Plastics Engineering - May 2014 - 16

Compounding: Efficient Equipment, Lean Trends________________

in kneading extruders have increased output, optimized
control, and expanded the realm of applications for kneading technology.
The TriVolution next-generation compounder from B&P
Process Equipment is a tri-kneader that can compound
more than just PVc and is crossing over into thermoplastic
compounding and reactive extrusion, says Michael lazorchak,
global product manager for B&P.
TriVolution can be used, for example, to compound biobased fibers into polypropylene for rheTech's rheoVision
compounds. in this application, it was found to have better
distributive and dispersive mixing control compared to a TsE,
without excessive heat generation. TriVolution can use up to
80% less overall energy consumption than a comparable TsE,
reports the company, and has about half the footprint of a
conventional twin-screw system.
The tri-kneader technology, introduced in 2010, increases
the flight-to-pin interactions compared to a legacy co-knead-

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er, which improves mixing and allows uniform dispersion at
lower melt temperatures. it also runs at a slower screw
speed, which reduces downtime and maintenance and
increases the life of wear components.
in reactive extrusion, the TriVolution is proving to have better degassing, reaction, and grafting efficiencies by creating
more exposed polymer chains and renewed surface in the
melt, adds lazorchak. several commercial units have been
built, with sizes including 30-, 60-, and 120-mm screw diameters. Others, including an 80-mm size, are currently being
manufactured. B&P is planning to build two TriVolution160 machines in 2014; this is the largest standard size in the
product line with rates projected up to 13,000 kg/hr.
At K 2013, Buss introduced its quantec g3 compounder, a
third-generation version of the Buss four-flight kneader.
The quantec g3 offers a larger processing window and
higher throughput than earlier generations. The g3 has a
longer process section with a process section-length (l) to
screw-diameter (D) ratio of 14 l/D, and a larger outer screwto-shaft-diameter ratio (1.62) that increases the available
throughput volume.
The screw flights use a patented surface geometry that
ensures a constant shear gap between the flights and kneading pins over the entire length of the screw flight. This
geometry maintains a constant shear force to eliminate
localized overheating and allow gentle kneading and mixing
for heat and shear-sensitive materials, notes the company.
The quantec g3 is delivered as an integrated compounding line that incorporates a feed system, pelletizer, and fully
piped heating and cooling units. The control cabinet, mounted directly on the machine, is fully wired and tested before
leaving the factory. This integrated design is engineered to
save the customer several weeks of on-site manpower for
installation and commissioning, the company adds. Many customers today run leaner and do not have internal engineering
support, thus the market is looking to the equipment manufacturer to supply a system that will quickly move through
commissioning to production, Buss explains.

Direct Extrusion
The demand for direct compounding extrusion systems, in
which raw materials are compounded and processed directly into a product rather than pellets, continues to evolve.
An advantage of direct compounding is that it eliminates
an extra heat history (i.e. pelletizing and remelting), which is
particularly important for materials sensitive to degradation.
it may also allow higher levels of reclaim.

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Plastics Engineering - May 2014

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