WORLD CLASS SHEET EXTRUSION SYSTEMS Corporate Headquarters Aurora, IL About PTi PTi is a leading producer of high quality plastic sheet extrusion systems. Engineered to exact standards PTi systems offer a unique array of design features resulting in superior equipment performance. Supporting a world wide marketplace, PTi provides its customers with sheet extrusion systems that manufacture sheet goods to the highest quality standards found anywhere throughout the industry. This brochure contains a comprehensive sampling of products and services that PTi offers. While not intended to be all inclusive there are many equipment configurations contained in the pages to follow that provide solutions to a multitude of applications facing the sheet producer for today and beyond.
ROLL STANDS PTi offers several roll stand configurations used to produce sheet gauges ranging from 0.006 1.000 inches/0.15 25.0 mm at sheet widths ranging from 24 130 inches/600 3,300 mm. REVOLUTION roll stands feature linear bearing guided roll actuation with direct acting cylinders positioned on roll shaft centers. TRIDENT roll stands feature heavy duty pivot arms for roll actuation using a lever advantage cylinder placement. REVOLUTION is available in vertical, horizontal and J-stack arrangements. TRIDENT is only available in a vertical and J-stack arrangement. Each model platform is available using pneumatic or hydraulic roll actuation (depending upon the application and roll loads required) and is equipped with a full complement of options and features as described in the pages to follow. Hybrid REVOLUTION Model VD701836* Five Roll Sheet Take-Off System used to produce high output sheet directly feeding a thermoformer (inline arrangement). Special features include PTi s patented telescoping frame for ease of operator access during thread-up and maintenance activities. Hybrid REVOLUTION features both linear bearing guided and pivoting arm roll actuation in order to gain the benefit of the direct acting cylinder roll actuation while reducing the primary nip centerline. Sheet Take-Off System in retracted open position for access to downstream side of the primary roll stand (PTi Patent No. 7,165,962 B2). 3 *Model VD701836 designation VD refers to Vertical Down stack arrangement, followed by 70 as the roll face width, then 18 as the first roll diameter and finally 36 as the middle roll diameter with all numeric figures in inch units.
REVOLUTION Model VD661518 Sheet Take-Off System used to produce high quality packaging sheet in roll stock form. System is specifically configured for CE compliance. Unique features include rear positioned lamination capability for the production of barrier laminated sheet materials. Back side of Sheet Take-Off System shown fully extended in the running position. Telescoping conveyor permits system retraction with pull roll unit remaining fixed such that downstream devices (i.e., winder in this case) can be installed in a stationary position. REVOLUTION Model J841830 Sheet Take-Off System used to produce high capacity packaging sheet in roll stock form. Unique J-stack design permits close approach die to nip point arrangement. Large roll shaft ports and rotary unions combined with specialty high flow water circuits optimize cooling performance required for the process. 4
PP/PS/PLA SHEET SYSTEMS PTi provides mono- and co-extruded sheet systems that are specially configured to produce a variety of sheet materials including custom and industrial sheet goods as well as sheet for blister-packaging, formfill-seal, re-sealable food enclosures, clam shells and generic food packaging. TRIDENT Model 6000/3500 Co-Extrusion Sheet System used to produce custom sheet. Downstream devices include a high speed sheeter and winder unit. Process: Custom Sheet Resins: Multi-Layer PE, PS, PP and PETG Gauge: 40 80 mils (1 2 mm) Width: 68 inches (1,725 mm) Rate: 3,000 3,500 pph (1,360 1,590 kg/hr Operator access platform for safe convenient access to die bolts Motorized roll gap control Installed in U.S. Model 6000 (6"/150mm) 32:1 L/D 500 HP AC Pivoting base permits ease of screw extraction into the aisle-way Tuck under motor placement minimizes machine footprint Model 3500 (3.5"/90mm) 32:1 L/D 150 HP AC Unitized base and pre-wired control panels provide ease of installation 5
REVOLUTION Model VD681624 features specialty quick disconnect drive shafts used to disengage the side frame mounted individual roll drives from the rolls for ease of pattern roll change-outs commonly used in custom sheet applications. Unitized configuration minimizes plant floor space consumption. Motorized vertical nip height control Roll temperature control water circuits located beneath the conveyor Diamond plate operator walkways throughout Air booster provides high roll load capability (600 PLI, 107 kg/cm) with pneumatics * The figures in these tables represent a rate contribution percentage increase that would be realized by coupling the primary extruder with the co-extruder for the model sizes shown. For rate data using other resins and/or co-extruder combinations please consult the factory. 6
HIGH CAPACITY PP PTi is a leading producer of high capacity sheet extrusion systems used for inline thermoforming. Recent technology advances permit large platen thermoformers to operate at both higher cycle rates and in-feed rates of extruded sheet. As these trends continue, PTi s high quality sheet extrusion systems will fulfill the added capacity requirements for today and into the future. TRIDENT Model 8000/6500/5000 High Capacity Co-Extrusion Sheet System including a TRIDENT Model VD701836 Five Roll Sheet Take-Off System, featuring PTi s patented technology for a telescoping auxiliary roll carriage. Model 5000 (5"/127mm) 32:1 L/D 300 HP AC Model 8000 (8"/200mm) 32:1 L/D 800 HP AC Direct driven rolls throughout Installed in U.S. Model 6500 (6.5"/165mm) 32:1 L/D 500 HP AC Process: Resins: Gauge: Width: Rate: Inline Thermoforming Drink Cups Multi-Layer PP 60 130 mils (1.5 3.3 mm) 65 inches (1,650 mm) 10,000+ pph (4,545+ kg/hr) 7
TRIDENT Model 7000 High Capacity Sheet Extrusion System featuring a REVOLUTION Model VD661830 Sheet Take-Off System. Process: Inline Thermoforming Portion Containers Resins: Mono-Layer PP Gauge: 20 60 mils (0.5 1.5 mm) Width: 55 inches (1,400 mm) Rate: 3,300+ pph (1,500+ kg/hr) Installed in Mexico Dual bolt continuous screen changer Pendant TITAN control interface Model 7000 (7"/178mm) 32:1 L/D 700 HP AC Operator access platform for safe convenient access to die bolts Pivoting base permits ease of screw extraction into the aisle-way High flow side-car water circuits including integral spare 8
PET SHEET SYSTEMS PET packaging markets continue to expand worldwide. PTi offers a complete range of mono- and co-extruded PET sheet extrusion systems for both inline thermoforming and roll stock applications. Four zone temperature control system with spare circuit for quick changeover REVOLUTION Model J841830 equipped with AutoGAP servo roll gap-control Dual bolt continuous screen changer Model 7000 (7"/178mm) 32:1 L/D 800 HP AC TRIDENT Model 7000 High Capacity Sheet Extrusion System featuring a REVOLUTION Model J841830 Sheet Take-Off System. Process: Resins: Gauge: Width: Rate: Roll Stock Mono-Layer PET 10-60 mils (0.25 1.5 mm) 74 inches (1,880 mm) 5000+ pph (2,270+ kg/hr) 40 offset for downstream equipment to accommodate spatial constraints Installed in Canada 9
TRIDENT Model 4500/3500 Co-Extrusion Sheet System used to produce packaging sheet. Downstream devices include a high speed winder unit. Process: Roll Stock Resins: Multi-Layer PET Gauge: 8 50 mils (0.20 1.27 mm) Width: 60 inches (1,525 mm) Rate: 2,000+ pph (910+ kg/hr) Installed in France Telescoping conveyor allows fixed placement of winder unit REVOLUTION Model R661518 with motorized roll gap and vertical nip height Model 4500 (4.5"/115mm) 32:1 L/D 300 HP AC Three-zone side car temperature control system with modulation valves and by-pass loop special for PET Model 3500 (3.5"/90mm) 32:1 L/D 150 HP AC Pivoting base permits ease of screw extraction into the aisle-way 10
BARRIER SHEET SYSTEMS Demand for technology driven barrier packaging solutions for form-fill-seal, modified-atmospheric packaging (MAP) and controlled-atmospheric packaging (CAP) continue to reach all time highs. The prolificacy of single portion barrier food containers can be seen on grocery store shelves worldwide. PTi provides high quality co-extrusion sheet systems used to produce these barrier packaging materials through direct extrusion and/or laminated film technologies as described below. TRIDENT Model 6000 Complex Co-Extrusion Sheet System featuring a TRIDENT Model VD781836 Five Roll Sheet Take-Off System for producing PS, PP and PS/PE based symmetric and asymmetric barrier sheet materials. Installed in U.S. Model 3500 (3.5"/90mm) Extruder for a Virgin Skin Layer Model 6000 (6"/150mm) Extruder for Regrind Materials Process: Roll Stock Barrier Packaging Sheet Resins: Multi-Layer PS, PP and PS/PE Gauge: 20 50 mils (0.50 1.27 mm) Width: 70 inches (1,780 mm) Rate: 4,500+ pph (2,045+ kg/hr) Model 2500 (2.5"/64mm) Extruder for the Barrier Layer 11
SIZING GUIDELINE Combine extruder sizes for the desired Regrind and Virgin Skin Layers based on the percent layer distributions indicated together with the Barrier Layers to yield the desired combination (Model 5000 refers to a 5 inch or 127 mm bore size). When using PET, regrind can not be recovered back into the process. For PE cap layers use PP sizing data interchangeably. Telescoping conveyor allows fixed placement of winder unit Model 2500 (2.5"/64mm) Extruder for Tie Layers Heavy duty, customized adapter network provides operator accessibility, permits feed screw removal pathways and pressure balanced bores to assure stable process conditions are maintained. Model 3500 (3.5"/90mm) Extruder for a Virgin Skin Layer Model 3500 (3.5"/90mm) Extruder for a Virgin Skin Layer Unique Five Roll Sheet Take-Off System features downstream operator access for safely cleaning rolls during production runs; individual roll drives; spare water circuit for roll temperature control and auxiliary screens for video gap and gauge profile viewing. 12
SPECIALTY SHEET SYSTEMS Various forms of extruded sheet are extensively represented within automotive, marine/recreational, agricultural, consumer/office, electronic/medical and construction marketplaces. PTi provides high quality sheet extrusion solutions for these applications. The systems represented in the following pages serve as a small sampling of typical custom and industrial sheet application examples. TRIDENT Model 5000 Sheet Extrusion System featuring a REVOLUTION Model VD6018 Sheet Take-Off System. Blender unit positioned above feed throat Installed in China Model 5000 (5"/127mm) 32:1 L/D 300 HP AC Quick roll change feature for ease of pattern roll change-outs Integral die support allows perfect alignment of sheet die Process: Cut Sheet Lenticular Resins: PMMA (acrylic) Gauge: 120 240 mils (3 6 mm) Width: 48 inches (1,220 mm) Rate: 1,200+ pph (545+ kg/hr) Precision rotary saws provide edge trimming and cut-tolength functions and include vacuum recovery of debris and dust by-products from all cutting activities. 13
TRIDENT Model 6000 Complex Co-Extrusion Sheet System featuring a TRIDENT Model J802440 Sheet Take-Off System for producing HMWHDPE based symmetric and asymmetric barrier sheet materials used to produce twin sheet fuel tanks. Process: Cut Sheet Barrier Fuel Tank Sheet Resins: Multi-Layer HMWHDPE Gauge: 240 480 mils (6 12 mm) Width: 64 inches (1,625 mm) Rate: 2,500+ pph (1,135+ kg/hr) Installed in U.S. Extended conveyor length permits suitable sheet cooling LIW feeders provide layer control via mass transfer technology TITAN Controls provide complete line coordination Telescoping conveyor allows fixed placement of cross cut saw and stacker unit Lower left image shows a typical vehicle that utilizes a twin sheet fuel tank. Upper left image shows tank placement in vehicle chassis. Bottom right image shows production facility and sheet staging areas. 14
SPECIALTY SHEET SYSTEMS PTi engineering delivers technical solutions to challenging processes including a complex co-extrusion solution for the production of Class A synthesized paint finishes for both thin and thick sheet gauge ranges (thin film for in-set injection mold/lamination as well as thick panels for thermoformed applications). REVOLUTION VU683030 Six Roll Secondary Roll Stand REVOLUTION VD681818 Primary Roll Stand Downstream Lamination configuration with dual Model 6000 (6"/150mm) Extruders. Model 3000 (3"/76mm) Extruder for Backing Layer Model 2000 (2"/50mm) Extruder for a Tie Layer 15 Model 2500 (2.5"/64mm) Extruder Equipped with a Twin Screw Side Feeder for a Specialty Color Skin Layer
Highly Customized TRIDENT Model 6000 Seven Extruder Co-Extrusion System configured with back-to-back REVOLUTION Sheet Take-Off Units. Process: Resins: Gauge: Width: Rate: Roll Stock and Cut Sheet Paint Finishes Multi-Layer Ionomer 15 300 mils (0.38 7.62 mm) 48 inches (1,220 mm) 2,500+ pph (1,136+ kg/hr) Installed in U.S. Model 1500 (1.5"/38mm) Extruder for a Masking Layer Special multi-manifold die equipped with auto-profile-control provides precise sheet tolerances. Operator access platform permits ease of operation during both thin and thick sheet production runs. Patent applied for 2007 Model 2500 (2.5"/64mm) Extruder for a Clear Skin Layer High performance water system features zone modulation roll temperature control for the six roll Secondary Lamination Roll Stand. 16
TITAN CONTROLS PTi has created a control system enabling operators to consistently run complex sheet extrusion systems across a wide range of operator skill sets that are common in today s production facilities. Many of the system examples referenced herein feature the TITAN control system equipped with advanced capabilities such as one button start-up via AutoRamp System Coordination. Swivel top permits versatile screen viewing. TITAN Plus Control System includes an ergonomic console with unique features such as a triple touch-screen capable panel that swivels 180 degrees; printer access and storage cubbies; durable work surface; USB and AC ports/plugs; alarm light bar; and optional integral seat. Icon menu selection for intuitive navigation. Convenient USB ports for laptop and keyboard connections and 120V outlet. Multiple access doors for ease of set-up and maintenance. 17
Utility Administration Run Control Process System Supervisor TITAN Plus TITAN PLC Control System * Features: Two Panelview-Plus Color Touch Screen Interfaces ControLogix PLC Platform Total Machine Control Full Graphic Display AutoRamp System Coordination Temperature and Pressure PID Control Recipe Storage (up to 50 recipes) Alarm/Fault Status (10,000 events) Trending (100 tags/minute/48 hours) Security Print Screen Modem-Internet- Support Color Printer Flash Card Storage Device TITAN Plus * Additional Features: Industrial-Grade Windows Based Computer State-of-the-Art Processor High Capacity Hard Drive-DVD/CD-RW WonderWare Run-Time License Color Touch Screen Interface Comprehensive Data Logging, Extended Trend Analyses and Recipe Storage Custom Report Capabilities Color Printer *Specifications subject to change. 18
CO-EX STRUCTURES... 2 & 3 Layer Structures A/B, B/A, A/B/A, A/B/C 2 or 3 Extruders Required 3 Layer FB with a SMD ~ ~ 3 & 4 Layer Structures A/B/A, A/B/C, A/B/C/D 2 or 3 or 4 Extruders Required 5 Layer FB with a SMD ~ ~ 3 & 5 Layer Structures A/B/A, A/B/C, A/B/C/B/A 2 or 3 or 4 Extruders Required 5 Layer FB with a SMD 3x2 Layer FB with a TMD ~ ~ 5 & 6 Layer Structures A/B/C/B/A, A/B/C/B/D, A/B/C/D/C/A, A/B/C/D/C/E, A/B/C/B/D/E 3 or 4 or 5 Extruders Required 5x2 Layer FB with a TMD 2 Layer FB/3x2 Layer FB with a TMD ~ ~ 7 Layer Structure A/B/C/D/C/B/A, A/B/C/D/C/B/E 4 or 5 Extruders Required 7 Layer FB with a SMD 5x2 Layer FB with a TMD ~ ~ 19 FB = Feed Block, SMD = Single Manifold Die, TMD = Triple Manifold Die
OPTIONS... Extruder Options Pneumatic Slide Gate Magnet Drawer Pivoting Extruder Base for Ease of Screw Removal Feed Screw Cooling Machine or Remote Mounted Panels Single Point Utility Connections Air Cooled Barrel Heaters Vacuum Vent Systems Dies, Adapters & Feed Blocks Fast Deckles Internal Deckles (full manifold or blade inserts for lips) Die Lip Heaters Contoured Die Body Fast Gap Insulation Blankets Spacer Adapters for Future Addition of Co-Extrusion Die Cleaning Carts Automatic Profile Control (APC) Future Addition of APC for Automatic Die Bolt Control Polymer Filtration Manual Screen Changers Hydraulic Slide Plate Screen Changer Dual Bolt Continuous Screen Changer Dual Bolt Continuous Screen Changer with Automatic Back-flush Continuous Rotary Screen Changer Continuous Rotary Screen Changer with Automatic Back-flush Roll Stand Options Spare Temperature Control Circuit Hydraulic Roll Actuation Boosted Air Roll Actuation AutoGAP Servo Hydraulic Roll Gap Adjustment Telescoping Conveyors for Fixed Downstream equipment Motorized Roll Gap Adjustment Motorized Height Adjustment Air Knife System for Thin Gauge Pneumatic Start-Up Leader Winder Water Cooled Pull Rolls, Idler Rolls Auxiliary Cooling Rolls Silicone Coaters Anti-Stat Bath Si2 Coaters for Top Side, Bottom Side or Both Sides Slitters Rotary Slitting Stations, Un-driven Heads Rotary Slitting Stations, Driven Heads Razor Edge Trim Slitter Edge Trim Recovery Systems Process & Instrumentation VideoGAP System Auxiliary Screen Display for Thickness Profile Melt Bank Illumination GFI Utility Outlets Installation & Site Services Track Installation for Downstream Components & Extruders Mechanical Installation Supervision & Assistance Machine Repair & Inspection Start-up, Process & System Training Pre-Startup Electrical Inspection Laser Bore Alignment Gauge Scanners Gamma Back Scatter Beta Sheet Thickness Scanners Automatic Profile Control (APC) via thickness gauge & automatic die bolts Controls TITAN Control System TITAN Plus Control System UL Certification CSA Compliant Controls CE Certified Systems Misc. Auxiliary Items Lamination Film Unwinding Systems Product Labeling via Ink Jet Printer In-line Shear Sheet Stacker Cantilevered Winder (capable of winding multiple webs) Turret Style Winder (capable of winding multiple webs) Sheet Accumulators for slowing or stopping the web during roll changes Jumbo Roll Winders Single Web Anti-stat coating system prevents static buildup on nested parts. AutoGAP digital servohydraulic positioning system for automatic roll gap control. Rotary slitter station enables precise slit cutting of sensitive sheet materials. Retractable air knife assembly moves into and out of position via hand cranks. Single-position winder is ideal for inline thermoforming applications. 20
CUSTOMER SERVICES... The success of a project is measured by the level of customer satisfaction that is maintained before and after the project has reached a conclusion. Manufacturers of machinery can be ranked accordingly by the level of service a customer receives once the equipment is placed into operation. PTi prides itself on being a world class manufacturer of high quality products and supplier of professional services. Customer satisfaction is our number one goal. Please contact one of our sales representatives for more information on PTi s products and services. 21
PTi provides our customers with a full complement of support services before, during and long after the start-up phase of the project. These services include: g Project planning, scheduling and coordination g Installation supervision and related support g Engineer services, start-up support and training g Mechanical, electrical and process diagnostics and troubleshooting g g g Laser bore alignment services Warranty and spare parts support Repair and modification site support Quality, Reliability and a Commitment to Excellence 22