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Film-Scrap Reclaim System from Conair Incorporates New ScrapSaver™ Fluff Feeder

scrapsaver
   

A new integrated film-scrap reclaim system, designed and built entirely by The Conair Group, Inc., recovers trim scrap, roll scrap and hand-fed film scrap, grinds it, and then reintroduces it to the extruder without hang-ups, surging and clumping. The system can handle film-fluff addition rates of 25% or more, thanks to a new ScrapSaver™ feeder, which keeps virgin and ground fluff separate until just before they enter the extruder feed throat.

This new system is part of a range of innovative products aimed at improving productivity and profitability in both mono-layer and co-extrusion applications in film, sheet, extrusion coating, pipe, profile, tubing, and wire & cable extrusion. This comprehensive new engineering initiative makes Conair Extrusion a single-source supplier. It brings together upstream extrusion auxiliary equipment (including material conveying and storage, gravimetric blending and resin drying), extrusion control systems, downstream sizing, cooling and cut-off equipment, and granulating and film-scrap reclaim systems.

A typical extrusion-scrap reclaim system includes:

  • trim pick-up system with induction blower for conveying edge and/or bleed trims from the winder;
  • granulator fitted with trim receivers and, if necessary, a roll-feed assembly;
  • film fluff blower that transports the ground material from the granulator catch bin to a high-efficiency cyclone (with dust filter) and drops it into the fluff hopper on the ScrapSaver machine;
  • ScrapSaver machine mounted on the extruder feed throat.

The ScrapSaver machine is designed to deliver a consistent ratio of ground scrap and virgin pellets. Two hoppers keep virgin and fluff separated until they reach the feed throat and are introduced to the screw flights. An auger in the fluff hopper ensures consistent feeding of the scrap, while the virgin pellets are gravity fed. Four different auger sizes are available to match virtually any extruder size or throughput rate. Scrap re-feed rates are typically up to 25% of overall extruder throughput, but higher addition rates may be possible depending on the extruder feed section, the screw design and the end product being extruded.

“The trick to feeding film fluff in combination with virgin material is to make sure you have balanced flow,” says Don Macnamara, General Manager, Conair Extrusion. “In our new ScrapSaver™ machine, Conair has accomplished that by feeding the fluff into the center of the material stream. Virgin pellets actually surround the fluff as it exits the ScrapSaver and enters the extruder feed throat, creating a smoother flow of material and ensuring a better scrap to virgin material ratio. That’s how we are able to achieve such high scrap rates.”

The ScrapSaver auger is driven by a variable-speed AC drive motor and controlled from a touchscreen operator panel displaying the motor load and speed. Once the ScrapSaver fluff auger speed has been set and the process stabilized, the controller receives a speed reference signal from the extruder motor and automatically follows any change in extruder rate to maintain the specified scrap/virgin ratio and eliminate inconsistent feeding and surging. The drive system comes equipped with current overload protection with alarm status which will prevent premature drive failure. Controls for the granulator, roll feeder, inducer blowers and fluff conveying fan are housed separately.

PROCESS EFFICIENCY/PRODUCT QUALITY
This method of directly recycling ground trim and roll scrap back into the process has many advantages. System costs are lower than those associated with repelletizing or scrap densification, and the material is not subject to an additional heat history. The system is automated and requires little operator involvement. Scrap inventories are kept low. Problems often associated with this kind of reclaim system – dust, feed fluctuations and limitations on scrap percentage – are substantially reduced in the Conair ScrapSaver reclaim system.

“We expect to deliver significant advantages compared to other systems currently available,” Macnamara says. “This is a brand new system, designed from the ground up by the world’s leading supplier of auxiliary equipment for plastics processors. It incorporates the most advanced components and controls, as well as the industry’s best granulators. We back it with a dedicated extrusion team that includes design, sales, marketing and technical support, and we will be able to offer it at prices that are equal to or less than what other suppliers charge.”

Conair plans to market the system globally to extrusion processors and extruder OEMs.

 

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

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