1. NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14

2. What costs should we reduce ?
Cost per Kg of output.
Cost per part produced.

3. Factors Include:
Kg or parts per hour
But good parts – minimize scrap.
Energy costs.

4. Output vs Screw Wear
00
20
40
60
80
100
120
140
160
180
200
.10 .20 .30 .40 .50 .60 .70 .80 .90 1.0
GRAM/SEC
CLEARANCE PER SIDE in mm
Screw Diameter = 120 mm. 130 RPM.

5. 118.20
118.40
118.60
118.80
119.00
119.20
119.40
119.60
119.80
120.00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
SCREWDIAMETERmm
Plot of Screw Diameter:
Measured
Max OD
Min OD

6. Special Coatings: X830
Hardfacing
Base
Material
X8000TM
Carbide CoatingStandard Surface Finish: (60 Ra)
Polished Surface Finish: Ra = 0.2 (16-32 Ra)

7. RATE OVER TIME
00
20
40
60
80
100
120
140
160
180
200
RATEGRAM/SEC
TIME
Screw 120 mm
____ = 4140/C56/Cr
____ =4140/X830/X-8000

8. Most Machines have „GP‟ Screws
(„General Purpose‟)
(Or „Generally Poor‟ ?)
(Or „No Purpose‟)

9. Mixing Screw Illustration (Pulsar Mixer)

10. POLYCARBONATE LENS PROJECT
 RESIN: PC (TYP 740-4) CLEAR
 100% CHECK ON BLACK SPECS
PROBLEM: SCRAP RATE ~ 20%
 DEMAG 200-840
 SCREW DIAMETER 45 MM
 L/D RATIO 22:1
 SHOTWEIGHT: 50 Grams
 CYCLE TIME: 23 Sec.
TARGET:
 IMPROVE PRODUCT QUALITY
 REDUCE SCRAP RATE

11. 44,80
44,85 39,60
39,58
43,0
39,7
44,4
-0,05
-0,1
258
240
159
100
DIA 38,0
12,010,2
59,0
-0,1
-0,2
± 0,5
STAMP:“ SN-XXXXX”
“17-4PH+ ST12-L1
2 x 30°
SPLINES
OD= 44,4 -0,05/-0,1
CD= 40,0 -0,05/-0,1
NUMBEROFTOOTH = 21
1020
1278
45 MM SCREW
Drawn by: almh Date:
Drawingnr.: SCHR_291NOTES:REVISIONS:
5.
4.
3. MATERIAL: 17-4PH-ST12-L1
1. CUSTOMER:
2. I.M.M. DEMAG 200-560/840This drawing is the property of
NordsonXaloy-Europe GmbH. Reproduction or
disclosure of any part of this drawing
or information therein and the use
thereof for making other drawings or for
making apparatus therefrom are prohibeted
without priar written consent of NordsonXaloy-Europe GmbH.
• DISTRIBUTIVE MIXER
• LOW SHEAR
• LOW MELT TEMPERATURE
• SUITABLE FOR SHEAR SENSITIVE
RESINS
POLYCARBONATE LENS PROJECT

12. RESULTS:
CYCLE TIME REDUCTION: 3 seconds
 SCRAP RATE REDUCED FROM 20 % to 1.5%
BASED UPON 6000 hrs:
productivity improvement 625000 pcs = 41%
TOTAL INVESTMENT € 5000 (screw only)
ROI: 21 days
POLYCARBONATE LENS PROJECT

13. NIPA Cost Saving Workshop
Screw Design & Smart Heat
21/03/14

14. AUTOMOTIVE PROJECT
 I.M.M. BATTENFELD HM 19000 - 2700
 SCREW DIAMETER 130 MM
 L/D RATIO 26:1
 SCREWSPEED MAX: 120 RPM
GOAL:
 PROCESS PP + 40% LGF
 SHOTWEIGHT: 4400 Grams
 OVERALL CYCLE TIME: 70 Sec.
 IMPROVE PRODUCT QUALITY

15. SN-#
4765 O.A.L.
395
1285
119,8
119,7
STAMP -
NOTE: STAMP NUMBERSSO THEYCAN
SPLINESACC. DIN 5480
BESEEN BYOPERATOR
130 MM SCREW FOR LGF
Drawn by: almh Date:
Drawingnr.: SCHR_458NOTES:REVISIONS:
5.
4.
3. MATERIAL:
1. CUSTOMER:
2. I.M.M.:BATTENFELD HM 19000This drawing is the property of
NordsonXaloy-Europe GmbH. Reproduction or
disclosure of any part of this drawing
or information therein and the use
thereof for making other drawings or for
making apparatus therefrom are prohibeted
without priar written consent of NordsonXaloy-Europe GmbH.
• DISTRIBUTIVE MIXER
• LOW SHEAR
• LOW MELT TEMPERATURE
• SUITABLE FOR SHEAR
SENSITIVE RESINS
AUTOMOTIVE PROJECT

16. RESULTS:
CYCLE TIME DEDUCTION: 4 sec = 5.7%
BASED UPON 6000 hrs:
productivity improvement 18702 pcs = 6%
INCREASE IMPACT STRENGTH 10%
TOTAL INVESTMENT USD 88500
(screw,barrel,valve)
ROI: 270 days
AUTOMOTIVE PROJECT

17. Product: Bucket: 10 Ltr.
Resin: PP MFI: 8
Shot-weight: 584 GR
Screw diameter: 98mm with LD = 25
OE solution 32,9 gr/rev
XALOY solution 35,5 gr/rev
Our design: MeltPro Barrier + Z-Mixer
Investment: 7500 EUR
Benefit:
• Cycle time reduction by 7.5%
• ROI: 40 days
PACKAGING

18. TWINSHOT
The TWINSHOT®
Co-Injection Technology
enables a conventional
machine with a single
barrel and screw to inject
two materials in a single
shot with one material
totally enclosing the other.

20.  SKIN RESIN:
PP+20%CaCO2
 CORE RESIN: Regrind
PP+CaCo2+blowing agent
 SHOTWEIGHT: 3800 Gr.
 INVESTMENT: 117500
 ROI: 160 days
TWINSHOT EXAMPLE

21. Nordson XALOY
PRESENTATION
Integrated Barrel
Heating Technology

22. Sustainability requires True Innovation
nXheat®
Induction heating
Mica band-heaters
Ceramic band-heaters
Infrared heater
systems
Insulating
blankets
SmartHeatTM
Integrated
Melt-Stream
Heating
1950
1960
1970
2003
2006
2011
Melt-Stream Heating
Evolutionary Timeline

23. Introducing , a heating coating
for barrels
A barrel heating technology that offers the:
 Best process control
 Most energy efficient
 Most reliable
 Most compact
 Safest
…barrel heating system on the market today

24. What is ?
 Plasma sprayed metallized-ceramic heater
coating
 Pure resistive heating
 Simple retrofit of existing heater bands
 Eliminates exposed wires for maximum safety
 Supplied with thermal insulation
Plasma heater layer
Integrated heating technology
Easy to thoroughly insulate

25. Benefits
• Improved Process Control
 Less Scrap – Higher Yield
• Superior Energy Savings
 Reduces your costs & saves money
• Safer Operation
 Less operator injury risk or fire potential

26. Improved Process Control
Non-uniform temperature distribution Uniform temperature---Fully insulated
What benefits could apply to your processes if you could rely on a 55% improvement
in temperature consistency shot to shot?
Temperature Response with Band-Heaters
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Temperature(o
C)
32
96
160
224
288
352
416
480
544
608
672
736
Temperature(o
F)
Temperature Response with SmartHeatTM
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
0 5 10 15 20 25 30 35 40 45 50
Elapsed Time (minutes)
Temperature(o
C)
32
96
160
224
288
352
416
480
544
608
672
736
Temperature(o
F)

27. Improved Process Control
 Uniform heat profile leads to a more stable process and
consistent part
Part Weight Variability
-0.5
-0.4
-0.3
-0.2
-0.1
0.0
0.1
0.2
0.3
0.4
0.5
0 5 10 15 20 25 30
Cycle Number
DeviaitonfromMean(grams)
Conventional Barrel
New Barrel
Band Heaters
SmartHeat Barrel

28. Improved Process Control
 Ramps to target 30% faster using 23% less energy
 Response time to maintain temperature is quicker

29. Superior Energy Savings
 30%-60% more energy efficient than band heaters
 Design watt density is 60% of band heaters
(1000 watt band heater = 600 watt SmartHeat™)
 Virtually eliminates heat losses to the environment
 Save on A/C expense
 For process temperatures up to 750oF (400oC)

30. Superior Energy Savings
Lab Machine Trials -- Power Distribution Profile
(36 mm screw, PP, 28 sec cycle, 38 gram shot, 249o
C/480o
F melt)
0
200
400
600
800
1000
1200
1400
1600
Nozzle power Discharge Middle Feed
Power(watts)
A) Band-heaters -- not insulated
B) SmartHeat -- not insulated
C) SmartHeat -- insulated
50% Less Energy
over Heater Bands

31. Safer Operation
SmartHeat™ barrels are supplied with a thermal insulation wrap and straps.
The complete system provides “Cool to the Touch” operator safety and the covered
electrical connections provide for significant fire hazard safety improvements.

32. Safer Operation
 Eliminate fire hazard from
numerous wires from multiple
heater bands
 All wiring run under
thermal insulation for safety
Elimination of all the loose wiring

33. Melt Pipes
SmartHeat Melt Pipe
• Uniform heat end to end
• No loose wiring (buried under the
insulation)
Conventional Heater Bands
• Non-uniform heat
• Loose wiring

34. Maintenance Free
 Eliminates heater band maintenance
 Simple retrofit to existing heater band wires and control
 Plastic resin easily chips off
Hardened resin just pops right off

35. Typical ROI
Southern US Southern U.S. (FL, TX, GA, AL, MS)
about 12 months air conditioning
Example
Customer: processor in Texas
Machine: 60 mm Engel machine
Utility Cost: $0.12/kWh.
ROI: about 12 months

36. Typical ROI
Midwestern US (OH, MO, IN, CA)
about 8 months air conditioning

37. Typical ROI
Northern US (MI, MN, WI, MA)
no air conditioning

38. Customer Testimonial
Siemon Company
55 Ton Milacron Roboshot Machine
8 cavity mold running Makrolon PC
Electrical Connectors
• ROI of less than 1 year
• Cut start up time by 50%
• 80% Improvement in shot to shot consistency

39. Customer Testimonial
Piolax Corporation
50 Nissei FN4000 Machine
32 cavity mold – 24 sec cycle
Automotive Interior Parts
• Energy savings of 59%
• Multiple SmartHeat being ordered

40. on Melt Pipes
Features
• Uniform heater coating around the
melt pipe
• Integrated heating system with
SmartHeat™ as part of the melt
pipe
• 25% energy savings or more
• Eliminate band heaters and their
maintenance
• Resin will not stick to SmartHeat™
coating
Benefits
• Consistent and uniform heating of
polymer providing a stable process and
fewer rejects
• Considerably less wiring creating a
safer, cleaner work environment
• Improved ROI using SmartHeat™
• Less downtime when SmartHeat™ is an
integrated part of the melt pipe
• Less downtime from cleaning

41. on Melt Pipes
Application photos

42. on Melt Pipes
Application photos / Paragon Films

43. on Nozzles
Feature
• Eliminate nozzle band heaters and
all their maintenance
• Uniform heater coating around the
entire nozzle
• Resin will not stick to SmartHeat
coating
Benefits
• Less downtime when SmartHeat™ is an
integrated part of the nozzle
• Consistent and uniform heating of
polymer providing a stable process and
fewer rejects
• Less downtime from cleaning

44. Superior Process Control
Better Shot Consistency
Stable, Uniform Heat Profile
Maximum Energy Savings
Maintenance Free
Extremely Durable & Safe
Summary