Growing demand for environmentally friendly foam with the environment

The company Berstorff GmbH (represented in Spain by commercial Coscollola), has put in place an installation of high-performance for the manufacture of cellular plastic plates hard polystyrene (XPS) for an Italian client located in the town of Verolanuova. With the new installation Schaumtandex ZE 110 / KE 400, host, the company offered a successful combination of double worm and extruder of a single screw extruder Sirap gem Insulation Systems, manufacturer of thermal lagging plates and plastic packagingit doubles the production capacity in the field of the manufacture of XPS. This production line also offers the advantage that it allows the use of expanders, as for example the CO2 agents, which are respectful with the environment.

With the commissioning of this new line up to a maximum of 1,500 kg/h production capacity, Sirap gem has at the moment of several facilities intended for the manufacture of plates of hard cellular plastic XPS for the industry whose production is basically intended for the internal market. XPS boards are characterized by the homogeneous structure of its closed cell foam. This feature makes it possible that the foam, which presents an average of 35 kg/m3 density, will provide great stability and resistance to pressure combined with a very low water absorption.

XPS boards enjoy a permanent growing demand due to the great advantages offered. His qualities are especially appreciated in application areas affected by the pressure or humidity such as isolation of floors and walls of basements. In addition to the XPS plates, Sirap gem also manufactures EPS (expanded polystyrene cell plastic plates) plates that are used for insulation in the construction industry.

According to his own statements, this Italian manufacturer was decided by the offer of Berstorff GmbH for investing in the new line of cellular plastic XPS foam extrusion because, with its unique combination in the world of extrusion machines double worm and a single worm Berstorff GmbH has become one of the leading brands in this segment. "The most important manufacturers of cellular plastic hard XPS boards currently used our technology of extrusion". "Only in the last 5 years sold 15 such facilities", explains Meyke, director of the Department of extrusion of plastic foams of Berstorff, and adds: "It due to the growing demand for XPS boards for the construction sector and for reasons of economic efficiency for processing plastics firms to demand extrusion lines that offer capabilities" production increasingly older but allowing at the same time the use of environmentally friendly expanders with environmental agents. A goal that is not normally achieved with two extrusion machines a single worm.

XPS boards are characterized by the homogeneous structure of its closed cell foam

Thanks to its wide range of products and their experience of many years in the construction of extrusion machines, the company Berstorff GmbH can offer not only extruders of double worm but also extruders of a single worm technically perfected. "Also in our lines XPS us is helpful our huge baggage of experiences in the construction of large extrusion machines a single worm, because the production capacity of a cell plastic foam production line not only depends on the ability of plasticizing of primary extruder"", but first of all of the power of the secondary extruder cooling", clarifies Meyke.

In an installation of extrusion tandem Berstorff functions as primary extruder an extruder of double worm of synchronous progress thanks to its optimum mixing not only allows the preparation of recipes with a large number of components, but also the use of agents expanders respectful with the environment as CO2. "We are currently equipping facilities XPS extrusion machines of double screw with host of 60 ZE-ZE 130 types and thus manage to cover an area of up to 2,000 kg/h production", informs Meyke. From a 1,000 kg/h production is used as a secondary extruder an extruder of a single worm of type KE 400 which is capable of further homogenized the mass melted and gassed polystyrene when it is at about 200 ° C and cooling up to 110 ° C. "Other unique features of our facilities are an optimized system of injection pumps consisting of three individual pumps for the injection of up three different types of agents expanders, as well as the use of special steel to ensure optimal corrosion protection in bolts host and cylinders." For the secondary extruder is still used as a means of circulating temperación water. "Best powers of secondary extruder cooling are achieved in combination with a special construction of the cylinders", explains the head of products.

The Italian manufacturer convinced him especially the speed and simplicity of the commissioning of the complete installation by Berstorff team. Just ten days after the installation the full line, with its 100 m in length, already was producing plates in desired specifications. In Verolanuova are working a double worm of the ZE 110 type extruder and a single screw extruder endless KE 400. These extrusion machines produce plastic foams with a standard net width of 600 mm and a thickness of 30 to 100 mm. The plates are cut transversely and edge practiced them a straight cut, execute slot and keyway or a Union with phased stapling, depending on its area of application. Optionally receive cellular plastic plates surface of special structure.