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Infrared Modules in Conair-Kreyenborg Dryers Stay Cool and Dust-Free for Longer Life

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The radiator modules in latest Conair-Kreyenborg infrared drum dryers (IRD) incorporate several design features that contribute to superior performance, greater installation flexibility and longer lamp life, as compared to other infrared dryers. Available in three basic models with as many as 200 custom combinations of drum size/design and power output possible, the dryers promise faster drying and reduced energy consumption in high-volume applications such as PET sheet and film.

A sales agreement between The Conair Group, Inc., Cranberry Township, PA, USA, and Kreyenborg Plant Technology, GmbH & Co., Senden, Germany, was concluded in early May. The pact gives Conair rights to sell a co-branded infrared polymer dryer to plastics processors worldwide. The addition of the IRD expands Conair’s dryer product line – already one of the most complete in the industry – allowing the company to better support the special requirements of PET processors.

“Whether your application can benefit from IR drying alone, a combination of IR and desiccant drying, or if desiccant drying alone is best, Conair now has a solution for you,” says Jamie Jamison, Conair Dryer Product Manager. “Conair has always been known as the industry’s foremost authority on resin drying, and in recent years we’ve made a huge commitment to serving PET processors. In 2007, we introduced EnergySmart®, a unique two-stage drying system aimed primarily at high-volume PET preform molders. In 2008, we formed a PET Team – a select group of Conair experts who are tasked with understanding and meeting the unique needs of that market. Today, the Conair-Kreyenborg IRD allows us to offer yet another drying option. No other company is as well positioned to meet the total auxiliary equipment requirements of any plastics processor.”

Jamison notes that there are several design elements that make the Conair-Kreyenborg products different and better than other IRDs on the market. “Chief among these” he says, “are the unique design of the infrared radiator module, the positive-pressure venting system and the user-friendly control system.”

RADIATOR MODULE ADVANTAGES
At the heart of any IRD are the short-wave infrared lamps. In the Conair-Kreyenborg dryers, they feature an integral reflector made of aluminum-oxide ceramic, which does not degrade as quickly as other materials, such as gold. The support into which the lamps are mounted is also ceramic, and it is perforated with thousands of tiny holes that allow air to flow freely around the lamps. During operation, a stream of air is continuously directed along the module and through these holes, keeping the entire structure as cool as possible. Because many of the polymer materials typically dried in an IRD are dusty, and because dust can damage the IR lamps, the laminar airflow in the Conair-Kreyenborg dryer is effectively sweeps dust away.

As the infrared radiation heats the plastic from the inside out, moisture is driven off. The positive airflow inside the enclosed drying chamber picks up the moisture and carries it away, along with any dust thrown off as material tumbles in the rotating drum. The air is extracted and vented through an exhaust pipe and into a dust filter if necessary. This feature can be especially important considering the fact that the ideal application for the IRD is drying dusty PET regrind.

The infrared module itself is mounted on a frame so that it easily slides out for maintenance and cleaning. The frame is supported inside the dryer (instead of being floor mounted). This means that the dryer-discharge height is not limited and can be changed to suit customer requirements. The dryer can even be installed on a mezzanine.

Auger feeding, another key feature, ensures reliably flexible throughput rates. Unlike other infrared dryers, which are flood-fed by gravity, the Conair-Kreyenborg IRD is fed by a variable-speed auger for added control.

The control is a Siemens touch screen which allows easy setting of temperatures and drum speeds. PID temperature controllers govern multiple zones within the dryer, maintaining temperatures within ±5°C, or closer if required in certain zones. The control is set up to operate in different modes depending on the materials being dried and different drying “recipes” can be stored for quick recall. Troubleshooting and software maintenance can be conducted remotely via modem.

THREE MODELS SUIT MANY APPLICATIONS
The Conair-Kreyenborg IRD comes in three basic models: Type A, a lab-scale dryer capable of throughputs between 44 and 330 lb/hr (20 and 150 kg/hr); Type B, with rated throughput between 150 and 2650 lb/hr (70 and 1200 kg/hr); and Type C, which offers throughput between 1100 and 11,000 lb/hr (500 and 5000 kg/hr). Each of these models can be customized with different drum dimensions and varying numbers of IR radiator modules to create the dryer required for a given application. Up to 200 different combinations are possible.

The most common application for the Conair-Kreyenborg IRD involves PET regrind, especially bottle and sheet flake. Here, users can take advantage of the fact that the IR dryer both dries and crystallizes at the same time, and it does so in a fraction of the time it takes in a conventional desiccant dryer and separate crystallizer. Typical residence time required to reach moisture levels of 300 ppm in the IR dryer is about 15 minutes, rather than the 4 to 6 hours required using a desiccant dryer and crystallizer. To reach a moisture level of 50 ppm, which can be required in some applications, it may be necessary to finish drying the PET for about an hour in a desiccant dryer. This is still considerably faster than the 6 to 8 hours required in a desiccant dryer alone. Additional benefits include the fact that energy consumption is reduced by 35 to 40% and the amount of material in process at any time is reduced 80 to 95%.

Regrind materials, which may vary occasionally in bulk density, can be readily accommodated by adjusting the fill level and speed of the rotating drum.

Besides PET regrind, other applications for the IRD include:

  • Drying and crystallizing PLA, especially PLA regrind, which can be difficult to crystallize
  • Drying ABS/PC alloys for sheet extrusion
  • Drying wood-filled compounds – IR drying is especially effective in handling the high moisture content found in these materials
  • Preheating PP, PE and PVC before further processing, to remove volatiles, for instance
  • Coating resin pellets with additives – continual movement in the rotating drum is beneficial when coating sticky materials like EVA

For more information, call the New Product Hotline at 1-888-486-6601

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