High-Performance Air Rings + Gauge Control Systems Reach Limits
High-Tech Air Ring COM3 with integrated Gauge Control System Proven peak performance for your extrusion line The new dimension in bubble cooling KARAT COM 3 air ring sets new standards: In the past the air ring limited the performance of a line. The new design of the high-performance air ring KARAT by Kdesign changes everything. Since its introduction it has been proven and tested in all applications and lines. Peak performance is no magic, but results from the profound knowledge of technical correlation, based on substantial fluidic studies and thorough practical tests carried out in cooperation with our customers. KARAT COM3 The advantages of this air ring concept are: Considerably higher output (by 25-60%) Easy handling Wide operating range Low power consumption (relating to performance in kg) Fast return on invest Easy to upgrade 2 Kdesign GmbH
Typical Installations of COM3 with integrated Gauge Control System Lamination Film Stretch Hood Film Karat COM3 250mm, 450-530kg/h Karat COM3 280mm, 380-480kg/h FFS-Film Packaging Film Karat COM3 180mm, 320-400kg/h Karat COM3 315mm, 500-700kg/h Kdesign GmbH 3
High-Tech Air Ring COM2 with integrated Gauge Control System The optimal system for your line Patent system Area of application: All air rings made by Kdesign are product- and customer-specific designs. The following types are available: Die sizes from 50mm to 2500mm diameter Operating range according to customers blow-up ratios Stationary and rotating die heads For lines with and without IBC Normal or long-neck bubble The high-performance air ring KARAT stands out for: Highest cooling rate Improved film tolerances Absolute even air distribution Excellent bubble stability Maximum air flow, minimum pressure drop Easy handling Optimal retrofitting of gauge control system VARIOcool 4 Kdesign GmbH
Gauge Control System HD High-Tech Air Rings KARAT COM2 HD (long neck) HDPE line 6µm production Improved thickness tolerance at 6µm production Air ring Karat 2 HD for HD-PE long-neck production VARIOcool HD is the optimal system for long-neck production. On these lines the entire cooling air stream is used for the profile regulation, making it incomparably effective. The different neck torsion is automatically detected, thus providing for the best control result, at any time. The gauge control system is integrated into the high performance air ring KARAT, so that a retrofitting of this air ring also effects a considerable performance optimisation. The performance increase on lines with long-neck as well with the KARAT air ring. Overview of the VARIOcool HD: Optimal profile improvement Automatic calculation of torsion Applicable also in combination lines Maximum line performance due to high-performance air ring KARAT Kdesign GmbH 5
Gauge Control System RD High-Tech Air Rings KARAT COM2 RD (Rotating Die) Air ring Karat 2 RD for LD- PE production rotating die For all rotating or reversing die heads or platforms we can offer the RD Systems especially designed for this application. Overview of the VARIOcool RD: Special components for this application, e.g. rotating air distribution systems Secure wireless data transmission Safe allocation of the thickness profile to the die Improved output Better air distribution Improved winding quality Optimal profile improvement 6 Kdesign GmbH
Gauge Control System SF/BS High-Tech Air Rings KARAT COM2 SF (Side Gusset Film) Improved winding quality For all lines with side gusset film production we improve not only the profile due to our special concept, but also the winding result on lines with stationary haul-off Overview of the VARIOcool SF: Special concept for side gusset film Optimized winding quality Easy handling VARIOcool BS (Basic) VARIOcool BS The advantages are: Rapid and effective regulation Clear separation of regulation and air ring functions Trouble-free retrofitting to existing air rings Almost independent from blow-up ratio Maximum operating reliability Low operating expenses in case of changing dies The flexible gauge control system which can be combined with any air ring is a proven system for quality improvement. Due to its modular and independent design the system can be adapted to the different air rings of almost all other manufacturers of blown-film lines. Kdesign GmbH 7
Gauge Control System AF Gigantic!!! VARIOcool AF The combination of VARIOcool with our high-performance air ring KARAT is the optimal system for agro foil lines and has been particularly adapted to the special requirements of aerofoil Overview of the VARIOcool AF: Maximum line performance, bubble stability and profile improvement Greater variability of width and thickness spectrum Applicable for die sizes of up to 2500mm and bubble circumferences of 25m Die 2000mm and bubble circumference 23m 8 Kdesign GmbH
Components Gauge Control Systems The optimal system for your line The gauge control systems VARIOcool are in use all over the world, in all applications. They are based on an alteration of the quantity of the cooling air and therefore requires no additional energy to the film. Due to the specially developed variants for the corresponding application and extrusion line requirements the highest degree of improvement for your product quality is guaranteed. Operation: The control cabinet contains PC and all control elements. Linear diagram Long term trend Polar diagram Control cabinet Overview of the VARIOcool: TFT display with touch screen operation Integrated laser printer Including remote diagnosis and service Comfortable visualisation based on Windows Network connection Integration of further automation components For the profile measuring we apply contacting, contactless capacity thickness measuring or radiometric thickness measurement devices placed on a reversing unit or in the collapsing frame, depending on application, film product and line design. Special measuring devices e.g. for barrier film are capacitive sensors placed in the collapsing frame or also contactless radiometric measuring set on reversing units. Telescope unit for big bubble diameter difference Capacitive contact / contactless Radiometric contactless Kdesign GmbH 9
High-Tech Air Ring Small step but huge effect! The replacement of your existing air ring by a high-performance air ring KARAT represents a small investment which will pay off rapidly. The retrofitted lines attain a considerable production increased (regularly over 25%) and an improvement of the film tolerances. Line with 315mm die head. After retrofitting 41% increased output and thickness tolerance improvement. Line with 300mm die head. After retrofitting 46% increased output and thickness tolerance improvement. Line with 550mm die head. After retrofitting 31% increased output and thickness tolerance improvement. Line with 100mm die head. After retrofitting 50% increased output and thickness tolerance improvement. The upgrade with our modern KARAT Air Ring keeps your line ready for higher quality demand and increased production to a new level. 10 Kdesign GmbH
High Performance Air Ring All around bubble cooling In addition to our Karat air rings we offer a wide range of auxiliary equipment: Motorised lip adjustment For an easier handling of bigger air rings and a reproducible adjustment of the air ring Lifting devices For an easier start-up and die gap cleaning Housing insulation To avoid the forming of condensed water Air distribution systems Low pressure drop, for a direct connection with the air ring Blowers and heat exchangers Matching the air ring Motorized lip and venturing adjustment Insulated housing KARAT 1: 80mm lip insert with gauge control system VARIOcool Kdesign GmbH 11
Gauge Control Systems MA The low-cost solution for profile optimisation This variant offers a manual profile optimisation. The adjustment is reproducible at any time by means of adjustment gauge, at a very low cost. Overview of the VARIOcool MA: Low investment Easy to upgrade to an automatic profile control Repeatable Manual actuators Eduard-Rhein-Str. 30 53639 Königswinter Ausfahrt 33, Siebengebirge Eduard-Rhein-Str. 30 D-53639 Koenigswinter Phone +49 2244-927852-0 Fax -92785225 info@kdesign-web.de www.kdesign-web.de