Compounding line produces up to 5.000 kg/h of PVC cable compounds
Buss AG, Pratteln, Switzerland, has delivered the world's largest cable compound line to Kabelbedrijven Draka Nederland B.V., Emmen. Maximum throughput is 4500 to 5000 kg/h, depending on formulation. The comprehensive production line, extending over four floors of the plant building, can process eight different PVC formulations using one and the same kneader screw geometry, without any other conversion outlay. Right from the startup in March 2009, this compounding line has met all the owner's expectations particularly with regard to product quality, dependability, operating convenience, and minimal product changeover times.
Decisive for unmatched cable compound quality is the BUSS quantec® 110 EV Kneader at the heart of this line. With a kneader shaft diameter D = 110 mm and processing length L =15 x D, this high-performance Kneader features the innovative four-flight technology already practice-proven in more than 100 compounding lines. Thanks to the enlarged intake zone, even the biggest filler volumes are handled without problem. The mixing and kneading screw configuration enables exception¬ally homogeneous colored compound production with high fillers content. To build up the necessary pelletizing pressure, the PVC compound is transferred through a cascade ducting system to a single-screw discharge extruder. This is followed either by dry or water-mist pelletizing, whichever is preferable, at a relatively low pressure to minimize temperature peaks on the die plate.
BUSS was responsible for the entire plant engineering, from heater-cooler premixer and gravimetric feeding system into the compounding line, to PVC pelletizing, cooling and drying for storage or bagging.
The overall concept worked out by BUSS in teamwork with the customer also met some important additional requirements, including integration of the entire compounding system in the existing plant, and time-saving erection with minimal impact on the ongoing production. BUSS engineering also covered the comprehensive central control system, focusing in particular on precise coordination between the heater-cooler mixer and the compounding line, above all for startup, which now takes only a few minutes.
With regard to the customer's demanding requirements, BUSS CEO Dr. Beat Sturzenegger points out that "Above all for such a complex PVC compounding line, it was decisive that BUSS assumed overall responsibility ranging from engineering, manufacturing and procurement to erection and commissioning. Without this single-source supply, it would hardly have been possible to complete the entire plant so rapidly and cost-effectively, moreover to attain such consistently high product quality and short product changeover times thanks to the comprehensive control system.
More Information: www.busscorp.com