Successful extrusion of polypropylene, or PP, depends on several factors. It is essential to carefully match optimal process conditions and parameters such as temperature, pressure, and speed for a successful process. When PP is also filled, the production line is put under additional strain.
The customer’s process involves compounding and extruding PP heavily filled with glass fiber and desiccant. The process resulted in high rates of premature wear to the extruder and melt pump with a standard melt pump typically showing signs of wear at 6 months and housing falling out of specification around 12 months.
For many years, the customer accepted premature wear as an inevitable consequence of their manufacturing process; however, Suurmond remained keen to investigate further, prompting an 18-month study to determine the root cause and any potential improvements.
Following consultation with our colleagues at MAAG, it was suspected the upgraded design features and volumetric efficiency of the ‘Generation 6 range’ could benefit this specific process. In 2020, we installed the first EX50-6 pump unit into the line and monitored it closely.
Over the following 12 months it became obvious previous issues experienced had been greatly reduced if not eliminated. The positive results prompted a further two lines to be upgraded immediately, an additional two lines upgraded the following year, and in 2023 expansion saw an entirely new line installed with an EX50-6 pump unit as standard.
Our customer is delighted to report several key benefits to their business:
The success of the roll out prompted the client to approach Suurmond with an additional request to help reduce waste on a second core product comprising of silicone rubber.
Again, in consultation with MAAG, we supplied a MAAG EX56 RB melt pump running with a Suurmond control system. In this case we significantly reduced waste and improved dimensional stability with the added benefit of removing load and reducing wear on extruder components.
Within a busy manufacturing environment, it is often all too easy to repeat what has ‘always been done.’ However, utilizing Suurmond as a partner and sounding board in combination with the knowledge and experience of our key supplier partners, we can help improve many processes. We look forward to discovering if we may be able to increase productivity, reliability, and profitability on your specific application.
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