EDI Press Release

‘CUSTOM ENGINEERED DIE SYSTEM’ (TM) CONCEPT DEBUTS AT NPE 2006 FOR EVERY TYPE OF FLAT-DIE EXTRUSION OR COATING OPERATION

EDI Builds Entire System between Extruders and Chill Rolls, Streamlining the Engineering of Production Lines, Increasing Their Productivity, and Enhancing Product Quality

CHIPPEWA FALLS, WI, U.S.A., February 27, 2006: Extrusion Dies Industries, LLC (EDI) now engineers complete flat-die extrusion tooling systems that enable machinery OEMs, processors, and web converters to single-source every component required for transforming molten polymer into film, sheet, and coatings, the company announced today.

In accordance with the Custom Engineered Die System (TM) concept to be introduced NPE 2006 (Booth 4661), EDI designs and builds ready-to-operate assemblies for installation between the extruders and the equipment downstream of the die lip exit. By integrating all components in a single system that is custom-engineered for a specific application, EDI makes it possible to exert greater control over product gauge and physical properties, reduce scrap and downtime, and increase line throughput, according to Christopher W. Curtin, executive vice president of sales and marketing.

“The die is the heart of the extrusion process,” noted Curtin. “By integrating the die with all of the components that work with it in shaping and conditioning polymer into a finished product, the Custom Engineered Die System increases the efficiency of the entire production line. This optimization is particularly important for today’s increasingly complex extrusion runs, where a die is fed by as many as five extruders to yield a single barrier film or other structure of up to eleven layers.”

As an example of a Custom Engineered Die System for a multi-layer application, Curtin cited one that EDI is preparing to ship to a stretch film manufacturer (see photo). The system includes a 215-in. (5,460-mm) Contour Die (TM) with Autoflex VI-R gauge profiler, nine-layer Ultraflow I-S feedblock, and a number of other components (listed in photo caption).

While the Custom Engineered Die System varies with the application, one system may include any or all of the following:

--FLAT DIE OR SLOT DIE COATING HEAD. A Custom Engineered Die System could be centered on virtually any film, sheet, extrusion coating, or proximity coating die offered by EDI, including the innovative tapered-shape Contour Die (TM), on whose design EDI has recently standardized all of its new cast film dies.

--GAUGE PROFILER. Flexible-lip adjusters include Autoflex (R) computerized and Ultraflex (R) manual systems.

--COEXTRUSION FEEDBLOCK. This could be designed to feed a complete multilayer structure into a single-manifold die or two or more multilayer substructures into a multi-manifold die. Types available include Accuflow (TM), which is adjustable online, and Ultraflow (TM), which is adjusted by means of interchangeable tuning inserts. A special feedblock adapter makes it possible to change the sequencing of layers in a coextrusion.

--DIE SUBSYSTEMS. Many options are available, including internal and external deckles for varying width online, the FastGap (R) mechanism for rapid online changes in thickness, and cleaning devices that make it possible to remove lip buildup without interrupting the extrusion process.

--MELT FEEDPIPES. These tubes connect extruders to coextrusion feedblocks or multi-manifold dies and are designed for minimal length and maximum streamlining in each specific application.

--VACUUM BOX. This web-impingement device removes air entrained between film and casting roll, then uses a high vacuum to stabilize the film on the roll.

--EXHAUST HOOD. This device removes smoke and volatiles generated during extrusion, keeping them from migrating into ambient plant air.

--DIE STAND AND SPLITTER. This custom-built support structure provides stable positioning of the die in the extrusion line and makes it possible to split and clean the die without taking it offline.