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Tag Archive: ASR

  1. Completing the ASR Part Three: The GF Series Film Grinder

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    The recovery of scrap generated during the production of blown film, cast film, tape and extrusion coating processes is a key element in reducing manufacturing costs. The Automatic Scrap Recycling system – or ASR®, for short – can recycle trim scrap and off-spec roll scrap in-line and turn your scrap back into profit without the expense of repelletizing.

    A complete ASR system consists of several components, and for the next three weeks Process Control is pleased to detail this patented Automatic Scrap Recycling system. The three components covered will include the following: The RMX Series Refeed Machine, the IN Series Trim Removal Inducer, and the GF Series Film Scrap Grinder.

    This week, PCC would like to highlight the features of our GF Series Film Grinder for automatic scrap recycling applications.

    The GF Series grinders from PCC are used as part of an ASR Automatic Scrap Recycling system for in-line recycling of production film scrap. GF grinders are designed to provide efficient, uniform grinding o film scrap. There are four cutting chamber sizes available along with different horsepower motors to accurately match the grinder to the scrap rate. Grinders are available in configurations that accept edge and bleed trims, roll scrap, and loose scrap.

    Standard carbide-coated knives are employed in the system, increasing the time between sharpening. The rotor knives approach the stationary bed knife, or knives, at a steep angle to ensure a clean scissor cut. This technique is used for maximum bulk-density and flow of ground scrap. The open rotor design improves airflow for cooling, permitting the highest possible throughput.

    Click here for more information on the GF Series Film Grinder.

    For more information on the ASR® Automatic Scrap Recycling System and Process Control’s other products and upgrades , please visit our website or contact us directly at sales@process-control.com.

  2. Completing the ASR Part Two: The IN Series Trim Removal Inducer

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    The recovery of scrap generated during the production of blown film, cast film, tape and extrusion coating processes is a key element in reducing manufacturing costs. The Automatic Scrap Recycling system – or ASR®, for short – can recycle trim scrap and off-spec roll scrap in-line and turn your scrap back into profit without the expense of repelletizing.

    A complete ASR system consists of several components, and for the next three weeks Process Control is pleased to detail this patented Automatic Scrap Recycling system. The three components covered will include the following: The RMX Series Refeed Machine, the IN Series Trim Removal Inducer, and the GF Series Film Scrap Grinder.

    This week, PCC will be featuring the IN Series Trim Removal Inducer.

    IN Inducer

    Process Control’s IN Series Inducers are designed to pick up and convey edge and/or bleed trims generated in the production of plastic film or other thin-gauge products such as foam, tape, paper or foil. These continuous trims are picked up by suction, conveyed into the inducer’s venturi section and blown to a destination such as a Process Control film grinder or a waste container.

    Process Control inducer manifolds are designed to insure that the air velocity at the pickup point is maintained so that the trims do not wrap around the cutters. The IN Series inducers feature an adjustable venturi to allow you to tune the inducer for peak performance with your installation. IN Series inducers have a higher induced air to primary air ratio than conventional trim removal systems, providing excellent pickup and conveying performance.

    IN Series inducers are designed to adapt easily to the installation requirements of your extrusion lines. The unit is shipped with its fan in a top-horizontal arrangement, but can be easily rotated in 90° increments to provide the required fan/venturi orientation. The fan may also be mounted remotely from the venturi using additional tubing.

    Equipment Diagram

    Process Control’s patented venturi design uses the same principle used to create lift with an aircraft wing. The venturi design is far more efficient than the more commonly used cyclonic design, resulting in more suction and far greater air flow per fan CFM. This efficiency reduces the required horsepower, which results in lower energy costs, reduced noise and easier separation of the trim from the conveying air at the grinder.

    Read more about it here.

    Trim Pick-Up Manifold

    Click here for more information on the IN Series Trim Removal Inducer.

    For more information on the ASR® Automatic Scrap Recycling System and Process Control’s other products and upgrades , please visit our website or contact us directly at sales@process-control.com.

  3. Completing the ASR Part One: The RMX Series Refeed Machine

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    The recovery of scrap generated during the production of blown film, cast film, tape and extrusion coating processes is a key element in reducing manufacturing costs. The Automatic Scrap Recycling system – or ASR®, for short – can recycle trim scrap and off-spec roll scrap in-line and turn your scrap back into profit without the expense of repelletizing.

    A complete ASR system consists of several components, and for the next three weeks Process Control is pleased to detail this patented Automatic Scrap Recycling system. The three components covered will include the following: The RMX Series Refeed Machine, the IN Series Trim Removal Inducer, and the GF Series Film Scrap Grinder.

    Today PCC is happy to show off its RMX Series Refeed Machine. This machine is specifically designed for use with Gravitrol® Gravimetric Extrusion Control Systems. The compact size also makes the RMX Series suitable for applications with headroom restrictions without sacrificing the performance that has made the ASR® Refeed Machine popular for film applications. The unique, double-compartment RMX Series Refeed Machine operates with a variable-speed auger/bridge-breaker assembly to compact and meter ground scrap from the inner hopper to the throat of the production extruder. The outer compartment contains virgin material which is gravity-fed to the throat. The virgin material completely surrounds the ground scrap as it enters the extruder. The extruder screw receives a consistent column of compacted ground scrap surrounded by virgin material.RMX

    This method provides consistent operation without extruder surging or starvation. With the standard extruder follower circuit, the refeed machine will increase or decrease the scrap rate in proportion to the extruder speed. This holds scrap percentage constant without additional operator attention. The touch screen operator panel with smart HMI provides full control and configuration of the drive system with minimal setup. The roll feeder and refeed status may be monitored from a single screen.

    rmx_diagram

    Click here for more information on the RMX Series Refeed Machine

    Be sure to also read up on the RMX Series’ new Operator Control Panel.

    For more information on the ASR® Automatic Scrap Recycling System and Process Control’s other products and upgrades , please visit our website or contact us directly at sales@process-control.com.

  4. Product Spotlight: New RMX Series Refeed Machine Operator Panel

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    Process Control is pleased to present an all new RMX Series Refeed Machine Operator Panel available for ASR® Automatic Scrap Recycling. Hardware includes an HMI/PLC combo with Digital and Analog I/O, Modbus, & Ethernet. A variety of AC drive brands are available. The RMX Operator Panel can operate as a standalone system, or it can integrate with PCC (and most other) grinder and roll feed systems. It also comes with the ability to integrate with supervisory systems via Ethernet.
    ASR RMX Unit

    Operation modes for this panel include an auto, manual, and maintenance mode. Auto allows the user to set the speed ratio, and the PLC calculates the correct refeed speed based on extruder speed. Manual allows for direct speed entry, and maintenance provides forward and reverse job for cleanout and inspection. Advanced setup options for this panel include an ad adjustable rate/frequency curve for special materials and a simplified interface. This means you can hide the options you don’t need!

    ASR RMX Display

    Most importantly, the RMX Series Refeed Machine Operator Panel provides a number of advantages. Smart HMI provides full control and configuration of drive system while competitors require in-panel adjustments. Monitor roll feeder and refeed status are read from a single screen, making the system easier and faster to read, plus system alarms are provided through a pop-up alert so it’s easy to find. Plus there is minimal drive setup because most of the parameters are set onscreen, and an easy switchover to various drive brands.

    For more information on the ASR® Automatic Scrap Recycling System and Process Control’s other products and upgrades , please visit our website or contact us directly at sales@process-control.com.

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  5. New, Updated Literature for ASR Scrap Recycling Equipment

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    Process Control has released new, updated literature for each of the machines in our ASR® line of scrap recycling equipment.  The cut sheets detail product specifications, features, options, and dimensions for each machine. To view the new literature, click the covers below!

    GF

    IN

    RMX

    If you have any questions or inquiries regarding any of the machines featured, feel free to email us at sales@process-control.com or contact your local sales representative directly with our Rep Locator.

     

  6. Savings Campaign in Plastics Technology and Plastics News

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    This month our savings advertisement campaign continues in Plastics Technology magazine.  The July issue contains the ad featuring our ASR Automatic Scrap Recycling System.  This ad features the financial payback our ASR  System can provide to your company as well as a diagram of the full system.

    This ad previously appeared in Plastics News along with our Blender Savings ad.

    Click the images below to view the full ads.

    ASR_FullPageAdv5BlendingAd2

     

    For more information on our ASR Systems or Gravimetric Blenders, please contact Mark Venable.

     

  7. Check our our new ad in Plastics News!

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    Check out Process Control’s new ad on the inside back cover of this week’s (May 27) Plastics News magazine!  This ad is the kickstarter of our Savings campaign for the rest of 2013 into next year.

    Click here to look at the ad up close.

    This ad features the financial payback our ASR Automatic Scrap Recycling System can provide to your company as well as a diagram of the full system.

    For more information on our ASR Systems, please contact Mark Venable.

  8. Completed ASR (Automatic Scrap Recycling) System – Part 2

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    Here is the second part of last week’s post on the completed ASR system.  Shown below are pictures of the 100HP GF Series film grinder that has been equipped with a roll feed allowing additional scrap to enter the system.  An air eliminator (not pictured) has also been made to separate the conveying air from the edge trims.

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    GF Series Grinder – Side 1

    Grinder_Side2

    GF Series Grinder – Side 2

    Roll Feeder

    Roll Feeder

    For more information on Process Control’s ASR Systems, please visit our website!

  9. Advantage of PCC Venturi Design in Trim Removal System

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    Trim removal systems are designed to pick up and convey edge and/or bleed trims generated during the production of products like film, tape and foam. These continuous trims are removed from the line by suction created in the inducer’s venturi section. The Process Control inducer design is particularly effective for handling tacky film.

    inducer close

    Process Control’s patented venturi design uses the same principle used to create lift with an aircraft wing. The venturi design is far more efficient than the more commonly used cyclonic design, resulting in more suction and far greater air flow per fan CFM. This efficiency reduces the required horsepower, which results in lower energy costs, reduced noise and easier separation of the trim from the conveying air grinder.

    PCC Advantage

    • Venturi design creates more suction and greater induced airflow per fan CFM
    • Reduced motor horsepower
    • Trim is more easily separated from conveying air
    • Inlet and outlet silencers available
    • No obstruction in venturi- can easily handle tacky film

     

     

  10. Completed ASR (Automatic Scrap Recycling) System – Part 1

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    Process Control Corporation (PCC) just completed an ASR (Automated Scrap Recovery) System featuring three 20HP Inducers, equipped with its trademark adjustable venture design that provides higher induced air to primary air ratio than conventional systems. The trim pickup manifolds are designed for up to 16 bleeds, 2 edge and 1 center trim. Trims are conveyed to a 100HP thin film grinder equipped with a roll feed allowing additional scrap to enter the system. The ground scrap is then blown to a cyclone feeding an extruder mounted RMX refeed machine. The PCC refeed machine’s unique design provides a consistent column of compacted ground scrap surrounded by virgin material to the extruder.

    IN Series Inducers

    IN Series Inducers

    RMX

    RMX Series Refeed Machine

    Manifold

    Trim Manifolds

    Check back here next week for pictures of the 100HP GF Series Film Grinder!

    For more information on Process Control’s ASR Systems, please visit our website!