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April 2024

Plastics In Focus Edition 2/2024

ProRate PLUS. Surprisingly Powerful.

In the continuous production of plastic products, equipment for the controlled feeding of bulk materials into extruders and/or mixers is essential. In most cases loss-in-weight screw feeders are used to feed the bulk materials. The flawless operation of loss-in-weight feeders is the key to successful production. But what are the most common challenges when operating screw feeders and how does the ProRate PLUS line meet the requirements of the plastics processing industry?

Coperion K-Tron ProRate PLUS Feeders - ProClean
The patent-pending ProClean rail system provides easy access for cleaning and maintenance at all times.

Cleaning and changing screws

When recipes need to be adapted to new applications or a change in bulk materials, the screw feeder must be cleaned and, depending on the material, the screws need to be changed. Normally, the screws have to be removed from the discharge point, which requires access from the front of the feeder. However, as several feeders are often positioned around a process inlet, access from the front is usually difficult or even impossible. The feed and discharge couplings would have to be disconnected and the machine moved out of position just to replace the screws. This process often takes 20 to 30 minutes, ties up manpower, delays the restart of production and reduces efficiency.

With the patent-pending ProClean Rail, ProRate PLUS gravimetric feeders offer an ingenious solution to this problem. The feeder can remain in position and, thanks to a special rail, the entire feeder base unit is detached from the hopper, pulled backwards and swiveled for better access. It is not necessary to disconnect the feed and discharge lines and the main structure of the feeder remains in position. Cleaning the screw trough and replacing the screws is extremely fast, done in 3 to 5 minutes. This allows for a faster restart of production and ties up less manpower.

Coperion K-Tron ProRate PLUS Feeders
Pre-configured pneumatic refill solutions are available for every feeder model.

Refill

Maintaining a constant supply of material to the loss-in-weight screw feeders is a critical aspect that comes with various challenges. Poor design or incorrect choice of refill equipment can lead to various problems during the refill process: 


  • Enormous dust generation due to excessive conveying speeds in a pneumatic conveying system can lead to clogged filters, blockages in the lines or, in the worst case, even endanger workers if the dust gets into the environment and is inhaled by people.
  • Refilling devices that are too slow or too small lead to very short refill cycles, which in turn leads to inaccuracies in the feeding performance.
  • Over- and underpressure due to incorrect filter surfaces, flooding bulk solids or poor discharge aids often result in over- or under-feeding.
  • In some cases, manual refill is necessary, which is time-consuming and increases the risk of errors.
  • Finally, there is always a risk of contamination during refill, especially when different materials are used in the same feeder.

In the ProRate PLUS line, pneumatic refill packages are perfectly designed to match each feeder model. This careful coordination ensures smooth feeding performance without compromise.
We offer vacuum receivers for pellets (without dust filters) as well as receivers with self-cleaning filters for powders, covering a wide range of applications. This promotes optimal performance for every bulk material. Each refill system has been perfectly dimensioned to ensure a precise conveying speed. This careful design ensures reliable feeding.

The flexibility of the ProRate PLUS line is demonstrated by the ability to combine it with different types of material delivery options such as big bag stations, silos, bag dump stations and more. This allows you to adapt your feeding system to your individual requirements.
Compact, preconfigured robust support frames are included with every solution. This eliminates the need for additional steel structures, simplifying installation and saving costs. 

The ProRate PLUS refill solutions are also directly integrated into the feeder control system. This integrated controller can be easily connected to the higher-level PLC, either via PROFIBUS or Ethernet. This ensures seamless communication and control over the entire feeding process system, further optimizing efficiency and accuracy. Integration of the controller into the feeder unit also allows for simple operation and monitoring of the feeding processes directly on site or remotely via the PLC.

Coperion K-Tron ProRate PLUS Feeders - Proflow
ProFlow activates the material with an optimized frequency and amplitude to minimize energy consumption while maximizing material flow.

Material flow

Efficient material flow is crucial for accuracy in loss-in-weight feeders. Using the wrong feeding tool can affect feeding accuracy and the performance of the entire system. The ProRate PLUS line offers single screw feeders specifically designed for precise feeding of free flowing bulk materials. If the material does not always flow freely, these feeders can be outfitted with a ProFlow bulk solid activator. ProFlow uses targeted vibrations to ensure a continuous and even material flow, which promotes consistent feeding and improves accuracy.

For moderately flowing bulk materials, such as powders, the ProRate PLUS line also offers the PLUS-MT twin screw feeder with horizontal agitator and steep hopper walls. The active movement of the material by the agitator together with the steep hopper walls helps to prevent bridging. As an option, the PLUS-MT can also be equipped with a ProFlow to achieve a reliable material flow.

Regardless of the configuration chosen, the ProRate PLUS line offers a choice of solutions to ensure smooth material flow and accurate feeding performance. With the careful selection of feed tools and the integration of innovative technologies such as the ProFlow bulk solid activator, we set standards for reliable and efficient feeding in industrial applications.

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