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K1014 Topline mit Entnahme und Stapeltisch


K1014 Topline mit Entnahme und StapeltischK1014 Topline mit Entnahme und Stapeltisch
KURTZ D-Log zur Erfassung von ProzessdatenKURTZ D-Log zur Erfassung von Prozessdaten
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Filling Injectors  

The appropriate filling of the mould is an important step when producing mouldings of particle foams. Through this, the quality of the moulding is substantially determined. The density distribution and an even filling are of particular importance. In regard to profitability also the total air consumption plays a decisive role. For a long time KURTZ has been providing cost-saving solutions to achieve the optimum filling process.

Fill injector B-Jet for a more efficient production

Little importance is generally attached to fill injectors in the manufacture of shape mouldings. They all have a Venturi nozzle to produce the negative pressure necessary for the transport of the material from the charging silo to the mould cavity. Their use therefore appears close to insignificant, as it represents only around 10 per cent of the total cycle time.

But on closer examination significant differences are revealed between the different types of fill injector in terms of structure, filling efficiency and reproducibility, which can provide substantial benefits in the manufacture of shape mouldings. It is a positive advantage to a processor to be able to use a single filler type for mixed operations in the processing of EPS (expandable polystyrene) and EPP (expandable polypropylene), no longer reducing the associated working capital. The need to maintain a single filler type also reduces the operational maintenance costs.

We support this benefit by means of a simple plug-in connector to connect the KURTZ B-Jet fill injector to the lower and upper sections of the filler. On release of the plug-in connector and the removal of the upper section, all of the injector seals are accessible and may be changed without the lower part having to be removed from the mould. As with injection moulding, the plug-in connector, with separation of the lower section that remains in the mould, makes repositioning works unnecessary, which means a quicker mould change procedure.

The dual-walled design of the lower section of the filler prevents the material from overheating and reduces the likelihood of malfunctions. The Venturi system in the lower section is wear-free and with its position close to the filling activity ensures reproducible filling and prevents material blockages caused by the injector closing piston. On the one hand, this reduces material consumption, and on the other, the even filling and resultant steaming increases the quality of the shape moulding being produced.

An essential benefit of the mould structure is the rotatability of the upper section and therefore also the location of the material supply pipe with regard to the positioning of the fill injectors. Three connectors to the fill injector ensure optimum, trouble-free operation, as "Filler Open" and "Filler Closed" can be controlled independently of the filling air, and if necessary the filling air can be adjusted in line with the degree of nozzle equipment of the cavities to be filled. In endurance tests, new kinds of seals and sealing materials have been tested to ensure that the KURTZ injectors are pressure and vacuum tight. This also ensures low-maintenance operation.

D-Log - Process Data Collection 

The D-Log is for physical values' monitoring of supply media in a particle foam production plant. When the individual operation windows required for each processing plant are fixed, a safe operation as well as correct and constant process parameters can be proved.

Steam, air and water can be monitored regarding pressure and temperature; vacuum and material transport concerning pressure. So, the KURTZ D-Log helps to cut wastes in production by displaying operation anomalies.

Besides a visual display, it can be used to switch off a plant in case the measured data are outside the defined range of tolerance. 

Central Vacuum System   

A central vacuum system is imperative for an efficient production with several machines.

A central vacuum station consists of several pumps with some of them being in continuous operation. The connection and disconnection of further vacuum pumps is controlled by sensors. 

Advantages of the KURTZ vacuum system:

  • Energy saving of up to 50 %
  • Increased production reliability
  • Optimum condensation
  • Discharge of condensate without venting of condenser
  • No vacuum tanks necessary
  • Extension of system possible