EQUIPMENT.

Dust-free profile cutting

The Femco oscillating-blade foam profiler is available for fast, accurate and dust-free foam cutting. This state-of-the-art profiler utilizes a small blade with a high oscillating speed and blade tension for superior accuracy and allows for unlimited twisting of the blade in each direction. An integrated costing program, interactive nesting feature and auto-run program are said to help to maximize yield and minimize waste. (Ferry Industries, 1687 Commerce Dr., Stow, OH 44224-1752)

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Heat transfer filtration units

Two high temperature filtration systems are said to economically maintain the efficiency of heat transfer fluids and oils by filtering out contaminants such as coke and sludge, and reducing fouling of heat exchanger surfaces. Operating at temperatures up to 650 [degrees] F (343 [degrees] C), the Sentry and Vector filtration systems clean and maintain efficiency of heat transfer fluid and oil for heat users such as extruders, molders, etc. (Liquid Process Systems, 5600 Executive Center Dr., Suite 306, Charlotte, NC 28212)

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Recycling

The WARD 24 waterjet abrasive recycling dispenser removes the waste product from a tank in an abrasive waterjet cutting system, separates the poor product into a container, then washes, cleans and dries the good abrasive so it is ready to be used again. The WARD 24 is the size of a desk and is said to result in significant savings. (Easijet, 200 Northeast Ave., Tallmadge, OH 44278)

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Pulse generator 

The M3 rotary pulse generator combines universal mounting capability with a heavy mill-duty design. It is designed for attaching to a NEMA 56C mounting face or as a hollow-shaft unit for mounting onto motor shafts up to 2-3/8" in diameter. The universal mounting provides the lowest installed cost of any rotary pulse generator available today, according to the manufacturer. The M3 rotary pulse generator mounts to all motor frame sizes. No C-face is required. With the addition of a foot-mounting kit, the M3 replaces either digital foot-mounted pulse generators or analog tachs such as the BC42 or BC46. Pulse rates from 240 up to 2,500 are available. (Avtron Manufacturing, 7900 E. Pleasant Valley Rd., Independence, OH 44131-5529)

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Hot air tunnels Gas-fired hot air tunnels with high air velocity are available for curing single or dual durometer compounds, with or without metal carriers. All models are based on modular construction and are said to feature excellent belt tracking with the capability of pre-splicing belts for ease of replacement. The ovens are available in 30, 40, 50 and 60 foot lengths. (Kiffer Industries, 4905 Rocky River Dr., Cleveland, 0H 44135)

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Rotocure

This rebuilder and supplier of rubber processing machinery offers the 60" Pirelli Rotocure. Technical features of the Rotocure include: curing drum diameter of 1,200 mm (60"); upper and lower drum diameter of 1,000 mm (40"), band width of 1,500 mm (60"); welded band length of 14,300 mm; stainless steel band thickness of 1 mm; maximum drum temperature of 360 [degrees] F; maximum curing field length of 2,800 mm (110"); network pressure of 170 psi, working pressure in the steam heated platens of 142 psi; press speed from 15 to 150 m/hr. (50-500 ft./hr.); and main motor power of 1.5 hp, d.c. This unit was built in the late 1980s and was used less than two years. Takeup, wind-up and labeling units are available. (Gomaplast Machinery, 500 E. Henry St., Wooster, OH 44691)

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Preformer

The C4 preformer is a combination of the C3 precision preformer and the technologically advanced HT computerized preformer. The C4 features plc controls and simple, three-step operation. It also stores multiple settings and has an automatic cycling feature. It is capable of maximum pressures of 3,500 psi and has an extended center for easy access cleaning. Accuracy of blank weight is achieved by simply adjusting the cutter speed at startup, or during operation, or by typing in the actual achieved weight of the blank and letting the internal processor calculate the necessary adjustments. The combination of standard mechanical push buttons and the simple electronic control panel are said to ensure operator efficiency. (Barwell, 460 Tacoma Ave., Tallmadge, OH 44278-2719)

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Granulators

The company's granulator automatically transforms large reject parts and other bulky or difficult-to-handle scrap into high-quality regrind. It is said to cost less than conventional equipment. The two-stage Shuttle Granulator literally planes reject parts into small pieces, then granulates the pieces into uniform regrind. (Maguire Products, 11 Crozerville Rd., Aston, PA 19014)

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Processor handcasting system

The company's handcasting system is said to help increase the productivity and quality of handcasted urethane parts. The handcasting system is said to provide well-designed equipment that is used to cast many types of molded parts using a wide variety of urethane prepolymers. It also is said to benefit the established processor using an automatic meter-mix machine by providing handcasting capabilities. (R&M Manufacturing, 15683 Chemical Lane, Huntington Beach, CA 92649)

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Spark detection system

Spark detection and extinguishment system sensors contain photo elements which detect a spark's infrared radiation. The smallest spark triggers the sensing elements and the system immediately releases a fine mist of water downstream, extinguishing the spark without interrupting production. Optional suppressant methods can also be employed. For high temperature applications, up to 1,830 [degrees] F, fiber optic cables and sensors are utilized. (GreCon, 7747 S.W. Cirrus Dr., Beaverton, OR 97008-5968)

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Production microwave ovens

Micro-Miser microwave ovens are short, efficient ovens that can be added to existing extrusion lines to pep up production. Designed with weather-strip lines in mind, Micro-Misers are said to offer the manufacturer an effective way to boost output by introducing the fight amount of microwave energy into the profile. A unit is comprised of one or several applicators, the number of which is determined by production capacity. (Kiffer Industries, 4905 Rocky River Dr., Cleveland, OH 44135)

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Oil weigh system

The OWS Series oil weigh system is said to deliver fast, accurate oil weighing and feeding into intensive mixers. It automatically meters up to 16 different process oils to robber batch mixers, ensuring uniform batch characteristics and cycle times, while reducing scrap, according to the manufacturer. This high precision, low maintenance unit features an enclosed cabinet, vibration-isolated pump-motor assemblies, and more. (Budzar Industries, 38241 Willoughby Pkwy., Willoughby, 0H44094-7582)

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Vulcanizer 

The company's vulcanizer is designed for processing robber hose at 150 psig and 400 [degrees] F, measures 72" in diameter x 20' in length and features a mechanism for wheel-less external cart-loading, a vertical lift door and the Rapidoor wedge-lock, breech action access door for fast, trouble-free material transfer, according to the manufacturer. The company's vulcanizers are built in a wide range of sizes and design pressures and can be vertically or horizontally oriented. In addition, the systems feature simple to sophisticated controls, depending on the application. Other available features include the Rapid/Cure continuous vulcanizer for wire, cable and hose, and the airplus-steam Rapid/Capper. Rubber vulcanizers can also be designed to use steam or dry heat. (WSF Industries, P.O. Box 400 Kenmore Branch, Buffalo, NY 1421D

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Portable blasting

Rubber manufacturers investigating the use of dry ice blasting to clean molds and other production equipment may consider the company's [CO.sub.2] MiniBlast PLT-5X, a single-hose portable blasting system that uses rice-sized [CO.sub.2] pellets as the blasting medium. The single-hose design maximizes available air dedicated to the blast stream, meaning added blasting aggression and faster cleaning in applications involving strong adhesion or thick coatings. Dry ice pellets are non-abrasive and they sublimate as they strike the surface being cleaned. (CAE Alpheus, 9119 Milliken Ave., Rancho Cucamonga, CA 91730)

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Rubber molding

The use of two middle platens in rubber molding allows for demolding and insert loading during cure time. With conventional systems, the splitting of four mold plates and the changing of two middle platens leads to very long cycle times, according to the company, which started a development project to reduce cycle movements from the usual 30 seconds to 10 or 12 seconds. The use of a very fast fully hydraulic clamping unit is said to provide total support for the cavities and very fast opening and closing movements. Parallel hydraulic ejector movements move while the clamp is opening and closing. Also, when the clamp is open, the two middle plates are changed at the same time and parallel to that the grip and pick unit removes the runner. Movements are monitored by means of a deterministic multitasking control. (Maplan, A-1060 Wien, Millergasse 9, Germany)

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Size reduction

The Vulcanator features a novel low friction cutter design which is said to quickly reduce whole bales of rubber into small bits while minimizing heat rise. Rotary knives pull the material into the cutting area and disintegrate the slabs to a size fine enough to pass through a special sizing screen. The reduced particles are then expelled from the bottom of the unit. This unit features optional stainless steel construction in contact with the product and a liquid seal option. Access doors are also provided. (Franklin Miller, 60 Okner Pkwy., Livingston, NJ, 07039)

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Plug-up detection system

The ABC plug-up detection system provides early warning of excessive material buildup in cyclones, dust collectors, hoppers and chutes, and can automatically initiate counter measures in the affected area before plugging becomes a serious problem. The ABC system utilizes an infrared transmitter and receiver to constantly monitor material flow. A photo diode in the ABC receiver responds to a signal emitted by the ABC transmitter. (GreCon, 7747 S.W. Cirrus Dr., Beaverton, OR 97008-5968)

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Cartridge dust collectors

Sternpulse Jet-Pulse cartridge dust collectors are said to be compact, easily-maintained, energy-efficient solutions to in-plant air pollution problems. Rated from 1,500 to 11,400 cfm, their proven design and efficient operation make them an attractive choice for chemical packaging, powder coating, pigment mixing and blending, and other nuisance dust applications. Stempulse dust collectors are available in 4, 6, 8, 12, 16 and 24 cartridge configurations. (Sternvent, 253 W. Fort Lee Rd., Bogota, NJ 07603)

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Linear motor technology

Linear servo motors utilize an ironless core design that is said to offer reduced motor cogging and provides high peak-to-continuous force ratios, and extremely high acceleration in high-speed applications. The motor itself has no moving parts, and is built to attach to the customer's bearing system. It can be custom configured to meet demanding industrial applications. Patented machine winding technology is said to offer exceptional unit-to-unit repeatability at a significantly lower cost, according to the manufacturer. This technology is said to provide the company's linear servo motors with exceptional electromagnetic characteristics, including a high force to coil weight ratio, peak forces to 250 lbs., continuous forces to 80 lbs., high copper fill and superior thermal performance. (MTS Automation, 14000 Technology Dr., Eden Prairie, MN 55344-2290)

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Twin screw extrusion system

Twin screw systems are configured to continuously mix high levels of metal fillers (90%+ by weight) with various polymer binders such as nylon, acrylic and various multi-melt point blends. A typical system includes a corotating intermeshing twin screw extruder equipped with a side stuffer, feeders, hot face pelletizer and vibratory cooling tower. The polymer is fed into the main feed throat and melted/mixed prior to the introduction of the metal powder via a twin screw side stuffer. Loss-in-weight feeders meter both the binder and filler feed streams into the extruder to maintain formulation accuracy. The compounded material is pelletized at the die face via a flywheel cutter and pneumatically conveyed to a vibratory tower, which conveys the materials upward via imbalanced motors to cool and separate the pellets. By separating plastication from the mixing step, component wear is said to be significantly reduced, since the metal fillers are not present during melting. (American Leistritz Extruder, 169 Meister Ave., Somerville, NJ 08876)

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Double planetary mixers

Heavy duty double planetary mixers are used for high viscosity products traditionally produced on sigma blade mixers. The latest double planetary model provides the capability to mix higher viscosity materials in batches to 400 gallons. The machines are supplied with specially built gearboxes designed to handle the increased torque of the higher viscosity applications. They also include new dual post airfoil hydraulic lifts to provide added rigidity and strength, according to the company. Standard options include vacuum or pressure construction, jackets for heating or cooling, scrapers to maximize heat transfer, and internal machining of the mix can and the blades for close blade to bowl clearance. This mixer is normally built using type 304 stainless steel. However, alternate materials are available to meet specific user needs. (Charles Ross and Son, PO. Box 12308, Hauppauge, NY 11788)

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Laboratory extrusion

The Yellow Jacket Bantam cast film extrusion system is said to be ideal for laboratory testing, research and development, quality control and extruding in very small batches. The lines produce cast films from a wide range of thermoplastics up to 6" (150 mm) wide and .010 inches (.25 mm) thick. The lines feature 1/4' to 5/8" Yellow Jacket Bantam extruders which are built using industry standard feed end driven screws and double reduction helical gearboxes. The Bantam Feedblock for multi-layer structures is available for two or more layer cast film. Flexible lip dies up to 6" wide are utilized for precision extrusion. For adequate precision cooling of the film, Bantam 6.5" cast film take-offs feature a 4.5" diameter water cooled hardened chrome plated chill roll standard, with various roll finishes available including matte, embossed and other types. Roll speed is easily adjusted using the speed pot. Edge pinning helps to keep the film in contact with the chill roll. (Wayne Machine & Die, 100 Furler St., Totowa, NJ 07512-1896)

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Injection molding 

Unyka series injection molding machines feature an increased opening stroke and a five-point toggle clamping system. These machines use variable delivery pumps as standard equipment. The Dynamika series is designed for high speed molding and is said to be the machine of choice for thinwalled applications. The series features a Vickers integrated motor pump to power the accumulator with closed loop servo-valve controllers, accumulator control on mold position speed, mold open and close, ejector speed and position and hydraulic motor speed. These servo-controller functions are said to provide improved precision and repeatability to the critical machine functions. Also produced are extended opening machines (Unyka CL) and co-injection molding machines (Unyka-2) suited for multi-component and multi-color injection processes. (Louis P. Batson, P.O. Box 3978, Greenville, SC 29608)

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Two-roll mill

The company's two-roll mills are said to be easily cleaned, versatile, compact, quiet and energy efficient, and feature automatic mixing and safety. A scaled up version of the company's laboratory mills incorporates very smooth stainless steel side frames, sealed roller bearings, lightweight spring loaded material guides which were in contact with the rolls, thermally efficient rolls, color touch screen PLC access unit, hydraulic nip control and a very compact design. A patented roll reversal system for automating the mix cycle (Mix Assist) was incorporated, plus an automatic safety test feature. The machines are said to be extremely quiet. Twin electrical variable speed drives are fitted to provide a variable friction ratio facility which is said to be of great benefit when mixing rubber and silicones, according to the company. The mill range will mix a variety of materials. (J.R. Dare Limited, Ashbridge, Trafford Park, Manchester, England M17 1RP)

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Two-drawer oven

The No 730 is a 500 [degrees] F electric cabinet oven, currently being used for heating flat urethane sheet material prior to vacuum forming. The 2,000 cfm blower, driven by a 2 hp motor, provides horizontal recirculated airflow through the workspace. The safety equipment for handling flammable solvents at a maximum operating temperature of 500 [degrees] F includes a purge timer, manual reset excess temperature controller, separate heating element control contactors, 975 cfm powered forced exhauster, powered forced exhauster air flow safety switch and a recirculating blower air flow safety switch. This oven includes an SCR power controller for [+ or -] 5 [degrees] F temperature uniformity throughout the workspace. Temperature is constantly monitored via a 24 hour, 10" diameter circular chart temperature recorder. (Grieve, 500 Hart Rd., Round Lake, IL 60073-9989)

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Injection valve

This manufacturer of screws, barrels and machine components has introduced a carbide-faced injection valve assembly that is said to decrease wear and increase valve life. Using a carbide coating, a wear resistant layer of carbide is applied to the valve's wear surfaces between the tip and ring or the seats and ring. This carbide coating is said to be particularly applicable to machines running abrasive compounds or utilizing glass fillers. (General Plastex, 35 Stuver Place, Barberton, OH 44203)

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Dispensing valve

The 2100-127 Snuf-Bak valve automates the dispensing of single-component adhesives, sealants, greases and other flowable materials while eliminating the mess of material dripping after the valve is shut off, according to the manufacturer. The double air-operated, automated dispense valve is said to be uniquely designed to ensure an immediate start and stop for all dispensing operations, with no run-on. It features a controlled flow rate and a snuff-back action at the nozzle tip for quick shut-off of material flow. The Snuf-Bak valve includes adjustable packing and abrasion-resistant seals and carbide hardened components. It is designed to handle both high- and low-viscosity materials. (Sealant Equipment & Engineering, 45677 Helm St., Box 701460, Plymouth, MI 48170-0965)

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Continuous printing system

The Print-A-Mark Model 5324 Direct Print is designed for continuous printing on web materials, such as robber and plastic film. Using precision-molded rubber dies and high contrast inks for use on both porous and nonporous materials, it is said to be an economical and simple solution for many coding applications. The lightweight unit is driven by frictional contact with the material to provide continuous printing up to speeds of 600 feet per minute. Built to European Conformity standards, the unit is said to be easy to install, operate and maintain with few adjustments and no complicated programming, according to the manufacturer. The 24" circumference type wheel has a width of 3" to accommodate a variety of character styles and sizes. For a highly distinctive, professional touch, almost any type of font can be used or any logo reproduced, according to the company. (Matthews International, 6515 Penn Ave., Pittsburgh, PA 15206-4482)

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Compounding extruders

Prodex extruders are available in screw sizes ranging from 2" to 10". Included are the Prodex I extruder featuring 24:1 L/D, air-cooled, non-vented, bimetallic barrels with choice of screws; the Prodex II, offering longer L/D ratios and available with either air or water barrel cooling and vented barrels; and the advanced Prodex III, available with screw diameters to 10 inches and barrel L/Ds up to 50:1. The Prodex extruders are said to offer processors several key benefits, including the ability to increase output and production rates, increased speeds (in some cases up to 800 rpm), improved mixing and dispersion, and faster changeovers and color changes, according to the company. All machines feature standard bimetallic barrels and are available with a choice of the company's Double Wave or Triple Wave screws for optimal performance, and now are said to feature higher output at lower temperatures. (HPM, 820 Marion Rd., Mount Gilead, OH 43338-1095)

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Thermoplastics filtration

The LK-SWE melt filter is a system developed on the basis of the company's standard K-SWE technology. This unit ensures the 100% continuous production process, i.e., a continuous melt flow is ensured at all times (even during the replacement of a screen) without any need for a shutdown of the downstream production process, according to the company. With this filtration system, engineers are said to have responded to customer requests and have enlarged the filtration area available in the melt filter, without modifying the size of the unit. If the screens and breaker plates are used along with the company's Super Plates (optional), this will further enlarge the actual filtration area. (Kreyenborg Industries, 6611 Bay Circle, Suite 100, Norcross, GA 30071)

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Blow molding scrap recovery

The 35-25/BLM can recover on-line all the process waste from containers of up to 5 liters in volume, including blow molded objects, tops and tails, and parison. Characteristics of the machine are said to include the following: hopper and opening of grinding chamber large enough to accept even wastes deformed at the beginning of the process; the grinding chamber is shaped in such a way as to capture blow molded objects, avoiding the characteristic bounce when they come into contact with the rotating blades; the speed of the rotor has been designed to give the best compromise between the need for a clean cut without tipping, high productivity, capture of blow molded objects, reduced noise and the elimination of material fly-back; high productivity/power ratio despite the fact that blow molded objects are of a difficult shape for efficient grinding; the energy supplied by the rotor tends to be dissipated in the deformation of the blow molded objects rather than used for cutting; and the discharging is suitably sized to give the necessary breathing space for working in line with a blow molding machine. (Tria di Anceschi e Figli Srl, Via E. Fermi, 8 1-20093 Cologno Monzese (MI), Italy)

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Gravimetric blenders

Applying new hardware and software advances, the company is said to have boosted by up to 200% the maximum throughput rates of its gravimetric blenders. This increase in productivity is said to be available as a standard feature across the company's entire weigh scale blender product line, enabling processors to employ smaller, lighter and less expensive gravimetric blenders on molding and extrusion equipment. (Maguire Products, 11 Crozerville Rd., Aston, PA 19014)

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Calender and service shells

Plastic calender and service shells for the tire, robber and fabric industries are said to offer significant advantages over wood shells. They are substantially lighter in weight, yet more durable, according to the company. Plastic shells are also said to eliminate product contamination and splintering that often occurs when using wood shells. Plastic shells are made from high-density, resilient plastic components with a tubular-steel center. (Everhard Products, 1016 Ninth St., S.W., Canton, OH 44707)

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Lab mixer

The company's 1/2-pint double planetary mixer model is designed as a table-top model to easily enable its use on existing laboratory benches or portable tables. All wetted surfaces, internal and external, are constructed of polished stainless steel. The stirrers are fixed and the mix bowl is removed by simply undoing a special hinge and clamp arrangement. The mixer is designed to run under full vacuum conditions and includes a variable speed drive. Charging and viewing ports are installed in the hood to permit close observation of the mix being processed. (Charles Ross & Son, 710 Old Willets Path, Hauppauge, NY 11788-0615)

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Small media mill

The patented QC-Mill is available for super fine grinding. This small medial mill is said to operate with unique centrifugal high circulation mode. The specially designed rotor of the QC-Mill is said to create strong centrifugal and shearing forces inside the mill. (Union Process, 1925 Akron-Peninsula Rd., Akron, OH 44313)

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Extruder

The ZSK 50 Mega co-rotating twin-screw extruder fills a size niche between the ZSK 40 and the ZSK 58, and has a user-friendly design with tie rods instead of individually bolted, flanged barrels, according to the company. It is heated with cartridge heaters rather than external heater shells. This design is also the basis for the ZSK 25 World Lab Extruder and the redesigned ZSK 40 Megacompounder. They are said to match the geometric design parameters, the speed range (up to 1,200 rpm) and the high torque capabilities of the larger size extruders in the company's Megacompounder series. (Krupp Werner & Pfleiderer, 663 E. Crescent Ave., Ramsey, NJ 07446)

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