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PMMA Altuglas Training

PMMA ALTUGLAS granules

EXTRUSION GUIDELINE

Edition4/21.01.2005/ 20pages

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Mont - Rho

EXTRUSION EQUIPMENT

ALTUGLAS granules can be processed on any conventional

extrusion equipment as long as the machine has sufficient horsepower to extrude at desidered output rate.

EXTRUDERS
The general specifications for extruders and methods of heating,cooling
and controlling are the same for ALTUGLAS resins and for most other
plastic.

Nitrided steel barrels and screw should not be used,their tendency to give
trace contamination by abrasion can be objectionable in processing clear
and translucent colours.

Xaloy barrels and hard tipped flight lands are recommended.

Chrome plating of the screw is not necessary for satisfactory processing but
is recommended because it makes sleaning the screw easier and provides
corrosion and abrasion resistant surface.

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EXTRUSION EQUIPMENT
A wide of variety of screw design may be used to process Altuglas resins.
Only properly designed screw will produce high quality sheet or profile
shapes from Altuglas granules.
Single - stage or two stage- screw may be used.
With two stages screw extrudate temperatures and output rates are more
uniform. Vacuum should be applied at the vent part of the barrel when
processing with two stage screw, otherwise,volatiles streaks may be appear
in the extrudate.

Single stage screw

Metering section

Transition section

Feed zone section

Single stage screw should have a L/D ratio 20 : 1 and medium

compression ratio 2.2 - 2.8

COMPRESSION ratio

L / D ratio

Ratio of depth of channel in feed

section to depth of channel in
metering section
Ratio of length of screw t o
diameter of screw

With single stage screw it is very important to dry very well the granules.
Level of residual moisture into granules 0.03%
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Pre drying of the ALTUGLAS granules

OPERATIVE CONDITIONS
DRYING TEMPERATURE / TIME
Altuglasgrade

V 920T
V044 V045
V 046

MI 4T
MI 7T
DRT

HT 121
327

De-humidifying

Traditional

Time/hours

70 75 C

75 80 C

24

75 80 C

80 85 C

24

80 85 C
75 80 C
75 80 C

85 90C
80 85 C
80 85 C

24
24
24

95 100 C
70 75 C

100 105 C
75 80 C

24
24

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Pre drying of theAltuglas granules

Effect of the air humidity vs drying performances

% residual moisture into granules

0,35
0,3
0,25

A
B
C

0,2
0,15
0,1
0,05
0
1

drying time (hours)

A= air at 70% U.R.

B = air at 50% U.R. C = air at dew point 40C

Level of residual moisture into granules vs. processability

Extrusion with venting system up to 0.25 %
Extrusion without venting system 0.03%
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EXTRUSION EQUIPMENT
Two stage screw
2 nd Metering

1st Metering

Transition VENT

Feed zone section

Transition

Vacuum pump

VENT

Single stage screw should have a L/D ratio of 24 : 1 to 35:1

and medium compression ratio 2.2 - 2.8

Ratio of depth of channel in feed

section to depth of channel in
metering section
Ratio of length of screw to
diameter of screw

COMPRESSION ratio
L / D ratio

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EXTRUSION EQUIPMENT
TWIN SCREW
IT IS POSSIBLE THE USE ALSO
WITH Altuglas grades.
The profile of the screw must be
decided with extruder producer in
order to avoid :
uncontrolled friction,high shear
stress, uncontrolled overheating.

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EXTRUDER ATTACHMENTS

BREAKER PLATES AND SCREENS

In general,use a breaker plate with nominal screening 20/40 or 20/40/60 mesh
packs are typical.
Additional screens can be help when the die offers low resistance to flow and
the screw has limited mixing or homogenizing ability

STATIC MIXER
Static mixers are frequently inserted between the extruder and the die to
provide mixing and to promote greater uniformity in the melt temperature of
the extrudate presented to the die and may conceivably permit higher output
rate without instability.
Whe properly designed,installed and temperature - controlled these units
produce only a small drop in pressure.

Typical static - mixer

for extrusion lines

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EXTRUDER ATTACHMENTS

MELT - PUMPS
Melt pumps are used tro give more
stable output to improve yeld and
product quality.
They can also increase increase
output rates.

DIES
Many different commercial sheet or profile dies have been used
successfully to extrudate Altuglas granules.
It is essential to provide dies with an effective and properly balanced
heating system having adequate sensitive controls, expecially when the
die is divided into heat zones,as in the usual sheet die

DIE FLAT SHEET

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EXTRUDER ATTACHMENTS
DIES
When an extrudate with minimal die lines must be produced,
the finish of the die lips is very important,particularly in the area
at and just ahead of the point where the melt leaves the lip
surface.

LIPS

Irregularities in the die lip surfaces in this area .whether caused

by mechanical imperfections or corrosion damage,can produce
die lines.
Serious rapid corrosion can occour at the die lip discharge if the
lips are low grade steel and expecially if moisture has not been
effectively removed from the melt and escapes at this point.
A good grade of alloy tool steel is certainly preferable when the
die must produce good results over a prolonged period.
Although chrome plating of the die flow surface is not necessary
but offers some benefits as low polymer adhesion / corrosion.
Disadvantages is the maintenance in case of damage
GOOD COMPROMISE :excellent steel polished (mirror surface)
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OPERATING CONDITION IN THE EXTRUDER

Extruder cylinder temperature setting vary with circumstance,

machine and screw design. The table annexed lists range of
temperatures applicable to Altuglas grades.

Altuglas
V0 44 45 -46

Altuglas
MI7T - DRT

200 220 C

205 225 C

Screw zone 2 (feed/ transition)

215 235 C

220 235 C

Screw zone 3

220 240 C

225 240 C

225 245 C

225 245 C

225 240 C

225 245 C

Adapter zone

220 240 C

220 245 C

DIE

220 240C

220 245 C

Melt temperature

230 245 C

230 245 C

Screw speed

40 100 RPM

Extrusion line
Screw zone 1

(feed)

(metering)

Screw zone 4

(vent)

Screw zone 5

(metering)

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40 100 RPM

OPERATING CONDITION IN THE EXTRUDER

The most important temperature,and one usyally most difficult to
establish is the rear zone (feed) because this temperature affect the
frictional forces in the feed area,it has a strong influence on the dry
solid conveyng rate and is therefore important in determining the
motor load and process rate.
The temperature of this zone should be given primary attention
particularly in a first run, and should be adjusted to provide a
permissible steady motor load and minimum variation of pressure
MELT TEMPERATURE
In operating extruders at relatively low productivity, a direct
correlation can be expected between the melt temperature
developed a the screw discharge and the cylinder profile
temperature,expecially in machine of slow diameter.
Because of the effect of the screw design factor the influence of
the cylinder temperature on melt temperature decrease with
increasing poductivity. Other factors,such as screw speed, head
pressure assueme the major role in determining melt temperature
DIE TEMPERATURE
The die temperature can be choiced to provide the best compromise
between any of the following objective:
1. To optimize the flow distribution from the die
2. To regulate on influence the head pressure
3. To suppress surface defects
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FLAT SHEET / OPERATED SHEET

Min. diameter of the roll : 300 mm.

Roll position

Altuglas
V0 44 45 -46

Altuglas
MI 7T - DRT

100 110 C

95 100C

95 105 C

85 95C

90 100 C

80 90 C

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EXTRUDED/ COEXTRUDED PROFILES

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Equipments for extrusion are generally made up of 3

parts:
a die performing and arranging the profile s geometry

a calibrator perfectioning the final product

a cooling system (in thermoregulated water)

COOLING SYSTEM

CALIBRATOR

DIE
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Steel,polishing, temperatures
control as die for flat sheet

Steel,polishing as die for flat sheet

temperature : 60 -70 C

Water temperature
40 - 50 C

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COEXTRUSION

Coextrusion is the process of extruding one material

on top of another.
Several layers are possible.
Two (or more) extruders required
Two main technologies :
Black box system
Multimanifold die

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COEXTRUSION

Concept of coextrusion is to obtain a final item (flat sheet,profile,tube)

with various layers using different polymers to obtain a final structure
using the specific properties of each polymer.
Example of application : two layers sheet ABS - PMMA to have a very
good mechanical propertiesl (ABS) very high aesthetic aspect level and
excellent wheaterability (PMMA)
Technology is the same of traditional extrusion using modified die
geometry and one extruder for each polymer.
It is possible to obtain final possible structure up to 8 - 10 layers
(experimental level) as example in food packaging sector where are
requested normally some properties as : mechanical,aspect, gas barrier,
ambiental humidity barrier.
Normally we have in industrial production item with 2 layers when the
adhesion is very good between the polymers, 3 layers when the level of
the adhesion is poor using a polymer in the core of the structure having
excellent adhesion between basic polymers (glue polymer)

PMMA
ABS

Good adhesion

PMMA
HIPS

Poor adhesion

PMMA
ABS

Good adhesion

HIPS

ABS used as glue polymer

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COEXTRUSION
dies

Traditional die flat sheet

Coextrusion 2 layers :

BLACK BOX system

ADVANTAGES

DISADVANTAGES

Simplicity - low cost

Restricted range of MFR

between the polymers

Existing die can be

used( little modification)
High number of
layers possibility

Not possible individual

thickness control of the
layers.

Coextrusion 3 layers : MULTIMANIFOLD DIE

ADVANTAGES
Polymers with large MFR
range can be used
Individual thickness
control for each layer
High degree of layer
uniformity
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DISADVANTAGES
Complex die design
High die cost
Limited number of
layers can be used

EXTRUSION GENERAL RECOMMENDATIONS:

START- UP Conditions
It is important to recognize that the static temperatures established at the
barrel walls,screw surface,adapter,die melt passages during heat up can be
alered substantially by the shearing force and frictional heat developed under
dynamic operation. With the possible exception of the surface temperatures
at the front and rear ends of the screw,these temperatures tend to increases
as the machine enter its operating mode. A reduction in motor load and
operating stress in the equipment usually occours as the machine aproaches
stressing of the equipment during start up

START - UP Procedures
Before start - up, set the temperatures controls for each zone to give the
predetermined temperatures and throughly heat the extruder and die. At the
end of preheating period,start the screw at low speed whilee making sure to
feed material slowly from the hopper. Never run the screw dry.
Continue
running the screw at low speed until an uniform extrusion is obtained at the
die.
If the pressure becomes too great,stop the run,determine the cause of the
difficulty and correct the faulty condition. When the flow of extrudate is
satisfactory increase the screw speed gradually and adjust the temperature
setting to operating conditions. In starting a partially loaded extruder that
has cooled the preheating period should be long enough to soften the
plastic in the barrel and die so that it can flow and permit rotation of the
screw without excessive resistance.

SHUTDOWN Procedure
If the operation is stopped for any lenght of time,shut off the feed and
immediately reduce the screw speed to a minimum. Run the screw at slow
speed until material stops flowing from the die,then turn off the extruder
and die heaters.
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