This year’s Kuhne open house can be considered as a complete success.
On 15th and 16th of November we presented our customers a selection of our actual product developments in Blown Film and Flat Film.
On both days Peter Kuhne gave the welcome speech.
On Wednesday our divisional manager for blown film, Marcel Perrevort presented the new developments and features in the blown film area.
Meanwhile, depending on the type of resin, film thickness, die and type of cooling, output capacities of up to 600 kg/h are possible.
Marcel Perrevort explained the details of the three layer blown film line KFB 60/90/60-1.600 IBC which is equipped with the proven Smart Lip Maximizer.
Incidentally the Smart Lip Maximizer can be retrofitted to many blown film die heads (also from other makers) later, which can increase the capacity of even older lines significantly.
Afterwards it was possible to have a look at the blown film line in running condition in our R&D center. The line was producing a stunning 410 kg/h out of a 250 mm die. The three layer film was 1.450 mm wide and 90µ thick. Even so the film was extremely tear resistant, water proof, absolutely smooth and gave high holding forces to the packaged items on the pallet.
4 independent AC motors per extruder drive guarantee the usual a high KUHNE production safety.
A lot of attention was also paid to our own software for the line control, KEC (Kuhne extrusion control). With the KEC it is possible to control the entire line from a single screen.
All parameters and output data can be recalled anytime.
After lunch there was time enough for discussions about the various applications of blown film lines with the Kuhne experts.
The highlights of the second day were new developments in flat film.
Rainer Bobowk, Divisional Manager Flat Film presented the latest trends and explained the features of the flat film line in the R&D department. Special attention was given to the High Speed Extruder KHS70EE-33D, the second Kuhne generation of this concept. The philosophy of this concept is to obtain high extrusion capacities by high screw rpm, rather than by bigger extruders.
The screw rpm of the first high speed extruder generation was in the area of 900, and the extruders were equipped with CMG (compact motor gear) drive technology. In the second generation the screw rpm is already at 1.500 and it makes no sense to have a gear box or even a pulley / belt transmission installed between the motor and the screw. Therefore a common development together with a reputable motor manufacturer was made which resulted in a water cooled AC direct drive with integrated thrust bearing.
For the end-user this solution includes a lot of advantages,- a smaller number of parts which need less maintenance and repair. The melt temperature was at a stable normal level despite of the high screw rpm. The melt quality and the time for colour changes are influenced positively because of the short residence time.
The line requires less spare which means the capacity per square meter of machine space is 4 times higher compared to a “normal” line.
The most important criteria is however a significant energy saving of up to 25% because of the drive technique with high screw rpm combined with the direct drive without loss of efficiency because of pulley / belts and the gearbox. The extruder is capable to melt up a capacity of up to 2.200 kg/h PS and 1.800 kg/h PP. Tests with other materials like ABS, PET, HDPE and bio degradable materials like PLA have already been made to a certain extend, however they will be continued.
The demonstrated R&D line was operated with 1.200 kg/h PP, based on 430 µ thickness and 750 mm width. There was a 840 mm flat film die installed. The line speed was at about 60 m/min. Generally a thickness range of 250 µ to 2.000 µ is possible.
Until the plastics exhibition K 2007 in Düsseldorf the downstream equipment of the line will be further developed. A maximal line speed of up to 150 m/min is the target.
The line fascinated the visitors to the same extend as the blown film line which was demonstrated on the first day of the Kuhne open house.
The personal conclusion of the open house for Stephan Halstrick, General Manager of Kuhne: I am extremely satisfied with the huge interest. Especially the large number of international visitors has shown that we are well positioned in the European market.
