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December 2024

Plastics In Focus Edition 5/2024

Modernization of Compounding Plants

How to improve system performance by implementing state-of-the-art product discharge and material handling technology

Coperion Compounding Plant

Compounding plants play a critical role in the plastics industry as well as in some chemical applications. By effectively blending and processing raw materials into more functional and application specific compounds, these state-of-the-art systems support the development of high-performance, customized materials that drive innovation and efficiency across multiple applications.

Compounding plant operators face significant challenges. Product quality must meet the highest standards of consistency. It must not be impaired by unwanted byproducts, such as fines or streamers, that can occur during the handling and processing of materials. At the same time, production lines often need to reach very high throughput rates and work with maximum efficiency to maintain highest profitability. Meanwhile, plant operators must show foresight and planning to ensure that adaptable systems are put in place to manage the processing of different material sizes and densities as demands change.

These challenges also present opportunities. Compounding plant operators can undertake targeted modernization measures to optimize performance.

Let’s take a targeted look at the product discharge and bulk material handling technology. Modernization measures in these two areas of a compounding plant can improve product quality and the productivity of the entire system. Such investments can improve product quality as well as plant productivity and efficiency, while promoting more sustainable operations by minimizing raw material usage and waste. These measures can also help avoid the generation of fines and streamers, which will subsequently reduce downtime.

  • 1. Multi-Discharge Feeder (MDF)
    Coperion Multi Discharge Feeder MDF

    Description and usage:

    Mechanical discharge unit for difficult flowing powders, such as Titanium Dioxide (TiO2), which can have small particles that may agglomerate and cause clusters, but do not permit the use of fluidizing aids.

    Technical features:

    The MDF uses a motorized impeller to feed the rotary valves installed at the outlet. The MDF is available with two to four outlet nozzles to feed multiple conveying lines simultaneously.

    Customer benefit:

    Reduces the risk of bridging caused by fine powders that cannot be discharged with the use of fluidizing aids.

  • 2. Big Bag Unloading Station BES-6
    Coperion Big Bag Unloading

    Description and usage:

    Designed for unloading big bags of a wide variety of products, the BES-6 offers different standard configurations and can be suitable for use in ATEX environments and seismic zones.

    Technical features:

    The BES-6 is available with many options, including a 25 kg bag unloading hopper. It is available with dust-tight accessories or an onboard filter unit with an aspiration fan to minimize powder leaks.

    Customer benefit:

    Enhances big bag handling by minimizing powder leaks and improving safety through ergonomic design and a flow regulator system for pneumatic accessories.

  • 3. Horizontal Fluidbed Separator (HFS)
    Coperion HFS

    Description and usage:

    The HFS is used to remove angel hair, fibers, and dust from granular products such as pellets before they enter a silo or are fed into a process or bagging machine.

    Technical features:

    Installed below silos or before feeding systems, the HFS cleans the product to avoid blockages in loss-in-weight feeders or in subsequent equipment. 

    Customer benefit:

    Improves the quality of the finished product by minimizing dust, fines, and streamers, thus preventing degradation of pellet quality.

  • 4. Slug Dense Phase Conveying
    Coperion Dilute Phase Conveying

    Description and usage:

    This conveying technology is designed for very gentle pneumatic transfer of finished product pellets (8 m/s as final speed), minimizing friction and wear, while preserving product features and quality.

    Technical features:

    It is suitable for conveying pellets without generating fines or streamers and prevents pipe wear when handling abrasive pellets, maintaining conveying parameters such as flow rate and pressure.

    Customer benefit:

    Ensures the integrity of finished pellets by minimizing friction and wear, providing a reliable solution for abrasive pellet conveying.

  • 5. Dilute Phase Conveying with Shot-Peened Pipes and GAMMA-BEND NT Deflector Elbow
    Coperion GAMMA BEND NT

    Description and usage:

    This system is designed for the gentle dilute phase conveying of soft pellets, minimizing the generation of dust and angel hair.

    Technical features:

    Designed as a segmented pipe bend with directed double wall deflection, the GAMMA-BEND NT reduces friction and the generation of fines. The unique geometric design prevents pellets from sliding against the exterior wall.

    Customer benefit:

    Provides an easy and cost-effective retrofit solution that significantly reduces the creation of fines and dust while conveying soft pellets.

Coperion 3D Scanning

3D Scanning: Ensuring optimal product sizing and selection

Some compounding plants have been in operation for many years. Inevitably, original engineering plans and drawings may have been misplaced or may no longer correspond to the current status of operation – which can be problematic when it’s time to modernize.

Coperion helps customers overcome these challenges by utilizing state-of-the-art 3D scanning systems to establish the configuration of the installed product discharge and material handling equipment. With accurate representations of size and layout, Coperion can ensure that replacement equipment fits optimally inside the current footprint.

Summary: Partner with Coperion to modernize your compounding plant

When compounding plants are initially built, they utilize state-of-the-art systems and components. However, as technology and market demands continue to evolve, new requirements may develop for handling different or new products and to integrate additional process steps, leading to the need for many plants to be optimized over time. Through extensive research and development, Coperion has continuously introduced high-quality product discharge and material handling equipment for compounding systems, providing significant benefits in plant operation. Today's advanced components are engineered to improve product quality, debottleneck existing systems, and optimize plant availability, efficiency and profitability.

The potential for optimization through modernization of existing systems is substantial, particularly for older plants. The older the plant, the greater the opportunity for improvement, making modernization a crucial step towards maintaining a competitive edge and achieving operational excellence.

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