The new Extruders Zephyr 40 L/D with high performance

ZEPHYR, THE NEW EXTRUDER SERIES IN 40 L/D BY TECNOMATIC OFFERS HIGH PERFORMANCE AT REDUCED POWER CONSUMPTION FOR PE AND PP PIPE EXTRUSION

The ZEPHYR extruders are the evolution of the ZEUS gearless extruders and VEGA 37 L/D series, to set new standards in the extrusion of pipes. A year on, from their presentation at K-show in Germany, several extruders have been sold and tested in production process with excellent results.

These new extruder series in L/D 40, designed by Tecnomatic engineers, offer a large number of innovative solutions that distinguish it and make it one of a kind in the market of pipe production. The key point and guideline of the new project was to increase the output rate at lower melt temperatures and power consumption.

The result has been achieved thanks to the adoption of a spiral grooved feed bush and to further improvements in screw design. The new feed bush ensures minor friction, commonly generated by raw material transport, with subsequent increasing of the specific and total throughput. The further development in screw design, with optimisation and enhancement of torque and shearing elements, have improved the output but have also led to process the material at lower melt temperatures.*

To complete the configuration and to meet the requirements for production efficiency the machines are equipped with torque or water-cooled motors (in this case with one or two steps gearboxes) and compact water-cooled inverters. These solutions combined with the mechanical features ensure outstanding power consumption levels (e.g. lower than 170 wh/kg for Zephyr 60.40 at 800 kg/h) but also low noise operation (< 74 Db), reduced workload for maintenance, higher efficiency within wide speed and load ranges, and faster dynamic response. The equipment also includes modules for a constant monitoring of power consumption and production cost calculation.

The result on the ground shows the evolution trend for pipe extrusion, which is the reduction of the extruders size, with increased screw length and smaller motors, to assure same output with a better energy efficiency. A comparison between a gearless extruder in size 60.37 and new Zephyr 60.40 is clearly showing the advantages in the adoption of this last solution.

EXTRUDERS COMPARASION in % (ZEPHYR 60.40 vs. ZEUS 60.37)
Max screw speed (RPM) 0%
Max. Output* + 42%
Installed power (kW) + 24%
Energy consumption ** a 550 kg/h (Wh/h) - 13%


*  Zeus 60.37 = 500 kg/h -  Zephyr 60.40 = 800 kg/h
** Below a 140 kW/kg for Extruders Zephyr 60.40 at 500 kg/h
 

Extruders Screw Zone Motor Gearbox Ouput (max) kg/h
Zephyr 45 45 5 Torque * No 500
Zephyr 60 60 5 Torque * No 800
Zephyr 75 75 5 Water-colled 2 steps ** 1.200
Zephyr 90 90 5 water-colled 2 steps ** 1.700

* ZEPHYR 45 & 60 re available also in traditional gearbox version di 1.700 kg/h
** With Z shape
 
* eg. Below 200c° with Extruders Zephyr 60.40 at 800 kg/h