Extrusion International USA 5-2020

29 Extrusion International 5/2020 tee our high quality standards to our customers.” High quality standards and … For the 3-layer sheet line from batten- feld-cincinnati installed in 2018, Staal og Plast first built an entirely new hall to house the line with a total length of 65 meters and also to provide enough space for the huge thermo- forming machine and extra space for handling the largest boards, which measure 2,500 by 8,000 mm. In the new co-extrusion line, the high-speed extruder 1-75 T6.1 is responsible as main extruder for the total capac- ity of up to 3 t/h. It alone reaches an output of about 2 t/h for HIPS. High- speed extruders come with a very compact design and reach their enor- mous output rates with high screw speeds. The melt’s residence time in- side the extruder is long enough to achieve optimal homogenization, yet short enough to prevent mechanical or thermal damage and thus ensure optimal melt attributes. In Denmark, the high-speed extruder plasticizes the material for the main layer, with in-house scrap resulting from change- overs and cuttingstamping being added to the virgin material. The material for the outer layers of the 3-layer composite is provided by two 1-75 T2.1 co-extruders. These, too, are high-speed extruders, each reaching outputs of up to 500 kg/h. “The outer layer, which comes into contact with the plant pots, is a distinctive feature absolute flatness must be ensured as a prerequisite for even watering of every plant. Sörensen is confident: “Thanks to our know-how of more than three decades, our customers can rely on us”, and he regards this as the main reason for his market success. Set for further growth “Although the market for ebb & flow trays is booming and we have a good order situation”, says Jacob Sörensen, “at present we still have some free ca- pacity on the new line.” He can there- fore well imagine that he could make polystyrene sheet as a service provider for other industries. Possible prod- ucts are mono-layer, 2-layer or 3-layer boards in virtually any desired dimen- sions with thicknesses ranging from 2 to 5 mm, and even in different colors if desired by customers. By the way, most of the ebb & flow trays are gray. The equipment in Ringe includes another sheet extrusion line for this purpose in addition to the new line, as well as a total of four thermoforming lines. The new line has replaced the second older line since 2018 and, apart from its high capacity, its main advantage is its low energy consumption, about 40% below that of the old line. In addition to the extruders already described, the new line includes a 3000-mm-wide flat sheet die, a roll stack with three main rolls and three post-cooling rolls, as well as a roller conveyor with thickness gauge and longitudinal cuttingtrim saws. At the end, there is a crosswise- horizontal cutting device for the up to 8m-long boards and a stackerstraddle carrier. “The line from battenfeld-cin- cinnati has evenexceededour technical requirements. We are perfectly satis- fied and well prepared for our custom- ers’ future enquiries”, Jacob Sörensen states with pleasure, and concludes with a big word of praise: “Over recent years, battenfeld-cincinnati has been one of our most reliable partners.” battenfeld-cincinnati Germany GmbH GrünerWeg 9, 32547 BadOeynhausen, Germany www.battenfeld-cincinnati.com of our trays. It is approved for food production as well as resistant to UV radiation and chemicals. We devel- oped its formulation in cooperation with a Danish partner company”, the Managing Partner emphasizes. … knowledge of customers’ needs as success factors While the requirements for food safety and UV-resistance of the outer layer are a matter of course for green- househothouse trays, the need for re- sistance to chemicals is a specific con- sequence of working with ebb & flow trays. These trays, on which the plant pots stand, are flooded at regular in- tervals with water containing the fer- tilizers needed by the plants. After a specific period of time, the water and the additives it contains are drained and returned to the tank. Naturally, the irrigation medium is recycled to minimize water consumption. “To en- sure the correct dosage, the water is tested and replenished with fertilizers each time prior to flooding”, Jacob Sörensen reports. He also knows that mobile table systems are today’s trend for modern hothouses. In contrast to conventional rolling tables, which are still being used and can be pushed to and fro on a frame, the mobile tables can be pushed in every direction. This enormously facilitates handling for the operators. Staal og Plast of- fers the right trays for every type of greenhousehothouse in the desired size and, above all, in high quality. For Precision calender with special high-performance rolls