High reliability and ease of operation are crucial for extrusion line equipment to minimize costly reject and unexpected stops. A 'maintenance-free' design concept significantly enhances extruder reliability and reduces operational costs.
Unexpected stops related to extruder failures are particularly costly. Leaving out fluids, pumps, and seals as much as possible in the design greatly lowers the risk of such failures.
Design Aspects for Reliability
AC Motors
Replacing DC motors with AC motors lowers both maintenance costs and energy costs.
Balanced Screw Design
A well-balanced screw design contributes to a 'maintenance-free' concept by allowing operation with minimal cooling, sufficient for processing. This reduces reliance on complex cooling systems. For double screw extruders, leaving out cooling holes for external screw cooling in the screw shafts allows for increased torque and potentially higher output, as this reduces points of failure.
Automated Controls
Modern electronic controls improve reliability and ease of use. Controls based on familiar concepts like Windows reduce training requirements for operators. Visualisation of machine settings on screen provides automatic checks, reducing mistakes and reliance on manual administration/registering. Tools like scanners integrated into control screens allow operators to make adjustments directly, reducing frustration and dependence on specialists.
FAQ Section
How does a 'maintenance-free' design improve plant efficiency?
A 'maintenance-free' design reduces unexpected stops and reject rates, both of which are costly and lower Overall Equipment Effectiveness (OEE). High reliability allows lines to operate consistently, potentially reducing the number of lines needed for a given output.
What specific design features contribute to lower maintenance in modern extruders?
Key features include well-balanced screw designs minimizing the need for complex cooling, leaving out unnecessary fluids, pumps, and seals, using AC motors, and implementing modern electronic controls with visual interfaces based on familiar software.
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Navdeep Singh Chawla
