A good start saves time and money
New retrofittable solution slashes start-up and changeover times in thin-sheet extrusion – with measurable raw-material savings.
Every start-up and every change of sheet thickness or raw material forces sheet extrusion lines into a time-consuming manual re-adjustment of the die and calender. Until the required quality is reached, the line produces scrap – costing time, material and money. With the BREYER Melt Bank Monitoring System (MBM), the Singen-based machine manufacturer BREYER GmbH now offers an intelligent, retrofittable solution that dramatically shortens exactly this phase.
The principle is as simple as it is effective. Special sensors positioned directly after the roller gap continuously monitor the melt bank – the small reservoir of molten polymer in the roll nip that is decisive for sheet quality. The system translates the sensor signals into a precise graphical profile of the bank, directly related to the individual die adjustment screws. Instead of judging the bank by eye, the operator sees exactly where to intervene and adjusts the correct screw to the right position straight away. The melt flow is thus controlled precisely by position, and uniform quality is achieved quickly and reliably.
The advantages are both qualitative and economic. Targeted die adjustment saves up to 50 percent of the time needed for a thickness change. Continuous visualisation keeps the melt bank uniform and stable, improving the surface and reducing thickness variations. Because the bank is held as small and even as possible, internal stresses within the sheet – invisible to the naked eye – are minimised as well.
MBM is designed as a retrofit and requires only a few components: application-specific sensors, a traversing unit developed for the safe mounting of the sensors on various calender types, a compact control box installed directly on the machine, and a clearly structured 19-inch touchscreen based on Siemens WinCC. Existing lines can be upgraded with minimal effort.
“A good start saves time and money” is how BREYER sums up the concept. The economic benefits typically pay for themselves within a very short period; on request, BREYER prepares a profitability analysis tailored to each individual line.
About BREYER
BREYER GmbH Maschinenfabrik, based in Singen (Germany), develops and manufactures high-quality extrusion lines for sheet and film. Under its promise “Innovations for better solutions”, the company supports its customers across the entire lifecycle of their equipment – from new lines through services, upgrades and retrofits. www.breyer.world
