'ts" in extruder operatioins and maintenance. Add to MyShow Planner




9:30am-10:00am NETWORKING BREAK


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10:00am-10:30am Drying Tips for Medical-Grade Polymers


Presented By: Mark Haynie, Novatec Add to MyShow Planner




10:30am-11:00am One-Step Size Reduction: The Latest Developments in Shredding


Presented By: Dana Darley, Vecoplan LLA A review of the latest vertical and horizontal shredding systems for processing all types and shapes of extruded scrap down to usable particle size. Traditionally, shredders have been limited to particle sizes of 1" to 1-1/2”, requiring further size reduction through a granulator to reach the required 3/8" or smaller particle size for re-processing. The challenge has been to move cutting technology from a pierce and tear approach to more of a cutting action, simulating the cutting action of granulator blades. The second challenge is cutting power and capacity…shredders are typically setup for high cutting power, with limited cutting capacity. One-step size reduction requires both high power and high cutting capacity, all while managing processing temperatures. Higher rotor speeds, cutting torque and number of cutting tools, also puts increased demands on the shredder design, which must be much more robust. The Vecoplan VIZ vertical and VKH horizontal represent the latest in size reduction technology, making one-step size reduction for a growing number of applications a reality. Add to MyShow Planner




11:00am-11:30am Blending and Control Options for The Extrusion Processor


Presented By: Bob Creppon & Frank Kavanaugh, Maguire Products Technology advances in gravimetric blending and control systems have allowed extrusion processes of all kinds better control their material usage while improving the quality of the products they produce. Add to MyShow Planner




11:30am-12:00pm Where to Remove Fines and Streamers


Presented By: Joe Lutz, Pelletron In today’s market place, clean resin without streamers and with a remaining dust content below 50 parts per million (ppm) is the requirement. Many resin producers find it difficult to meet this standard with their existing pneumatic conveying and dust removal systems. Therefore, these contaminants need to be removed before your extrusion process so that the material that you melt is free of streamers and dust. Melting clean material yields better quality end products and less maintenance headaches. Fortunately, there are various established methods for minimizing the generation of dust and streamers and efficiently removing these contaminants. Unfortunately, there is no “one size fits all” solution. One simple approach is to modify an existing high-speed dilute phase pneumatic transfer system into a custom designed Strandphase® transfer system that uses lower velocity conveying gas. Along with replacing standard pipe bends with special elbows like the Pellbow, you can drastically reduce attrition created by conveying your material. Test results show the convey gas velocity and the type of elbow used is directly proportional to dust and streamer generation. A video demonstrates how the proprietary Pellbow works. Even the most efficient conveying system will still create some dust and maybe even some streamers. The best way to remove dust and streamers is using a dedusting system designed specifically for granular plastic products. The Pelletron DeDuster is designed to remove even electrostatically charged dust and very long streamers in one system. Every application is different but it is recommended that a DeDuster® be mounted directly to the inlet of an extruder, injection molding machine or packaging silo outlet to ensure the best quality material is being used downstream. A video demonstrates the working principle of the DeDuster. Add to MyShow Planner




12:00pm-1:00pm Lunch Presentation: Is Old Technology Thwarting Your Ability to Attract Employees


Presented By: Dustin Barlow, Integrated Control Technologies Imagine that a Millennial took a job at a call center and all they had to work with were rotory phones. Although the company had good benefits and there was a history of life-long employees, the new employee became quickly frustrated and resigned. It might be the conclusion of the management that the next generation was not as loyal or had the level of commitment of previous generations. Although there may be some truth to that statement, it has nothing to do with their resignation. Therefore, it is possible that machinery utilizing obsolete technology for control can result in poor employee retention as well as keeping the best and the brightest employees away. This presentation discusses this and how making the proper investments in your machinery today will help guarantee a more profitable future and attract better employees. Add to MyShow Planner





Tuesday Film & Sheet

1:00pm-1:30pm Trends in Melt Filtration for Sheet


Presented By: Monika Gneuss, Gneuss Inc. Screen changers or other melt filtration devices play a key role in extrusion applications in removing contamination, such as paper, wood, aluminum foil, rubber, gels or other unwanted plastics. Filtration is a requirement for most extrusion lines today and can have a significant impact on the production line efficiency and end product quality. At the same time, melt streams are becoming more and more contaminated, as processors are using more reclaimed materials. Reclaim source, whether industrial or post consumer, and desired filtration fineness play an important role when choosing the right filtration technology. Rotary Melt Filtration systems can offer solutions for challenging applications. Several case studies will be presented. Add to MyShow Planner




1:30pm-2:00pm Screw Design Differences Between Smooth Bore Designs, and Grooved Feed Extrusion Applications


Presented By: Walter Smith, Xaloy Extrusion screw designs are designed differently, depending; if the machine is a smooth bore machine, or a grooved feed machine. The screw designer also, must take into account the machine configuration, whether the machine is a (2) piece configuration, or a one-piece; thru barrel configuration. The (2) piece configuration is a seperate feed section, bolted upstream of the extrusion barrel, with an air gap between the two peices, thermally isolating the barrel, from the feedblock. The one-piece configuration, is a one piece, thru barrel, with the feed port machine into the barrel itself, which is not theramally isolated. Add to MyShow Planner




2:00pm-2:30pm Challenging the Limits of Thin-Gauge PP


Presented By: Sushant Jain, Processing Technologies International Producing high-tolerance thin gauge sheet has its challenges, but is successfully managed when weighing the variables involved and the equipment needed. What constitutes thin gauge for various materials will be defined, along with the technological requirements needed for successful processing, reliability and maintenance. Environmental sustainability and cost savings involved with light-weighting will also be discussed. Case studies for various thicknesses will examine the thermal analysis to time comparisons trials (the critical first 40 – 60 milliseconds for fractional millimeter sheet) and the rheological homogeneity of the melt curtain.




2:30pm-3:00pm Troubleshooting a Film Extrusion Process with Rheology and Flow Simulation


Presented By: Oliver Catherine, Cloeren Inc. Film extrusion and coextrusion have become extremely competitive and are increasingly complex. Troubleshooting such an operation is equally complex due to the components involved in an extrusion line. In this presentation, we will review examples of troubleshooting such a complex process using advanced analytical tools form the polymer characterization lab as well as numerical tools such as flow simulations. Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Process Conditions & Procedures to Reduce Waste and Optimize Efficiency & Quality in Extrusion


Presented By: Thomas Bezigian, PLC Technologies Film & Extrusion Consulting Extrusion is now a commonplace technology used in a wide number of fields such as blown and cast film, cast sheet and profile extrusion. Despite the extensive physics, chemistry and other science and engineering expertise required to accomplish modern extrusion processes, extrusion basically remains a commodity process. Manufacturers around the world strive for maximum output and minimum waste and efficiency. Quite often management is unaware of the negative effect that some scheduling and manufacturing practices have on product quality, waste and efficiency. This paper will focus on these issues and reduce the mathematics of chemistry and physics into wisdom and practices that will result in improved product quality and efficiency, as well as reduced waste. Add to MyShow Planner




4:00pm-4:30pm Recycling Poly-anything


Presented By: Simon Jay, Plasmac This paper will present some case studies of recycling some previosuly un-recyclable materials such as 9 layer barrier films and laminations of PE / PA / EVOH and Aluminium products and how in this era of the Circular Economy Plasmac is helping its customers meet their targets (and those of the brand owners) in stopping plastic based products from going to landfill. By repelletising these products and finding new applications for the material produced, these previosuly un-recyclable products now have a value to the business and reduce the businesses impact on the environment. Add to MyShow Planner




4:30pm-5:00pm Non-Nuclear Online Sensors for the Direct Thickness Measurement of Polymer Film and Sheet


Presented By: Eric Reber, Mahlo The extrusion industry has lived with the use of nuclear gauges (Beta, Gamma) for the online measurement of film and sheet "thickness", even though these types of gauges really measure basis weight from which thickness must be inferred. If there are density changes in the extrudate caused by the addition of colorants, opacifiers, or any other chemical additives, then the thickness calibration of the basis weight gauge will shift which can result in significant errors. Advances in UV, visible and infrared optical interferometry have resulted in a family of online direct caliper sensors for the measurement of films down to sub-micron thicknesses. Also, Improvements in high resolution optical distance sensors are now replacing nuclear basis weight gauges for the direct thickness of extruded sheet. The physical principles of these sensors are presented along with their real-world performance in industrial manufacturing environments. Add to MyShow Planner




5:00pm-6:30pm OPENING RECEPTION


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Tuesday Compounding

1:00pm-1:30pm A New Simulation Tool for Flow Analysis in Corotating Twin-Screw Extruders


Presented By: John Perdikoulias, Compuplast A newly-developed simulation software is used to analyze the performance of closely intermeshing self-wiping corotating twin-screw extruders. This software implements simulations based on a macroscopic composite model for non-isothermal plasticating extrusion of polymeric materials enabling the computation of simulation results within a few seconds. It can be used for design and optimization purposes for conventional as well as reactive extrusion applications. Required inputs include screw and barrel configuration, material properties and processing conditions while outputs include axial profiles of key variables such as pressure, temperature, degree-of-fill, stress and deformation rate as well as overall residence time distribution and specific energy consumption. The functionality of this simulation software will be demonstrated through numerical simulations in selected polymer compounding and pharmaceutical applications. The software is developed using a server-client model, so that the client component of the software requires minimal resources. The client graphical user interface (GUI) has been developed as a web application for cross-platform compatibility and may be used on any computer or mobile portable device with an HTML5 compliant web browser. Add to MyShow Planner




1:30pm-2:00pm Polymer Devolatilization: Practical Information for a Complex Process


Presented By: Rob Jerman, Extrusion Technology and Innovations/Extrusion Edge Despite the major commercial significance of devolatilization to the plastics and polymers industry there is little available on the topic that targets end users. In this presentation, the controlling variables for devolatilization are presented along some useful rules of thumb for optimizing performance of devolatilization systems in single and twin screw extruders. Practical guidelines for solving common DV problems will be discussed along with some guidance on how to tap into available resources for design and optimization of DV systems. The talk will also briefly cover the range of processing equipment available for devolatilization and how to choose the best device or combination of devices for your particular product needs. Add to MyShow Planner




2:00pm-2:30pm How to Ensure Reliable Feeder Performance When Handling Recycled Plastics


Presented By: John Winski, Coperion K-Tron Plastics are used to manufacture an incredible number of products we use every day. Suffice it to say one good reason to recycle plastic is that there is just so much of it. This presentation will address the various forms of recycled plastics that exist and key considerations that a user may need to address using a bulk solids feeder to reprocess these materials. Presentation is suited for engineers, purchasers and plant managers who are looking to understand how their current equipment may be adapted to improve and maintain overall product quality, increase yields and minimize downtime to meet current and future processing needs. Add to MyShow Planner




2:30pm-3:00pm New Developments in Single Screw Mixing


Presented By: Keith Luker, Randcastle During the past decade, single screw extruders have advanced technology so that they compete, and sometimes exceed, the compounding ability of twin screw extruders. This paper will review the principles of single screw compounding, successes and the latest, surprising, advances. Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Processing Shear Sensitive Materials on a Co-Rotating TSE


Presented By: Dean Elliott, Entek Extruders Co-Rotating Twin-Screw Extruders (TSE) are high shear mixing machines. But what happens when the continuous mixing efficiency of a co-rotating TSE is required for materials that are sensitive to high shear rates? This presentation discusses preferential configurations of your co-rotating TSE and provides operator processing tips to achieve the highest possible output rates while achieving the mix quality without over shearing the materials. Add to MyShow Planner




4:00pm-4:30pm WPC Processing with Co-rotating Twin Screw Extruders


Presented By: Edward Gay, Krauss-Maffei Corp. Wood plastic compounding presents various technical challenges such as temperature management, distributive mixing, removal of volatiles and susceptibility to degradation. The modular design of co-rotating twin screw extruder enables the process configuration to be optimized for successful WPC compounding. This presentation will include an overview of co-rotating twin screw extruders and insight of how to compound WPCs with co-rotating twin screw extruders. Additional topics including benefits associated with compounding WPCs on co-rotating twin screw extruders (such as process customization, ease of replacing worn parts, high screw speed and throughputs), process limitations and scale-up will be discussed, as well. Add to MyShow Planner




4:30pm-5:00pm Custom Solutions for Powder Handling Not Necessarily Required for Vacuum Conveying Systems Used for Compounding and Extrusion Lines


Presented By: David Kennedy, Vac-U-Max Most vacuum conveying systems do not require custom solutions in order to meet requirements for powders and bulk solids. Pre-engineered vacuum conveying systems are now so technically advanced that they are useful as-is for a wide range of industries including plastics processing. This presentation provides situations, including real-world examples, when turnkey packaged conveying systems fit and when custom enhancements are necessary. Add to MyShow Planner




5:00pm-6:30pm OPENING RECEPTION


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Tuesday PPT

1:00pm-1:30pm Rubber and Silicone Extrusion Basics


Presented By: Bill Kramer, US Extruders Processors wanting to expand into rubber or silicone extrusion need be aware of the basic differences as compared to plastic extrusion. Silicone typically needs to be mixed on a mill prior to extrusion, and both types of elastomers are normally fed in strip form to the extruder via a roller feeder. Extruders designed for elastomers are shorter than plastic machines and operate much cooler. The extrudate is heated for vulcanization after the die exit instead of cooled as in plastics. Extruder design requirements for rubber and silicone are discussed as well as processing basics. Add to MyShow Planner




1:30pm-2:00pm High Speed Tubing Extrusion Advances


Presented By: Bob Bessemer, Novatec Commodity medical tubing such as flexible PVCs, are typically processed at speeds more than 500 feet per minute with many advances over the last 10 years which have enhanced tolerances enabling processors to run faster, but post-extrusion tube shrinkage remains a significant issue. We will discuss prior enhancements which are now the current standard of the industry and then detail how further improvements can be made. Add to MyShow Planner




2:00pm-2:30pm Progress in Inline Pipe Measurements: Radar Technology Comes to Extrusion


Presented By: Jan Petermann, Inoex For several decades now plastic pipes have been measured inline. However, currently used technologies also challenge the user in many ways, either by elaborate conversion work on the system for dimensional changes or by frequent calibration procedures or in some cases the use of water as coupling medium. The contactless radar technology so far known and used for distance control in the automotive sector offers advantages in terms of accuracy, usability and safety aspects. This work will demonstrate an advanced radar sensor technology which is able to resolve 5mm thin-walled plastic pipes and measure pipes inline with an accuracy of ±0.05mm and a user independent repeatability of 0.001 mm. The sensor technology itself will be demonstrated and the wide range of use cases as 100% measurement systems for gas or water pipes in combination with case study data will be presented. As a focus this work will demonstrate process automation use cases with different control loops like haul-off control or thermal die head centering. The corresponding cost saving of each control step will be presented to analyse the return of investment time of a measurement system. Add to MyShow Planner




2:30pm-3:00pm Screw Design in Counter-rotating Twin Screw Extruders


Presented By: Haikun Xu, Krauss-Maffei Counter-rotating twin screw extruders have been the predominant process machinery for PVC in the past few decades. These end applications include PVC pipe, profiles, sheet, pellets, etc. In this paper, the screw design concepts for counter-rotating twin screw extruders will be discussed and the mechanism for counter-rotating twin screw extruders will be explained. In addition, state-of-art wear protection technologies for the screws, maintenance, and related topics will be covered. In the end, important process parameters for counter-rotating twin screw extruders will be emphasized and how one can use them to troubleshoot the processing issues for optimized process. Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Adaptive Extrusion: Multi-Functional Die and Extrusion Technology


Presented By: Kris Ivie, Graham Engineering The one resource you cannot increase is time. A business in today’s economy requires efficient use of time to stay competitive. Most of today’s businesses demand technologies that will allow for faster to market, higher efficiency, higher utilization of equipment, and shorter transition times from product to product. The traditional functions of mixing and pushing plastic are no longer enough for modern extruders. In this presentation we will go over a number of current and emerging technologies for extrusion and how they are impacting the industry. These technologies will include new control technologies such as pressure feedback control and direct drive servos, adaptive die technologies such as self-alignment and alternating materials, changeover technology such as modular barrels and quick change clamp technology, and future manufacturing technology such as CFD simulation and 3D metal printing. Add to MyShow Planner




4:00pm-4:30pm How Inline Grinding Can Help Support Extrusion Workflow


Presented By: Andre Adams, ACS & Max Cummings, Teel Plastics No matter what type of process is the mainstay of your plastics manufacturing operation – injection molding, thermoforming, extrusion – every floor manager knows that the waste materials generated can be significant. Ideally, those materials are reclaimed back into the process. By grinding the plastic materials down to a size that’s similar to the virgin material, you drastically decrease waste and mitigate the amount of virgin material in the process.
Regardless of the size of your operation or type of manufacturing process, regrinding of plastic components has the potential to create substantial savings. There are multiple types of size reduction equipment including shredders and granulators that can be used to transform the material into a more useable state. The type of machines utilized in a process depend on the material characteristics, size and density. Considering the annual savings over many manufacturing cycles, it’s vital that the right type of granulator is chosen based on your unique plastic processing operation, type of materials, labor, floor and storage space, and many other factors.
To help get the most from regrinding, plastics manufacturers typically use one of two types of manufacturing floor configurations and the equipment designed for that workflow – a central granulator or a beside-the-press/extruder (inline) granulator. (It should be noted that Under-the-Press (UTP) granulators are sometimes categorized with inline granulators, although they are generally located beneath a plastics thermoforming line) Each approach to regrinding has pros and cons that are unique to each operation, so the onus is on floor managers and manufacturing engineers – with the help of a knowledgeable equipment partner – to determine what works best to meet the company’s unique needs, limitations, and goals.
Although a central granulator configuration offers many benefits for those operations that are well-suited for that equipment, this white paper will focus on inline granulators. We’ll explore the top reasons you might want to choose this type of granulator equipment for your plastics extrusion process, as well as other considerations. Add to MyShow Planner




4:30pm-5:00pm The Evolution of Chipless Cutting


Presented By: Gerry Lamorte, Custom Downstream Systems For many years we have seen new chip less cutting equipment that have been introduced to our industry. Words like Swarfless Planetary Cutter and Hot Knife Blade Cutters are becoming more and more popular. In this presentation we will discuss the evolution from the Planetary saw to the Swarfless planetary cutter and from the traditional up-cut saw to the hot knife cutter. Are the chip less cutters better machines when compared to the work horses of our industry? Will the chip less cutter become our new work horse? Let find out the answer to these questions during this presentation. Add to MyShow Planner




5:00pm-5:30pm Improving Quality in Hose Production


Presented By: Thore Sørensen, Fenner Mandals AS We show how multivariate design and response surface modeling were applied to a lay-flat thermoplastic (TPU) hose extrusion process full-scale experiments. Clear quantitative relationships were found, which to a large degree match existing qualitative process understanding. For instance, it was quantified how adhesion between weave and TPU improves with increased extrusion screw speed and extrusion head temperature. The results can readily be used to inform operators in real-time of important quality parameters of the hose currently under production. The clear results also indicate that increased process automation is achievable. Add to MyShow Planner




5:00pm-6:30pm OPENING RECEPTION


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Agenda - Wednesday, October 14

Wednesday General Sessions

7:30am-8:00am Investing in Aging Equipment


Presented By: Dan Barlow, Integrated Control Technologies Investment is the act of putting money or effort into something to make a profit or achieve a result for a future benefit. There is a big difference between money spent on repairing a machine to get a line running as opposed to upgrading the machine in such a way that it not only solves the problem today but also addresses the challenges of tomorrow. Repair of a machine requires little planning and it usually does not solve the problem, especially if it can happen again. In such cases, we are "kicking the can down the road" leaving the problem for someone else to solve. Investment requires planning and commitment and is pro-active as opposed to re-active in behavior. Proper risk assessment and planning are required when considering an upgrade. All upgrades should include five important factors to guarantee a future benefit. Add to MyShow Planner




8:00am-8:30am Removing the Myth Between Melting Point and Processing Temperature


Presented By: Braulio Polanco, Scientific Extrusion One of the biggest challenges for plastic processors is inconsistency in polymer quality. In some cases, the polymer lot to lot variation can be so significant that will require changes to the process. However, very few companies invest in equipment to test the polymer to understand its thermal characteristics and flow behavior. In many extrusion and molding operations, changing the process temperature is almost forbidden. This is in part due to the lack of information about polymers and how they behave. In this session, we will define melting point and scientifically show how processing temperature is derived. In addition, we will demonstrate relevant polymer testing data that will clear the misperception that melting point correlates to processing temperature. Add to MyShow Planner




8:30am-9:00am A Sustainable and Economical Way to Color Plastics


Presented By: Paul Maguire, Riverdale Global Discussion on how using liquid color in extrusion can substantially improve sustainability while also saving money with lower energy usage, reduced cycle times, less waste, and more. We will also discuss a new line of additives, with a focus on achieving sustainability goals, including increasing PCR content in your finished product. Additionally, an overview of the latest developments in the field of liquid color technology will be provided. Add to MyShow Planner




9:30am-10:00am NETWORKING BREAK


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10:00am-10:30am A Comparison of Screen Changer Designs for Precision, Tight Tolerance Extrudates


Presented By: Justin Marriott, Parkinson Technologies In this presentation, we will present the various melt filter/screen changer technologies, the recent advancements, and how they can benefit extrusion operations. The primary focus will center on discontinuous, semi-continuous, and continuous screen changers explaining how each type can benefit an extrusion process. We will address discontinuous and semi-continuous screen changers where the extrusion system must be shut down or disrupted to change the filter. We will also explain what impact this can have on the economic operation of a production line. We will discuss the various continuous melt filter technologies and how each technology benefits a production line. Case studies will be reviewed to show the improved economic operation of a production line when changed from a discontinuous or semi-continuous to a continuous screen changer. At the end of the presentation, we will summarize the advantages and disadvantages of each filtration system. These considerations are to assist in the decision on which system would work best for the processor's operation. Add to MyShow Planner




10:30am-11:00am Value-Added Recycling via Twin Screw Extrusion


Presented By: Charlie Martin, Leistritz Extrusion Most recycling systems take post-consumer and post-industrial reclaim feedstocks and convert these materials into a usable product. The operative word is “usable”. Twin screw extruders compound raw materials into value added products. This paper will highlight potential applications for the combination of recycling reclaim materials and value added compounding. Case histories and target expansion areas for twin screw technologies as part of reclaim systems will be integrated into the presentation. Add to MyShow Planner




11:00am-11:30am What We’ve Learned About Industry 4.0: Where we will be by NPE2021?


Presented By: Alan Landers, Conair The IoT push in our industry over the past 5 years has driven rapid technology advancement that allows for smarter processing and smarter factories. The newest control systems not only govern machine operation, they also monitor and record a host of setpoint and actual process parameters that can be viewed on a dashboard that displays individual pieces of equipment, entire lines, entire plants, or entire companies. That data can usually be downloaded manually or automatically to various database systems and compiled into reports and analyses that can support process-optimization and productivity-enhancement programs. Powerful equipment monitoring and visualization functions, plus advanced cloud-based data storage and analytics that were barely a dream 5 years ago, are now available. By NPE2021, there will be even more developments. If you order a piece of equipment, or an entire processing line at NPE2021, the equipment you receive will be the most advanced ever produced in our industry. These newest developments will help molders not only collect and analyze information, but utilize it to achieve new levels of process, performance and quality optimization. Predictive diagnostics and maintenance programs will ensure the most efficient operations in history, making our industry “greener” than ever, while providing maximum equipment uptime. This presentation will review today’s technology and describe very near-future opportunities to create smart factories. Add to MyShow Planner




11:30am-12:00pm Understanding the Advantages of Using Pressure Control to Minimize the Effect of Process Variations


Presented By: Kevin Slusarz, US Extruders Pressure control is a process enhancement that allows for a control system to make changes to an extruder. Using the principal that a constant pressure drop through a fixed resistance is equivalent to a consistent mass flow rate. This control system will maintain a consistent output, minimizing or eliminating a product to exceed specifications. Based on this and using a PID control loop, small changes in screw speed are used to maintain a constant pressure. The data presented in this paper will be a series of case studies showing common process changes that can affect the output of an extruder and compare the reaction time of pressure control versus no control. The paper will compare pressure control to no control and then evaluate common variations seen in production such as temperature changes in the raw material and bulk density changes. Add to MyShow Planner




12:00pm-1:00pm Lunch Presentation: Employee Quality Certification: The Missing Workforce Skills Gap


Presented By: Lewis Yasenchak, P&Y Management Resources Extrusions Workforce Improvements Effecting the Bottom-Line: Finally, a hands-on Employee Quality Certification program for manufacturers and service industries. Add to MyShow Planner




9:00am-9:30am Energy Efficient Processes for Extrusion


Presented By: Joseph Dziedzic, ACS Group We will provide an overview of various equipment used in the Extrusion process. Discuss the various ways to enhance efficiency in the process and the benfits that can be achieved. Review new echnology and how it can help enhance energy efficiency. Review Maintenance Options for current equipment. Review Upgrades that can be made to improve efficiency. Add to MyShow Planner





Wednesday Film & Sheet

1:00pm-1:30pm Science Has Found A Way: Cost Benefits of Next Generation High-Speed Extrusion


Presented By: Sushant Jain, Processing Technologies International LLC The development of a high speed 90 mm extruder takes system performances to new levels in regards to output and flexibility. Discussions will include how advances in technology have brought about multi-resin capabilities, higher regrind recovery rates, reduced maintenance costs and increased throughput with a minimal changes to the physical footprint size of the equipment. Case study analysis will provide further insight into the technology’s capability of efficiently processing various low bulk density feed stocks, overlaid with capital, operating and production cost savings – demonstrating a 30-35% increase in output and 20-25% increase in manufacturing footprint efficiency over the current high speed technology. Add to MyShow Planner




1:30pm-2:00pm Boost Film Productivity and Quality with Retrofits


Presented By: Gerd Kasselmann, Windmoeller & Hoelscher Add to MyShow Planner




2:00pm-2:30pm Enhanced Filtration Technologies for PET Recycling


Presented By: Parke Strong, Nordson Due to increased societal pressure to protect limited natural resources, manufacturers of polymers and polymer-based products realize the potential impact of recycling. Conserving resources, reducing emissions, saving energy, reducing landfill footprints, and creating a more sustainable future are all positive results gained from recycling polymers. Nordson BKG® is aware of this immense potential, embraces the responsibility, and is committed to the development of products and processes to support sustainable PET product lifecycle. In PET recycling, recent technological advances in filtration offer a highly effective and cost-efficient solution for many recycling opportunities. A recent enhancement to BKG® filtration technology is the FlexDisc™ filtration medium. This is a rheologically enhanced filter design that incorporates multiple stacked filters within a single filter housing. A significant feature of this design is the enlargement of the filtration area without an increase in the machine footprint on the production line. Combined with a backflush filtration system, the FlexDisc™ will help reduce backflush waste, leading to a reduction in filter screen usage and waste disposal. Add to MyShow Planner




2:30pm-3:00pm Winding Options in Film Extrusion: What’s Best for Your Application


Presented By: Mark Wodrich, Macro Engineering & Technology Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Modern Extrusion Die Technology for Sheet Applications


Presented By: Sam Iuliano, Nordson Sheet extrusion die technology has undergone rapid development over the past decade. While features such as a basic chocker bar for distribution control, exchangeable lips, and standard external deckles are still being used today; newer and more efficient extrusion die features are a better fit for most processors. Now available is motorized variation of the die lip exit gap while simultaneously controlling a critical variable - the internal lip land length. New restrictor bar mechanisms now can tune the flow distribution from a single adjusting point, making control faster and more repeatable. The latest sheet width adjustment systems combine internal with external deckles to reduce the size of the edge beads - allowing for sheet thickness tolerances to be achieved with minimal operator intervention and reduced edge trim requirements. All of these developments help sheet processors to reduce waste, speed product changeovers, and more readily meet product quality requirements. Add to MyShow Planner




4:00pm-4:30pm Handling and Processing Thin, Low Weight, Low Bulk Density Materials in Sheet Production and Reclaim Systems


Presented By: A.J. Zambanini, Conair As the packaging market becomes a more intensely competitive high-volume sector, processors constantly look for improved technology to meet their special requirements for maximum productivity, quality, and profitability. Manufacturing is now being forced to look for equipment that helps plastics reduce energy consumption, make better use of raw materials, reclaim scrap, and improve process yeild. Understanding the best practices and new technology in handling and processing this historically difficult thin, low bulk density materials, will be key in maximizing efficiency and supporting sustainability efforts worldwide. Add to MyShow Planner




4:30pm-5:00pm Accuracy, Automation for Blown Film Width Control


Presented By: Michael Pilolli, D.R. Joseph The focus of this presentation will be on the dynamic physical changes that a film web undergoes past a blown film line’s primary nip, specifically as it relates to stretch and shrink. The theme of this discussion will then focus on the importance of accuracy automation to account for the dynamic changes that cause layflat (web width) drift, resulting from production changes that are often unaccounted for, including operator measurement error. Add to MyShow Planner




5:00pm-5:30pm Quick and Easy Thermal Cleaning of Multi-Layer Blown Film Die Heads


Presented By: Andrew Dickinson, Schwing Technologies Complex multi-layer blown film die heads are becoming increasingly important in the production of high-quality films. Perfect cleaning of blown film die heads is a prerequisite for good product quality. SCHWING Technologies provides safe and fully automatic systems for cleaning large and heavy blown film die heads up to 1.7 meters in diameter. Add to MyShow Planner




5:00pm-6:30pm GRAND RECEPTION


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Wednesday Compounding

1:00pm-1:30pm Troubleshooting for Co-Rotating Twin Screw Extrusion Processes


Presented By: Jeff Galloway, Krauss-Maffei Process troubleshooting skills are critical to running a successful co-rotating twin screw extrusion process. In addition to solving intermittent problems, process troubleshooting skills can also aid in process optimization. This presentation will review common challenges and troubleshooting strategies for co-rotating twin screw extrusion processes. Troubleshooting related to key process steps (such as feeding, melting, mixing, venting and pressure building) and product quality will be discussed. The benefits of using process data and other observations of the process coupled with straightforward calculations will be discussed and specific examples will be given. Add to MyShow Planner




1:30pm-2:00pm A Scale-up of Journey: Pharmaceutical Class Compounds Developed via Twin Screw Extrusion


Presented By: Brian Haight, Leistritz Extrusion Thermally sensitive active ingredients and water-soluble polymers are processed via twin screw extrusion to manufacture many of prescription drugs we ingest every day. In early stage development, very limited (and expensive) amounts of materials are available. Hence, atypical twin screw extruder geometries are used to process small batches of less than 50 gm to test the feasibility of a formulation. If deemed viable, scale-up to more conventional twin screw configurations is the next step. Studies were performed to optimize the processing a thermally labile drug with a water soluble, pharmaceutical grade polymer. Initial studies were performed on a nano-16 co-rotating twin screw extruder with 1.2 OD/ID ratio, then a ZSE-18 co-rotating twin screw extruder with 1.5 OD/ID ratio, and then a ZSE-27 counter-rotating twin screw extruder with 1.5 OD/ID ratio. Once the mixing mechanism and boundary conditions were understood, successful scale-up was the result. The lessons learned may be applied to any extrusion scale-up exercise. Add to MyShow Planner




2:00pm-2:30pm The Perfect Pellet


Presented By: Adam Dreiblatt, Century Extrusion Troubleshooting compounded pellet quality issues and understanding customer requirements are the focus of this presentation. The demands for consistency are dictated by the susequent processing of pelletized compounds in both extrusion and injection molding applications. Compounders tend to lose sight of who the real customer is, and the impact of compund quality on customer profitability. The requirements for compounding the "perfect pellet" are identified in this presentation. Add to MyShow Planner




2:30pm-3:00pm Oxo-Biodegradables and the Future Of Plastics


Presented By: Robert Dalleska, Color for Plastics Every week news outlets throughout this country report on some form of plastics waste issue. From Plastics news in June of 2019 there were 8 such articles. In Jan of 2020 there were nearly double at 15. Crain Communications believes so strongly in the effects sustainability and recycling will have on the plastics industry they rebranded the European version of Plastics News to be titled Sustainable Plastics. OXO-Biodegradables are another excellent opportunity for the plastics industry to get ahead of the public outcry to divest themselves from plastics completely. Aside from working toward sustainability we can take action immediately for single use and disposable plastic products in the form of OXO-Biodegradables. OXO Biodegradable additives enhance oxo-biodegradation of plastic products into more environmentally safe byproducts. They are engineered to promote oxidation, leading to the molecular breakdown of plastic. Microorganisms then complete the biodegradation process, metabolizing the remaining polymer structure as food, generating water, carbon dioxide and biomass (humus) as by-products. OXO-Biodegradables assist in shortening the lifecycle of polypropylene (PP) and polyethylene (PE) plastics products. Suitable applications include bag, film, garden, agricultural, food packaging and container/utensils, cap and closures, strapping, toothbrushes, golf tees – the list is long and growing. Our technical experts can assist you to determine the suitability of your specific product application for OBPA treatment. OXO-Biodegradables are cost-effective – they typically only add 1-4% to material costs depending on the product and lifecycle expectancy. These additives are handled just like color additives, requiring no special handling techniques or new equipment. OXO-Biodegradables are proven to be recyclable in both industrial and post-consumer recycling streams with no detrimetal effects on the resulting recyclable. They are shown to be non-toxic to sensitive plant, animal and aquatic life. Without the transition of plastic into digestible material, normal plastic products will persist in the environment without any need. Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Historical Perspective of the ZSK Twin Screw Extruder with a View to the Compounding Line of 2030


Presented By: Sabine Schoenfeld, Coperion Application requirements for polymers continue to push the performance envelope with respect to better qualities, improved characteristics and lower costs to name a few. For the manufacturer to meet these requirements and still make a profit, the compounding line needs to operate efficiently with maximal output, a high onstream factor and minimal off spec product. The co-rotating fully intermeshing twin-screw extruder continues to be the primary technology for compounding applications. The most significant reason is that is has not become a mature technology but has continued to evolve during the intervening years since it was commercialized in 1957. For example, in the past 20 years several significant developments have been introduced. These include a) the implementation of high torque (power) designs, b) the use of increased screw rpm in conjunction with high torque for improved operating flexibility and productivity, c) a breakthrough technology for feeding difficult to handle low bulk density materials and d) new geometry elements for improved melting and mixing. In addition to mechanical related advances, drive and control systems have also improved over the years. DC motors and drives have been replaced by more efficient AC systems. RPM and temperature controls have migrated from analog to digital. Hand written data sheets have been replaced by data acquisition systems capable of real time system performance analysis. Some offline QC, such as Melt Index, can be integrated into the compounding line. The above is a partial list of advancements in the 60 plus years since the twin-screw was introduced, but what about the future. What compounding technology advancements will occur over the next ten years? This presentation will bring up ideas about the design and capabilities of and around the compounding line in 2030. On the one hand, by selecting suitable calculation programs, it is possible to transfer a new process to production machines without long-term test series. We will present some examples of how finite element method simulations can be implemented in the design of a new line. On the other hand, the integration of Industry 4.0 certainly offers the possibility to run a more efficient production. Add to MyShow Planner




4:00pm-4:30pm Pelletizing in a Post-COVID-19 World


Presented By: Damon Patton, Nordson The COVID-19 Pandemic will serve as a paradigm shift for all industries and markets. For the foreseeable future, global, political, and socioeconomic factors will be summarized by the term “Post COVID-19”. Its impact on thermoplastic product, application development, and processing trends will tax our collective knowledge bank and imagination. As Processors seek to extend the performance range of people, resources, equipment and technology a plurality of complexities will result in difficult and costly process and product quality issues for the compounder and their customer base. Nordson’s goal is to assist the industry in predicting and proactively mitigating these headwinds to success in a Post COVID-19 world. In this presentation we will: 1. Discuss potential impact of COVID-19 on Processors 2. Assign potential impact on operation models 3. Outline major process issues associated with this trend 4. Provide potential mitigating actions / steps Add to MyShow Planner




5:00pm-6:30pm GRAND RECEPTION


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4:30pm-5:00pm The Magic of Cleaning with Dry Ice in Compounding


Presented By: Steve Wilson, Cold Jet LLC No matter how large or small a compounder, there is a great demand to improve productivity and quality (Quality and Availability OEE Scores). This can be a balancing act between using the most effective technology while working within a budget. This presentation discusses the advantages of cleaning components of the compounding line with dry ice. There are numerous components of the compounding line that need to be cleaned, from dies, breaker plates, screw, etc. Dry ice is being utilized to address the cleaning needs of several of these components in order to eliminate excessive downtime. This presentation will demonstrate how various polymers can be cleaned from these components. This cleaning is not only quick and effective, but also non-abrasive. Supporting research from several independent mechanical and thermal studies (Kettering University, Materials & Process Associates, James Snide, etc.) will be presented to demonstrate that cleaning with dry ice can actually extend the asset life of line components. The attendee will also achieve an understanding of the common type of dry ice media commonly used in cleaning, the science behind how the process works, and how to implement the process in their facilities. Prepare to believe in magic! Add to MyShow Planner




5:00pm-5:30pm Finding the Right Fill: Wood Plastic Compounding with an Enhanced Twin Screw Extruder Setup


Presented By: Christoph Pielen, President Finding the right formulation that works in a process environment is a challenging task that consumes a lot of time and sometimes even very expensive production test runs. Lab scale equipment is ideal to minimize the development time to validate and optimize the formulation. The presentation highlights a case study to investigate the right material and the right fill for an optimized process showcasing a enhanced lab scale compounding setup including loss in weight feeders and a novel way of creating test specimen straight out of the compounding process. We chose a sustainable approach with a sawdust filler for a typical wood plastic compound formulation. Add to MyShow Planner





Wednesday PPT

1:00pm-1:30pm Your Old Puller Could be Used as a Pitching Machine or a Boat Anchor, Not as Part of Your Extrusion Line


Presented By: David Czarnik, Conair Twenty years ago, extrusion pullers weren’t much different than the pitching machines available in the batting cages at your local high school baseball camp. Plug it in, set a speed, and start running. One pitch come at you at 54 mph, and the next one could be 63 mph. One hour your puller is running at 100 feet-per minute the next it’s at 111 feet-per minute. Close enough, right? That’s not the case today. Today’s pullers are extremely precise. This precision is necessary if your process counts on stability, consistency, and quality. Since pullers regulate extrusion speed, sizing, surface finish, wall thickness, cooling, and mechanical properties, the precision of the puller is of the utmost importance to your process. The most precise variable speed pullers of 10 years ago, were considered “perfect” at ±1 to 2%. Typical pullers today feature a choice of vector or servo drives. Both are considered brushless AC drives, and both deliver a far, far greater degree of speed regulation and precision than the drives of even a few years back. Today, speed regulation accuracy for brushless AC motor drives is 10 to 100 times better, ranging from ±0.1% for high-quality vector drives to ±0.01% for quality servo drives. This presentation will explain the differences between yesterday’s pullers, todays, and even tomorrows pullers. Increased precision, improved controls, improved programming, repeatable consistency, and a wide range of speeds with constant torque are advancements that affect the bottom line. Today’s precision pullers – there’s no reason not to take advantage of the return on investment. Add to MyShow Planner




1:30pm-2:00pm A New Software Tool for Efficient Profile Die Engineering and Optimization Using Both 2D and 3D FEM Flow Analysis


Presented By: John Perdikoulias, Compuplast A new simulation package has been developed that allows users to use both a 2D or fully 3D FEM flow analysis for Profile Die engineering and optimization. In addition to the traditional, 2D cross section analysis, the software can easily import a 3D FEM mesh and automatically, apply the required boundary conditions. After the 3D FEM simulation has completed, the user can easily post process the results, using “Path lines” or “Cuts”, for correct flow field characteristics and distribution. The software also incorporates the previously presented “Profile Digitizer” which allows users to easily and precisely quantify the extruded product shape for comparison with the simulation results, using their mobile phone camera. This information can then be applied towards “calibrating” the simulation for small errors in material properties and then making precise adjustments to the die geometry for improved flow distribution and final product shape. Using this methodology often reduces typical die development to 2 or 3 trials. Users that already have experience with a particular material can often use the software to achieve an acceptable product with the initial trial thereby saving considerable amount of material and time. Add to MyShow Planner




2:00pm-2:30pm Quench Cooling of Extruded Products: Approaching it Depends on the Material


Presented By: Rick Barnes, Paulson Training Quench cooling or cooling by direct water contact is used extensively in the cooling of smaller extruded products. Depending on the material being extruded, the cooling water may be hot or cold, and may flow in the same direction as the product or in the opposite direction. This presentation will examine the temperature of the cooling water, its direction of flow, and its rate of flow. Add to MyShow Planner




2:30pm-3:00pm A Unique Method of Curing Low Durometer Urethanes in an Inline Process


Presented By: Bob Bessemer, Novatec Extruding low durometer urethane medical tubing is a challenge for several reasons. The tubing is so tacky that if the tubes touch each other, they can't be separated when cutting; also, if the tube is flattened, it does not rebound. To overcome these challenges the tubes are typically cut to a longer length than required and manually hung on racks for 24 hours and allowed to dry, then they are cut-to-length manually, which requires high labor usage and costs. I will discuss a new low durometer tube processing method that can help to solve these challenges. I will show how to extrude, cool, cut, and cure extremely tacky urethane tubing in an inline process. This technology includes, a three-temperature zone multi-pass vacuum tank to enhance the surface characteristics of the urethane tube, minimize stretch and allow precision cutting to desired length in line. The cut tube will then be ejected to a perpendicular conveyor oven outfitted with a stepping system to enable the cut tubes to travel through a heated chamber (165-170° F) for approximately one hour with the tube exiting the oven in a cured state. We will discuss in detail, the effect of the tube traveling through the tank going from hot, to cold, to warm water zones, as well as why the tube is maintained in a water bath for longer than typical with the use of a three-pass tank with two servo-driven wheels. We will also discuss how the tubing can normalize in the process to minimize shrinkage. This solution represents a cost and time-saving solution to a problem medical tube processors have been working to overcome for years. Add to MyShow Planner




3:00pm-3:30pm NETWORKING BREAK


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3:30pm-4:00pm Simulation of Extrudate Cooling, Shrinkage and Distortion in a Multi-calibrator Post-die System of a Complex Extrusion Die


Presented By: Mahesh Gupta, Plastics Flow During extrusion of complex profiles with multiple pockets, such as those used for manufacturing of PVC windows, some (or all) of the external walls of the extruded profile are in contact with the calibrator walls. Vacuum in the calibrators pulls these external walls to the calibrator surface. However, internal walls of the profile and the external walls which are not in contact with the calibrator surface, continue to distort as the extrudate goes through the calibrators in the post-die system. Post-die analysis of multi-pocketed extrudate profiles is particularly complex because thicknesses of external and internal walls are typically quite different. Furthermore, the cooling rate, shrinkage and distortion of external walls are also very different from those of the internal walls. The presentation will discuss the simulation results for flow in a complex bilayer coextrusion profile die combined with the analysis of extrudate cooling and distortion as it goes through multiple calibrators in the post-die system. Different cooling rates are enforced on the extrudate walls which are in contact with a calibrator, on external extrudate walls which are not in contact with a calibrator and on internal walls of the extrudate. The extrudate is analyzed as a fluid near the die exit and then analyzed as a solid by a thermo-mechanical analysis away from the exit. Effect of non-uniform velocity at the die exit as well as that of cooling shrinkage on extrudate distortion is included in the simulation. Add to MyShow Planner




4:00pm-4:30pm Measurement Options for Pipe, Tube and Profile


Presented By: Keith Donahue, Zumbach There have been numerus advancements and even breakthroughs in recent years for existing technologies available for Dimensional Measurement of Plastic Tube, Pipe and Profile to offer higher performance, new applications, and even, at times, lower cost. In addition, there have been advancements with new technologies which offer, in some cases, imrpovements over currently used technologies. This presentation will examine the developments and the future direction of the critical dimensional measurement and control sector. Add to MyShow Planner




4:30pm-5:00pm Profile Extrusion Technology Update 2020


Presented By: Dan Cykana, Extrusion Solutions, LLC New developments in profile extrusion processes, tooling and applications. Add to MyShow Planner




5:00pm-5:30pm Energy Efficiency in the Plastic Industry


Presented By: Gerry Lamorte, Custom Downstream Systems Energy consumption and carbon footprint are becoming a growing concern worldwide. Therefore, in order to contribute in reducing our carbon footprint, we are trying to change our habits and our production processes. Although changing our energy consumption in our production facilities may not be an easy task. So what can be done to have better energy consumption machines? During this discussion we will focus mostly on the water cooling equipment and see what can be done to reduce their energy consumption. Add to MyShow Planner




5:00pm-6:30pm GRAND RECEPTION


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Agenda - Thursday, October 15

Thursday General Sessions

8:00am-8:30am How Hot is Your Food? Feed Temperature in Extrusion


Presented By: Allan Griff, Griff Extrusion Feed temperature affects production rate, melt temperature and thermal stability, contamination, mixing quality and sometimes thickness variation. Yet is is seldom measured and even less often controlled. This talk will explain such effects, including variability, other sources of heat, heat history and reuse of scrap, and additive feeders. Add to MyShow Planner




8:30am-9:00am Size Reduction/Reclamation Solutions for the Extrusion Market: Safety, Quality, and Cost Savings


Presented By: John Farney, ACS Group This presentation will delve into the critical areas for material reclamation in today's market. The focus is makingthe reclaim effreot more affordable, safe and sucessful. At present a huge portion of materials from both post-industria and post-consumer sources goes to landfills, thus minimizing the effrot and compromising our environment and habitat. The goals is to educate in the latest trends, designs, and processes to make virtuallyt any effoert more complete and successful. Add to MyShow Planner




9:30am-10:00am Rheology as Opposed to Melt Index as a QC Test


Presented By: Steve Post, Thermo Fisher The primary instrument used by the industry to qualify the rheological properties of a raw material is the melt index test. But melt index is really a crude test and does not define the rheological or physical properties – catalyst technology, long chain branching and molecular weight distribution have so much more impact on the behavior of the material in the process as well as the end physical properties. Rheometers are far from being new devices, but have always been too sensitive, expensive or labor intensive to be used in a normal QC environment. We will examine three different LLDs; all with the same melt index, but with different rheological curves. Add to MyShow Planner




10:00am-10:30am NETWORKING BREAK


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10:30am-11:00am Key Considerations for Selecting a Blending and Material Handling System


Presented By: Mark Jordan, Advanced Blending Solutions Modern product structures are increasingly more complex. With more layers and materials than ever, and increasingly specific additives and resins, it is important to have total control of your process with increased pound to pound consistency and traceability. Extrusion lines for producing such complex structures are often integrated into existing infrastructure at the plant, which leads to interfacing issues between new and existing material supply, blending, and IT processes. New technology allows for increased consistency, full traceability, easy operation and quick changeovers. Add to MyShow Planner




11:00am-11:30am Extrusion Process Control Using an Online Rheometer


Presented By: Azadeh Farahanchi, Dynisco The growing tendency towards productivity, efficiency, and sustainability among manufactures and recyclers in the plastics industry arises the necessity of timely control of the process and quality while eliminating the waste amount. Online rheometers have increasingly been used in variety of extrusion lines in order to have continuous data stream of rheological properties and real-time information on the process without any delay for the laboratory testing. A newly designed online rheometer has been developed to duplicate the test conditions of laboratory rheometers, continuously provide information on the melt flow rate (MFR), shear viscosity, intrinsic viscosity, and extensional viscosity of in-process extrudate materials. The present work aims to describe how this online rheometer has been designed on an extruder to constantly control the amount of volumetric flow rate and driving pressure while considering the effect of reservoir pressure, entrance pressure drop, and capillary diameter. As a result, this online system continually measures various rheological parameters which closely matches those from a melt indexer or a capillary rheometer. Moreover, through calculation of activation energy for a specific material and introducing a temperature correlation, it has been investigated how this online rheometer considers the temperature dependency of material`s rheological properties and accurately measures these parameters at various operating temperatures. Add to MyShow Planner




11:30am-12:00pm Extrusion Gear Units: Design and Maintenance


Presented By: Roman Siegfried & Steve Rogan, Artec Machinery A perspective from the gearbox manufacturer and maintenance mechanic as it relates to the extrusion process. Discussing development and design of new extruder gear units, and identifying specific failures encountered during shop overhauls and field inspections correlating them to probable cause such as design, process, or environmental conditions. Add to MyShow Planner




9:00am-9:30am How to Implement a Purge Program for Extruders: Reduce Scrap & Downtime to Achieve Processing Excellence


Presented By: Jarred Packard, Asaclean-Sun Plastec Many processors in extrusion know that they should implement a purge program but just don’t know how to get started. This presentation will discuss what data to collect, how to collect it, and how to measure performance when you introduce purging to your process. Our purging expert will explain different tangible ways purging compounds can improve efficiency and will discuss several customer examples of how purge programs helped them reduce costs. Additionally, he will walk you through several tips for extrusion to get the most out of your process. What you will learn: • Understand your purging data • Choose a Purging Compound that fits your needs • Address existing processing pain points • Introduce a plan to improve efficiency moving forward Add to MyShow Planner





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