Case Study - CO-EXTRUSION PRESS LINE FOR PLASTICS

Automation Solution for the Plastics & Composites Industry

This co-extrusion press line, built by TCA for a customer in the plastics and composites industry, integrates both a 2-1/2" cap extruder and 4-1/2" core extruder to produce parts in 6", 9" and 12" widths.

It includes latest technology heaters and temperature controls to keep the polymers at the optimal temperatures, and a TCA180 ton servo press for fully programmable, high-speed, high-precision operation. Other notable features of this co-extrusion line include a press feed walking beam system and a scrap system that grinds the fall-off from the trimmed parts. It is controlled by a Siemens TI505 Platform PLC, with a Profibus DP interface, which is located between the trimmer and cooling belt system for easy access.

Fully designed by our engineers and built by our skilled machinists and machine builders, this 10' x 60' line was full tested at our site running at over 90% uptime before being shipped to the customer.

TCA supervised the installation and commissioning, and provided extensive documentation, including schematics of all the hydraulic, pneumatic, and electrical subsystems.

HIGHLIGHTS

PROJECT DESCRIPTION

We manufactured this Co-Extruder Single Press Line for use within the plastic and composites industry.

CAPABILITIES APPLIED / PROCESSES

Mechanical Design

  • Design Co-Extrusion Press Line
  • Created 3-D Models

Manufactured in-house using our CAD/CAM equipment and capabilities

PLC Programming

HMI Design & Programming

Documentation

  • Hard Copy and CD-ROM Copy of Machine Manuals 
  • AutoCAD Assembly Drawings and hydraulic, Pneumatic and Electrical Schematics
  • Line Layout Drawing
  • Foundation Bolt Plan

Site supervision of installation

Commissioning of System

Operator and Maintenance Training

Warranty

  • 1 Year Warranty up to 3,000 Hours Running Time

CYCLE TIME

6 to 6.5 Parts Per Minute

OVERALL SYSTEM DIMENSIONS

10 ft X 60 ft

PRESS LINE FEATURES

Integration of 2-1/2" Cap Extruder and 4-1/2" Core Extruder

  • Including Extruder Controls
  • All Interconnecting Piping
  • Gear and Screen Changer Pump Spool Piece
  • Heaters
  • Temperature Controls

Charge Conveyor System w/ Automatic Charge Cutter

TCA Designed & Built 180 Ton Servo press

Press Feed Walking Beam System

Hot Bed Conveyor

Integration of Laser Printer

Part Trimmer Station

  • Accommodates 6", 9", and 12" Wide Parts

Scrap System

  • Processes Scrap Through the Grinder

Siemens TI 505 Platform PLC w/Profibus DP Fieldbus Interface

Human Machine Interface (HMI)

  • Located Between Trimmer and Cooling Belt System

OVERALL LEAD TIME

19  weeks