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| The new COMPEO compounding system from BUSS opens up new horizons by permitting optimized application-specific line configuration. Photo: © Buss AG |
The COMPEO series, which has premiered at NPE 2018, is a major step forward for Buss AG's compounding technology. Put together from standardized modules, the series permits cost-effective configuration of specifically optimized compounding lines for an extremely wide range of processing tasks and temperatures. These extend from traditional segments such as PVC and cable compounds via highly filled polyolefins to engineering polymers with processing temperatures of up to 400°C (750°F). Even hybrid lines for processing very different products are simple to configure, while fully retaining the conventional features of BUSS Kneader technology such as high-intensity mixing, high filler contents and precise temperature control.
Configurable for specific processing tasks
One key factor in the high flexibility of the COMPEO Compounder is the ability to combine conventional three- or four-flight kneading elements with new elements comprising two or six flights and to use them at any desired position in the process section. As a result, previously conflicting aims, such as a high specific throughput at a controlled energy input, can be simultaneously achieved. All the flights are generated as free-form surfaces which means that they provide uniformly intense product shear, so preventing local overheating.
The modular concept also means that process length, the type and number of feeding units, temperature control and degassing can all be optimally tailored to the specific processing task. A vertical inlet screw or side feeders can also be used instead of an inlet hopper. Further side feeders can be provided along the processing zone, while liquid additives can be injected directly into the product at any desired position through kneading teeth with a bore.
The newly developed COMPEO discharge unit, which is used for all processing tasks, is based on the principle of a slowly rotating conical twin screw. Irrespective of compounder configuration, the discharge unit reliably builds up pressure for downstream units such as screen changers and pelletizers and ensures constant throughput even at high back pressures. The housing of the discharge unit can be completely removed for ease of maintenance and cleaning.
An optimum combination of efficiency, ergonomics and operability
The new screw geometries and improved raw materials feed mean that the throughputs of earlier models can be achieved at 20% lower screw speeds. In addition, BUSS has boosted torque density by 15%. This permits longer mixing zones and thus stabler process conditions without any additional increase in energy input.
All these improvements combine to make the COMPEO series' processing window much larger than in previous series. As a result, throughput can be varied in a ratio of 1:6. This increases both line flexibility and ease of operation, for example on startup or when producing small sample batches.
The great majority of pipes and lines is located within the machine behind easily cleaned casings. A gearbox cover reduces operating noise and increases occupational safety. Thermal insulation of the process section minimizes energy losses while standardized modules mean that capital costs are up to 30% lower than those for previous models.
Fully IoT-compatible
The touch screen line controller with its OPC UA interface makes COMPEO completely Industry 4.0 compatible. Built-in recipe management makes changing products pretty much a matter of pressing a button. All significant line parameters are displayed, logged and archived. In addition, process parameters such as temperatures, power consumption or specific energy input, and thus the efficiency of the line, can be continuously monitored.
