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June 14, 2021 11:06 AM

Entek introduces high-torque extruder, vacuum feed technology

Catherine Kavanaugh
Senior Reporter
Plastics News Staff
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    Courtesy of Entek

    Entek twin-screw extruders can be equipped with new vacuum feed technology developed to improve throughput rates for “fluffy” or low-density materials, which drag large amounts of air into the extruder and limit volume.

    Lebanon, Ore-based Entek Manufacturing Inc. introduced the first product in a new series of co-rotating twin extruders with an online unveiling of a machine that was three years in the making to deliver more torque density and open the door to a new market.

    The HT72 twin-screw extruder — HT as in high torque — has a robust construction and a large motor for 24/7/365 production in not only the packaging and home building markets but commodity compounding and masterbatch, too, particularly for glass- or talcum-filled polymers.

    Entek officials also introduced a new vacuum feed technology (VFT) during the webinar on June 8, which is the same day a patent for a VFT flow sensor went public.

    The online presentations took the place of product launches at the NPE2021 trade show, which was scheduled for May 17-21 but canceled by the Plastics Industry Association because of the pandemic.

    The HT72 was designed to provide high throughput for continuous production of large batches of materials and is Entek's first machine to enter the market for high-output commodity and masterbatch compounding, according to Linda Campbell, Entek's vice president of sales.

    Campbell has been waiting more than a decade to get into those markets. During the webinar she held up a list of companies published by Plastics News in 2011.

    "It's the top North American compounders and concentrate makers," Campbell said. "I've had my eye on that list, not every day, but I promise I read it at least once a week. That's my vision and focus and who we will be meeting with to make sure they know about this new technology."

    The torque of the HT72 is 18 new meters per centimeter cubed compared to roughly 14 Nm/cm3 torque density of Entek's QC3 extruders, according to Dean Elliott, Entek's technical processing manager.

    "This kind of blows the rest of our fleet out of the water," he said.

    The HT72 also features the newly patented sensor that detects vent flow, which is an upset to process conditions caused by molten polymer coming out of the extruder through a vent or getting into the vacuum system.

    "It creates a big mess and it's a fire hazard," Elliott said. "The sensor looks for vent flow before it happens so you can alert the operators. They know the problem is happening before they see the physical evidence."

    In addition, the HT72 has a dashboard for overall equipment efficiency data that can be accessed at the machine or remotely as well as mistake-proof screw elements and shafts.

    "When the team is assembling a screw shaft they don't have to worry about whether the screws are oriented in the right direction because they can only go one way," Campbell said.

    Other HT72 benefits include a low-decibel, water-cooled motor; real time vibration monitoring; real time oil quality monitoring; an easy access offboard cooling system; full stainless-steel shroud for easy cleaning; insulation blankets to retain heat; point of use tools; quarter-turn, standardized retained fasteners; and hinged guards for quick access.

    Vacuum feed technology

    The HT72 and all of Entek twin-screw extruders can be equipped with the new vacuum feed technology, which was developed as part of a project to improve throughput rates for "fluffy" materials and discharges of fluffy powders.

    Materials are considered fluffy or low-density when they drag large amounts of air into the extruder, which then limits volume.

    Several years ago, Entek looked to its research and development team to overcome problems related to volumetric limitations in compounding fluffy or low density fillers.

    "While doing this, a team member suggested we apply a vacuum to the extruder and forcibly remove the air out of the low density materials to achieve a higher output rate," Elliott said. "This idea was explored and it became the beginning of VFT or vacuum feed technology."

    The team then had to overcome challenges related to removing air without pulling the powders into the vacuum system.

    "Through innovative screw and barrel design of the extruder, we were able to come up with a method or full design of the extruder screw which captures the powders as the vacuum is drawn across the extruder," Elliott said. "VFT can improve output rates by as much as 1.8 times that of traditional atmospheric venting."

    The technology, which is offered by license, includes pilot plant trials at Entek to configure the extruder for the customers' materials of formulation and to demonstrate the throughput rate improvement compared to traditional extruder atmospheric venting.

    Investment plan

    Entek also will spend $5 million on new equipment for its machine shop to increase output and improve lead times on our wear parts.

    "We think that's really important for customer service," Entek President Kim Medford said.

    Moving forward on the VFT and HT72 developments wasn't as easy in the midst of COVID-19 lockdowns, restrictions and uncertainty, Medford also said.

    "We were right in the middle of the unknown impacts of the pandemic," she added. "Making investments was really challenging for us. But we get to be here today because our team in a time of great uncertainty came together and to bring new solutions to customers."

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