Compressors
Optimum air supply
Assembly concept for extrusion blow molding machines. Kautex Maschinenbau develops and manufactures extrusion blow molding machines. Machines from the KBB series are assembled, tested and optimized in the new production hall. The required compressed air is generated by Atlas Copco compressors and flexibly supplied to the machines via swivel-mounted booms.
The KBB extrusion blow molding machine series has been on the market since 2013. It is suitable for the production of packaging such as bottles and canisters. Several articles with volumes of around 50 milliliters to 30 liters can be produced. Kautex has installed a modern assembly concept in the new hall. The areas for a total of nine final assembly stations are generously dimensioned; each station has a separate supply of the necessary process energy. Compressed air, cooling water and 630-ampere electricity are supplied via large cantilevers that can be swiveled 180 degrees. The machines are also tested and adjusted in the assembly hall; customers accept the machines from Kautex on site.
When designing the machine supply, particular attention was paid to the compressed air, which must be available in sufficient quantity and quality for the blowing process. Pressure, volume and speed are relevant parameters for the product result. In the process, the plastic granulate is first melted in the extruder and pressed into the so-called head via a screw conveyor. Here, the individual plastic layers are brought together and formed into a tube, which is transferred to the molding tool and inflated in the mold using compressed air. The mold is cooled with water to harden it before the finished hollow plastic body is cooled with compressed air. The air requirement is therefore immense.
The shorter the cycle times, the more efficient the entire process. Kautex enlisted the support of Luft-Vogel Drucklufttechnik in Neunkirchen to set up the compressed air station. Vogel laid a ring line consisting of almost 200 meters of Airnet components from Atlas Copco. The compressed air line system made of anodized aluminium is tight, flow-optimized, corrosion-resistant and quick to install. The KBB machines are supplied with compressed air from the ring line via a further 40 meters of Airnet lines and hoses. The compressed air is supplied by three oil-injected screw compressors of the latest generation from Atlas Copco. The volume of compressed air generated corresponds exactly to the demand. The ES6 energy-saving system from Atlas Copco controls the utilization of the compressors. A 4,000-liter compressed air tank helps to absorb peak loads.
The compressed air station is supplemented by an OSC 600 oil-water separator and UD+ filter. Thanks to a special technology, these filters achieve the same air purity that would normally require two conventional oil filters in series - and are around 40 percent more energy-efficient because the pressure drop is significantly lower. The new compressed air station with the latest GA screw compressors from Atlas Copco is highly efficient and was therefore eligible for funding from BAFA - the German Federal Office of Economics and Export Control. pb
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