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Coating lines - LAMICOR, the extrusion coating process by Reifenhäuser
Extrusion coating by means of Reifenhäuser's LAMICOR process means:
Material webs such as paper, aluminium foil, plastic film, textiles, and nonwovens are coated with thermoplastic raw material and permanently bonded into a composite.
- The manufacturing of the plastic film (substrate) and the subsequent processing takes place in one work cycle.
- This process does not use any pollutant solvents and adhesives.
Areas of application
By combining different materials, product-specific properties that open up additional areas of application are achieved.
Drink cartons and packaging paper for food are classic examples for products manufactured by means of extrusion coating. Depending on the combination of source materials, a wide range of other products that were previously inconceivable have become commonplace: Lorry canvas covers, sails, or party tents made of material composites are good examples for the success of extrusion coating.
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The konos series of conical twin-screw extruders is the fifth conical machine generation developed by Cincinnati Extrusion. Konos machines are being manufactured by the inventor of the conical twin-screw extruder and are founded on the tremendous experience of a company that has built over 6,000 conical extruders so far.
Our customers benefit from this experience. The konos series has an enormous processing latitude, long life, and an extremely good price-performance ratio. It comprises the standard models konos 38, 50, 63, 72, and the co-extrusion models konos 38 and 50 coex.
Konos machines perform excellently at both low and high melt pressure, and also as co-extruders. Their processing characteristics and advantageous design features make them the machines of choice for a wide range of applications.
Various feeding modes can be realised depending on the property of the material and the product requirements. A gated hopper, a dosing unit or a stuffer can be used.
With the EXcPRO-XP control unit, incorporating the latest trends and developments in the field of personal computers and programmable logic control, konos extruders are even more cost-efficient.
Cincinnati Extrusion offers several extruder lines for a wide range of applications.
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Battenfeld Extrusionstechnik offers extrusion lines for fencing and complete plastic fence systems (posts, pickets, etc.).
PVC or WPC fencing profiles offer many advantages:
- low maintenance requirements and costs
- easy and inexpensive assembly
- easy to clean
Battenfeld Extrusionstechnik offers complete extrusion systems for plastic floor panels and other outdoor applications.
Major advantages of PVC or WPC floor panels:
- low maintenance requirements and costs
- easy and inexpensive assembly
- easy to clean
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Battenfeld Extrusionstechnik manufactures tailor-made solutions for foam profile extrusion:
Main applications include:
- window sills
- outdoor floor panels
- shutter panels
- beads
- frames, etc.
Foam profiles are mainly characterised by their low specific weight.
If high surface finish is required, a layer of rigid PVC can be co-extruded
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Battenfeld Extrusionstechnik manufactures custom-made extrusion lines as well as the miniBEX standardized line for the production of technical profiles.
Major applications include:
- edge bands for the furniture industry
- scanner profiles
- high-precision profiles, IC tubes, etc.
Main features and benefits of miniBEX lines:
Plug&play-line with standardized and perfectly matching line components, consisting of:
- different extruder sizes with output rates of up to 130 kg/h PVC
- all processing units can be utilized without further line modifications
- calibrating table, 4 m or 6 m long
- caterpillar or belt haul-off
- saw or knife cutting device
- also available as twin-strand version
- short delivery times
- excellent price-performance ratio
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Battenfeld Extrusionstechnik offers complete extrusion systems for siding / wall cladding applications.
Major advantages of PVC or WPC siding profiles include:
- low maintenance requirements and costs
- easy and inexpensive assembly
- easy to clean
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Battenfeld Extrusionstechnik manufactures extrusion lines for the production of window profiles with output rates of 15 kg/h - 800 kg/h.
- extruders can be operated with all major die systems
- custom-made line configurations
- Battenfeld Extrusionstechnik also offers the compact and standardized winBEX extrusion line for window profiles
- winBEX is suitable for processing WPC
- woodfiber content of 60% possible.
Main features and advantages of winBEX extrusion lines:
Consist of standardized and perfectly matching line components, including:
- different extruder sizes
- calibrating table with 2m and 5,5m segments
- caterpillar or belt haul-off
- saw or knife cutting device
- all wood-plastic-composites currently available can be processed with this standard line
- short delivery times
- excellent price-performance ratio.
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Extruders
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- Specifically developed profiles, easily and with high stability.
- Reusability of the elements.
- High flexibility at a reasonable price.
- All elements are assimilable in the system.
- Each point of the part is attainable.
- 98% of the Parts of the catalog are available from stock
- Trouble-free fine adjustment on the spot is possibly
- Trainings are offered for the construction of robot-hands
- Development of standard modules of the expansion of the kit
- Development of special elements to solve the customer's problems. Many standard parts for the Robotbhand Kit were developed in this way
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Profiles
Esbelt manufactures, through extrusion, a wide range of profiles made from PVC, polyurethane and polyolefin to be placed transversally on belts for lifting products or longitudinally as containment or guidance.
Runer Profile
A runer sidewall is also available which is very flexible, resistant to compression and available in a wide variety of heights.
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-Storage/Sawing Systems with combined cantilever arm and cassette storage. Operating gantry crane fully automatically transports individual bars to an integrated CNC-saw and restores remnants automatically.
-The inventory control computer keeps quantities automatically up to date, therefore highest possible reliability and minimum idle times due to perfectly coordinated individual components.
-A sawing center replaces as many as 3 to 7 stand-alone saws
-Material weight up to 2,5 tons/individual bar
-Diameter of bars: 20 - 320 mm
-Fully automatic handling of bars with a length of 0,45 - 12 m
-Integrated KASTO-Band or Circulars Saws, optional with carbide blades
-Short chip-to-chip time when changing bars
-Duo-systems combine cantilever arm and cassette storage
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COMET T4
CNC machining centre with 4 controlled axes. It can be configured with motor-driven vices acting independently or positioned along the X axis and is designed for machining operations on bars or workpieces made of aluminium, PVC, light alloys in general or steel. It can handle bars up to 4 m long. The 4th axis allows the electrospindle to be controlled by the N/C continuously in the range 0° to 180° for machining on the profile contour. It is provided with an 8-place tool magazine on board the X axis slide, capable of containing 2 angle machining heads and a side milling cutter, for machining on the 5 faces of the workpiece. It also has a traversing work table which allows easier workpiece loading/unloading and increasing the machinable section considerably.
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The structure is made of a base with a sliding upright in its rear section. Both are in electrowelded steel duly stabilised after each work phase to ensure that there is no interior tension; they are sized to guarantee stability and precision during machining operations.
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TK 441/3 - 4-axis CNC vertical machining center equipped with an electric spindle that can rotate around the C axis, this allows for machining on three sides of a profile with just one clamping operation.
This machining center is designed for drilling and conventional milling processes and also for copy-milling operations on aluminum extruded profiles and other materials, including steel profiles up to 5 mm thick, steel reinforced PVC, composite materials and various other plastics or wood.
The TK 441/3 model can be implemented in every industry and its flexibility and robustness allow to efficiently machine components that require high performances, such as aluminum profiles produced by the largest extrusion press all over the world.
Standard versions are available in 3 machining lengths: 3500, 6700 and 8400 mm. Upon request the machining center can be manufactured in different lengths in order to meet the special needs of each customer.
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DUBUS is recognized as one of the leaders for the design and manufacturing of cuting and machining centers for the aluminium industry. Innovation and many technical breakthroughs have contribuuted to the production of high performance and reliable centers combining machining precision with production flexibility.
Derived from the ALUFLEX 8001 concept, but for higher production rates, the ALUFLEX 9001 offers the same standard of performance, strength and flexibility. Profiles of a maximum length of 7.5 meters are transferred automatically from the 10 to 20 bar loader to the bar feeder n°1 and inserted into the machining unit fitted with 8 to 10 electrospindles running at 24,000 rpm. Machining operations carried out on all 4 faces. The complete profiles are then conveyed to the bar feeder n°2 and put into the sawing group to make straight cuts, miter cuts or angular cuts. In order to balance machining time with respect to sawing time, it is possible to incorporate into the cutting unit a further 1 to 3 additional drilling units, thus obtaining optimum rates. Each machining center allows the ejection of pieces either direcly to the operator or, using a 2-axes robot, for unloading and automatic classification.
The ALUFLEX centers allow the machining of several ranges, brands or types of frames, for example slidings or windows with 2 openings inward/outward.
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Benefiting from a long experoence in aluminium or light metal profiles machining, the CND 2000 S is especially adapted for machining operations on 3 faces. Its modular equipment is numerically controlled by a NUM controlling system.
The clamping principle allows to set in reference the workpieces on Y and Z axes. Associated with the movable length stop on the X axis, it assures double station operations and anticollision control thanks to DUBUS software.
The machining spindle fitted on the 4th numerical positioning axis offers all possibilities of drilling, milling and screwing on curved or complex shape profiles. The high capacities of this electrospindle allow to optain important machining power ( betwenn 5 and 12 kW ), while maintaining an extremely high rigidity of the whole machine. The tool changer on the gantry provides this equipment with very large production flexibility.
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SATELLITE XL
5-axis CNC machining centre with moving gantry structure. Designed for drilling, milling, thread cutting and cutting on bars or workpieces of aluminium, PVC, light alloys in general and steel. The moving part of the machine consists of a gantry with precision rack and pinion drive. The high power (10Kw in S1) electrically-driven spindle with HSK40F tool holder allows machining operations, including heavy duty work, with optimum results in terms of speed and accuracy. A 9-place tool magazine is installed behind the moving gantry structure. The 300 mm blade is housed separately. The machine can be used in double mode so as to minimize machine downtime, as it is possible to change the workpiece (load/unload) in "concealed" time. It is also possible to load and consequently machine, workpieces whose codes and machining operations differ between the two work areas. The gantry is provided with a guard which, besides protecting the operator, also reduces the noise impact on the environment.
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Titan is a 5 controlled axes machining centre.
The axes slide (X, Y and Z) on high precision, robust, reliable linear guide-ways (35mm) with recirculating ball blocks with four contacts. The axes movements are controlled by brushless Yaskawa servomotors by means of pinion, rack and mechanical system for backlash recovery for X axis (longitudinal) and high precision ground recirculating ball screw and preloaded lead for Y (transversal) and Z (vertical) axes.
The C and D axes control the electrospindle rotation, positioning its axis in any direction square to the surface of an upper hemisphere.
Standard configuration:
•5 controlled axes: linear X, Y, Z. Rotating C and D axes able to execute machining operations in interpolation
•Automatic tool magazin max 24 tools positioned on sliding carriage
•Electrospindle HSK E50 17,5kW (S6) 19.000 rpm with liquid cooling system
•8 vices with 4 independent movements (opening/closing, positioning, locking and traslation) controlled by electric servomotors
•Semi – integral guard with automatic opening of frontal doors
•Machine bed and sliding carriage in electrowelded steel
•Machine bad designed for an optimal chip and cooling liquid collection
•Central lubrification fot the members of movement
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TK 442/3 - 5-axis CNC vertical machining center equipped with an electric spindle that can rotate around the B and C axis, this allows for machining on five sides of the profiles with just one clamping operation and with no angle heads.
The rotation is powered by a brushless engine. The precision reducer that is provided allows both for a rotation from 0° to 360° along the vertical axis, with increments of 0.01°, and for angle adjustments between +90° and -90° along an axis on the horizontal plane.
This machining center is designed for drilling and conventional milling processes and also for copy-milling operations on aluminum extruded profiles and other materials, including steel profiles up to 5 mm thick, steel reinforced PVC, composite materials and various other plastics or wood.
When the machine is provided with a special circular blade it is also possible to perform butting, trimming and composite cutting operation.
The TK 442/3 model can be implemented in every industry and its flexibility and robustness allow to efficiently machine components that require high performances, such as aluminum profiles produced by the largest extrusion press all over the world.
Standard versions are available in 3 machining lengths: 3500, 6600 and 8200 mm. Upon request the machining center can be manufactured in different lengths in order to meet the special needs of each customer.
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The 5-axis machining CM 27 has become a synonym for first class
routing operations. This MAKA series allows the three-dimensional machining of any kind of material to be used in the pattern and model making industry as well as castings and light metals.
This series combines sector-specific features with the advantages of a light
machine tool and is used wherever economical heavy-duty machining is
required: by manufacturers of prototypes, in the automotive and rail vehicle
industry as well as by manufacturers of large-scale wooden mouldings or
patterns.
Outstanding feature of the machine is the high flexibility: Routing, sawing,
drilling, thread cutting or -routing can be performed in almost any angle;
a rigid and dynamic design, a high Z axis, a heavy-duty routing unit
as well as well-proven 5-axis technology are only some of the advantages.
The large tool magazine with a deposit for a saw blade allows complete
machining operations with only one clamping.
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