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Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists.

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Presentation on theme: "Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists."— Presentation transcript:

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2 Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists. We manufacture feed screws of the highest quality, and provide service and a product that is second to none. We service the plastics and rubber industries to processors and OEMs worldwide, countries such as USA, UK,EUROPE, RUSSIA,MIDDLE EAST,AFRICA,ASIAN Countries etc….. Our Technical and Engineering Department offers more than 15 years of experience in the field of plastic machinery and screw design. We have developed our own line of screw designs which can be tailored to suit your application. We stand behind the parts we produce and provide long term support for our products. Ever since it & we believe in the quality first, honesty to customers, prompt services to customers satisfaction. INDRODUCTION INDRODUCTION

3 Our comprehensive production facilities enable us to perform the entire manufacturing process in-house. As for new screw or old rebuild screw, we utilize traditional methods to achieve the highest international standards. Feed screw cutting machines over 6m (20 ft.) long x 20 cm (8 in.) diameter Milling and turning Welding of hard facings Heat treatments (Ion & Gas nitriding, Vaccum hardening) Chrome plating max. length 6 m (20 ft.) Deep hole boring/trepanning Honing 200 ton press Complete Production Facilities

4 To assist in ameliorating the designs off different Screws & Barrels for running different plastics polymers. To assist in increasing your extruders out put as well as prolonging its service life. To assist in increasing your extruders according to your specific melt quality. Better processing of film and reduce scrap and also cost saving of resins. Speedy returns on your initial high investments by our products. Kaivanya extrusion use strong R&D skill work closely with our customers to ensure quality products that produce high end output at a very economical price. KAIVANYA SERVICES

5 Equipments Plasma Nitriding furnaceMicroscopic Structure Hardness TeterQuality Control Thread Milling

6 KAIVANYA EXTRUSTION TECHNIK PRESENTATION ON EXTRUSION Single & Twin Screw & BARREL(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)

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9 Extrusion moulding is a manufacturing process used to make pipes,filim,hoses,drinking straws, curtain tracks, rod and fiber,yarn,cable & wire,sheet,rope,sutli,&other product. The machine used to extrude materials is very similar to injection molding machine. A motor turns a screw which feeds granules of plastic through a heater. The granules melt into a liquid which is forced through a die, forming a long 'tube like' shape. The shape of the die determines the shape of the tube. The extrusion is then cooled and forms a solid shape. The tube may be printed upon, and cut at equal intervals. Extrusion Process Extrusion Process

10 Screws are made from nitro alloy steel like 34CrAlNi7, 41CrAlMo7 etc. toughening, tempering, stress relieving, gas nitriding & additional bimetallic coatings can be incorporated on flights depending on the process application. We also do special surface treatment like hard nickel plating, chrome plating & titanium coating depending on the material to be proceed. Our ability to design and manufacture some of the industrys most advanced and efficient feed screws is one reason we have been an extrusion leader for more than 15 years. With our R&D facilities and team of experienced polymer process engineers, we offer customers world class screw design and technical capabilities. Extrusion Molding Screw Extrusion Molding Screw

11 KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion screws in India. Our designs cover all facets of the extrusion industry from thermoplastics to natural and synthetic rubber. We have a 13 year plus record in this industry from which we have built up significant data, soundly based on experience and results. Screw construction is hard faced, nitrided or hardened & nitrided, for highly abrasive materials we can supply screws with Tungsten carbide coatings on the flight flanks and core diameters, or in the case of highly corrosive polymers such as Fluoro polymer a Duranickle based screw is offered. Designs are available for single flight metering screws, single barrier screws, double barrier screws, variable pitch flights, multi start flights and slotted flights. Two stage screws for vented extruders are also offered. Mixing sections, the more common of which, include Maddock (spiral or straight), Hoechst, dulmage, pinned, pineapple or combinations of these designs are available. Our capacity ranges from 25mm up to 200mm depending on L/D ratio. Explanation For Extrusion single Screw

12 Rubber Extrusion Screw

13 Extrusion Feed Bush/Grooved Sleeve

14 Extrusion Static Mixer

15 Single Screw Extruder Model (Screw Dia) mm L/D (Driving Motor) kw (Capacity) Kg/h Ket Ket Ket Ket Ket Ket Ket-65A-65A Ket-65B-65B ket Ket Ket Ket

16 KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion twin screws in India. Based on this fact, kaivanya Factory machined the best plasticization satus & blending quality are achieved. New configured screws, which can be application to process PVC pipes & profiles are developed by kaivanya Factory. Also anticorrosion & wear resistant material are developed. Polymer material can be sheared & compressed more softly in screw. Extruders with twin-screw and short distance between screws are better than other types, because of their high capacity and good thermal and mechanical stress. The powder mixing with chemical additives and melting with thermal and mechanical energy in three zones (feed, compression and metering zone) and because of gear pump and screw's pressure, converting to final product in latest plate. Explanation For Extrusion Twin Screw

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18 This has enabled production of Twin Barrel with approximately twice to thrice the service life of nitrided barrels at just 20% to 25 % addition cost. This renders the economic efficiency factor irrelevant in purchasing decisions. An additional benefit is the extended service like of twin screw extruders with wear resistant barrels can be operated at normal output for a longer period, without incurring through put losses due to wear. Thus production costs are reduced while competitiveness is improved. Twin Screw Barrel

19 KAIVANYA EXTRUSTION TECHNIK PRESENTATION ON INJECTION MOLDING SCREW & BARREL (Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)

20 We manufacture screws for both thermoplastic and thermosets, standard metering design or QLT for improved melt homogeneity and mixing. These can be hard faced, nitrided or hardened and nitrided with optional hard chrome plating. Whether you are manufacturing containers for packaging, duct joints for air conditioning or automotive components, we have a screw design available to suit your process for LDPE, HDPE, PP, PVC and more. INJECTION MOLDING

21 The feed section establishes solids convey in the same way as a conventional screw. At the beginning of the transition zone, a second flight is started. This flight separates the solids channel from the melt channel. As material progress down the transaction. melting continues as the solids are pressed and sheared against the barrel, forming a melt film. The barrier flight moves under the melt film and the melt is collected in the solid pellets and melted polymer are separated and different function are performed on each. The melt channel is deep, giving low shear and reducing the possibility of overheating the melted polymer. the solids channel becomes shallower, forcing the unmelted pellets against the barrel for efficient frictional melting. breakup of solids bed does not occur to stop this frictional melting. the solids bed continues to get shallower and finally disappears into the back side of the primary flight. Injection Molding Screw

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23 Injection Molding Barrels

24 Injection Head & Components

25 Injection Ring Plunger Sets

26 Tie Bars

27 KAIVANYA EXTRUSTION TECHNIK PRESENTATION ON BLOW MOLDING PROCESS(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)

28 Blow molding is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tube-like piece of plastic with a hole in one end in which compressed air can pass through. The parison is then clamped into a mold and air is pumped into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected. Blow Molding Process

29 Blow Molding Screw

30 Blow Molding Barrel

31 Blow Molding Retrofit Spares

32 The feed section establishes solids convey in the same ways as a conventional screw. At the beginning of the transition (compression) zone, a second flight is started. This flight separates the solids channel from the melt channel. As material progress down the transition, melting continues as the solids are pressed and sheared against the barrel, forming a melt film, the barrier flight moves under the melt film and the melt is collected in the solid pellets and melted polymer are separated and different function are performed on each. The melt channel is deep, giving low shear and reduction the possibility of overheating the melted pellets against the barrel for efficient frictional melting, breakup of solids bed does not occur to stop this frictional melting. The solids bed continues to get shall over and finally disappears into the back side of the primary flight. Decompression zone. In this zone, about two-thirds down the screw, the channel suddenly gets deeper, which relieves the pressure and allows any trapped gases (usually moisture or air) to be drawn out by vacuum. Second metering zone. This zone is like the first metering zone, but with greater channel depth, and repressurizes the melt to get it through the resistance of the screens and the die. How does the Barrier Screw Works? How does the Barrier Screw Works?

33 PRESENTATION ON BIMETALLIC SCREW & BARREL (Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm) KAIVANYA EXTRUSTION TECHNIK

34 BI METALIC BARREL - HVOF THERMAL SPRAY TUNGSTON CARBIDE COATING 1 SURFACE-PREPARATION 2 THERMAL SPARY 3 MIXING ROTORS 4 Rolls5 As sprayed screw

35 6 Diamond Polish 7 SMALL SCREW 8 Final Quality

36 BIMETALIC BARRELS

37 How does tungsten carbide protect from abrasion wear?

38 Abrasion Resistance Test Data

39 PTA WELD OVERLAY BORON CARBIDE COATING

40 Base Material 1.Nitro alloy 2.AISI AISI Stainless Steels,17-4PH,316 5.Special alloy steel Hard Facing Layer 1.KET183 (Ni/Cr/Boron/WC-35%) 2.KET 156 (Nickel- Cr/Boron) 3.KET163 (Nickel- Cr/Boron) 4.KET188 (Ni/Cr/Boron/WC-19%) 5.KET 900 (HOVF) TUGSTEN 88Wc/12 % Co Root Treatment 1.Nitriding 2.Chrome plating 3.Vapor Deposition 4.HVOF Thermal Spray Tool Steels 1.D2 2.H11,H13 3.V4,V9 4.CPM9V,CPM-S90V

41 SCM440(1.7225) High Tensile Strength Full hardening (56 HRc) High Toughness Flame Hardening Chrome Plate Nitride Hard Face SKD11(1.2379) Full Hardening (60 HRc) Multi Purpose Screw Good Abrasive Resistance Good Corrosive Resistance (11% Chromium) Glass Fill 20% SKD61(1.2344) Hot Work Tool Steel Full Hardening (52 HRc) Good Abrasive Resistance High Temp. Hardness Good Abrasive Resistance Nitride Stainless 17-4PH Full Hardening(48HRc) High Toughness High Temp. Excellent Corrosive Resistance Hard face Nitride

42 Special Alloy High Chemical Resistance Inconel 625 Nickel Base (21% Chromium9%molybdenum) Hastelloy C276 Nickel Base (15% chromium,16% molybdenum Hard Face Plasma Transfer ARC(PTA) Screw Flight Built up Cobalt (stlelite 12,48 HRc) Nickel(colmonoy56,52 HRc,KET63) Tungsten Carbine KET86,88 70,75 HRc

43 Chromium Boride Hardness Tungsten Carbide Hardness Nickel Based Material Hardness 49-56HRc Anti-Abrasive /Corrosive Nickel Based Material Hardness 48-59HRc Anti-Abrasive /Corrosive

44 Element are Atomization to tiny droplets, mixed to a certain percentage. Hot Isostatic pressing. Fine & Uniform Micro Structure. Good Toughness. Stainless Steel Grade. Nitride Process can enhance the PM tool Steel hardness but it is not common practice. Companies Provided – Bohler,Germany

45 Nitride Surface Case Depth : mm Hardness : 1000HV Base Material Hardness HRC Iron Nitride

46 Backing Steel High Tensile strength Steel Chromium /Vanadium 950MPa Tensile Strength 630 Mpa Yield Strength High temp. operating Condition Alloy liner Anti –abrasive Anti-Corrosive Base Material High Tensile Strength

47 KET 56 Chromium Boride/Carbide Iron Base Material Hardness: HRc Anti- abrasive Glass Filled Application KET63 Chromium Boride/Carbide Iron Base Material Hardness: HRc Anti- abrasive Glass Filled Application KET 83 Tungsten Carbide Nickel Base Material Hardness HRc Anti-abrasive /Corrosive High Wear application KET 88 Premium Grade Tungsten Carbide Hardness HRc Excellent Anti-abrasive/corrosive

48 KAIVANYA EXTRUSTION TECHNIK PRESENTATION ON REBUILDING OF Screw & Barrel(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)

49 We hard-surface, straighten, machine, grind, and polish to precision tolerances. Special hard-surfacing alloys are made with Nickel, Tungsten-Carbide and Molybdenum. Screw Modification -- Engineering designed to your specifications. Our expert consultation assures exact results. Twin Screw Rebuilding -- Straight or Conical Twin Screws. Barrel Manufacturing -- Extrusion and Injection molding barrel with bimetallic inlays. Barrel Resleeving and Honing -- Partial resleeves up to 24 inches or honing to an even oversize dimension. Components Building and Repair -- All replaceable components. Chrome-Plating -- On site by our sister company Central Florida Plating. Inspection Certificate -- All incoming and outgoing screws, barrels and components are inspected and Rockwell tested for hardness and print accuracy. Rebuilding of Screw & Barrel Rebuilding of Screw & Barrel

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51 Screw Rebuild/Repair Barrel Rebuild/Repair Rebuild the top of the flight with hard facing (Satellite & Colmonoy) Repair the internal thread Repair the shank (drive section) Repair the NPT thread Repair the removable nose Re-sleeve the stroke section or full length of the barrel with standard bimetallic, carbide or corrosion resistant liner Repair the grooves within the barrel and on the feed housing section Reline and repair the water jacket for a rubber processing barrels Pressure testing and acid flushing for rubber processing barrels Press-out broken screw from barrel

52 Rebuilding Process O.D. Rebuilding Flight Renovation Screw Re Joint Special Coating Crack Root Key Way Spline Repair

53 Straightening Nose Resisted Nose Rethreading Root Rebuilding Flight Rebuilding Crack Fights

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