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Highlights and news K 2019
Promix Solutions, leading supplier of Foam Extrusion Systems, Static Mixers and Melt Coolers will be presenting several highlights at the upcoming K show. Under the motto ‘Yes, we foam!’ the company would like to open the dialogue on how Promix Physical Foaming Systems could help you to save raw material cost, improve your foam quality and reduce your company’s carbon footprint.
The gas dosing system, one of the key components for physical foaming, has been upgraded and presents itself in a fresh new look.
To complement the product portfolio, Promix is launching PROCELL® 1, a newly developed chemical nucleating agent promising smallest cell sizes and highest foam quality.
Upgrade of gas dosing units includes a new look of the cabinet
Yes, we foam! Experience foaming
By continuous further development, the Swiss company has advanced its physical foaming technology with eco-friendly CO2 or N2 blowing agents.
Promix has more than 200 industrial installations, including a number of OEMs that have successfully integrated Promix foam extrusion technology into their extrusion lines. At the K show, Hall 9, E32, Promix will showcase the relevant key components for physical foaming and exchange information on experiences and possibilities within the specific application fields.
The products that have been foamed with the Promix systems feature a very uniform microcellular foam structure and the density reduction is typically in the range of 10% to 60%. Industrial application references range from packaging film and thermoformed sheet made of PP, PS and PET, PP and PE boards, foam core and corrugated pipes made from PP and TPE as well as profiles made from PA, ABS and other materials. Recently, foaming of cable sheathing has become another successful application. A strongly increasing interest for physical foaming has been observed in extrusion blow molding. Thus, Kautex Maschinenbau, Hall 14, A16-A18, is going to present a running line with integrated, machine-adapted Promix foam extrusion system to demonstrate production of a foamed water bottle at the exhibition. Another example is a foamed PET cup for hot-fill applications, which has been developed by the Austrian SML Maschinengesellschaft mbH, Hall 17, C39-C42 and their project partner for thermoforming, Kiefel Bosch Sprang Hall 3, E90. The foaming technology was supplied by Promix Solutions.
PS foam trays with very even foam structure resulting in improved tray stiffness
New look of gas dosing units unveiled
Promix supplies CO2 and N2 gas dosing systems which have been developed to suit specific needs in foam extrusion. The devices are characterized by an extremely high dosing accuracy, reliability and easy operation. At K 2019, Promix is going to unveil the new look of their gas dosing stations. The redesign of the cabinet is not only improving accessibility, but also providing a fresh and modern appearance. The upgrade includes new configuration of the electrical and mechanical components as well as updates to the control software. Depending on the model, CO2 and N2 dosing systems can cover a dosing range from as little as 3 g/h up to more than 10’000 g/h. Promix will be happy to demonstrate the functionality of its new gas dosing unit at the booth.
PROCELL® ensures excellent foam quality
For best results in physical foaming, not only a suitable blowing agent (i.e. N2 or CO2) is required but the addition of a nucleating agent is also of high importance. To complement the product portfolio, Promix is going to launch PROCELL nucleating agents. PROCELL sets new standards in the foaming of polyolefins and enables high-quality microcellular products. Its suitability for use in food also allows applying PROCELL in the food packaging industry. Order your product sample at the K show.
Profitable solutions for light foam production
Promix offers relevant key components to optimize the production of light foams such as XPS / XPE / XPP / XPET. These components enable further reduction in foam density, improve foam cell structure and increase line throughput, resulting in considerable cost savings. Promix P1 Cooling mixer technology is a unique combination of a highly efficient static mixer and a powerful melt cooler. The novel patent-registered technology pushes the boundary when it comes to cooling of polymer melt and other viscous fluids. The simultaneously occurring mixing and cooling effects in the P1 cooling mixer create very efficient cooling very close to the solidification point of the melt without the risk of freezing or building of deposits. The melt temperature is homogenized over the whole cross section. Depending on process requirements, the ideal melt temperature can be exactly adjusted and kept constant over time. Whether it is a tandem or long single screw line, thermal insulation boards, packaging film or insulation for tubes or pipes: Promix will analyze the current line concept and present solutions to optimize the line and increase the profitability.
More than 100 installed P1 cooling mixers- from small pilot plants with a throughput of 10 kg/h up to industrial lines with a capacity of more than 2000 kg/h – have been in operation and demonstrating the success of this novel technology.
Promix P1 cooling mixer improving the cell structure
Visco P – True real time quality control
Amongst its well-known Static Mixer program, Promix is also presenting Visco-P. Visco-P is a „real “inline viscometer which measures viscosity directly in the melt stream and requires no bypass. The measurement takes place in real time and allows continuous monitoring of raw material quality and process conditions.
This allows immediate intervention in case of problems and helps to avoid scrap. The Promix Melt Blender which serves as a measuring device helps to improve the product quality and tolerances of the desired extrudate. Visco-P is suitable for almost any extrusion process and has also been in use for the production of PET sheets and foamed products.
1 PROCELL is a registered trademark in Switzerland (registration no. CH696002)
COMPANY PROFILE
Promix Solutions AG, a “spin-off” of Sulzer, stands for mixing, foaming and cooling in plastics processing and polymer production. The company serves the industry with effective solutions for cost savings and quality improvements in extrusion and injection molding. A motivated team with long standing experience and extensive process and application know-how ensures excellent consultancy and service. The portfolio consists of mixing nozzles, melt blenders, foam extrusion systems, CO2/N2 Gas Dosing Stations, Key components for the production of light foams, melt coolers and inline-viscosity measurement systems.
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PRODUCT-OVERVIEW
For more information please click on the pictures:
Mixing nozzles and static mixers for injection molding - Improve your process now!
You can solve many of your today problems in a fast and cost effective way without interrupting your production. Find the hidden potentials to further process optimizations. Save master batch costs of up to 30 % or reduce the cycle time.
For more information please click on the links below:
• No color streaks and flow lines
• Improved surface appearance
• Better incorporation of regrind material
• Better balancing of cavities in hot runner systems
• Better tolerances
• Increased tensile strength
• Close to maintenance-free processing of liquid silicone rubber
â–ºCase studies
â–ºMixing Nozzle Finder
Promix mixing nozzle concept
The Static Mixer is installed directly in the nozzle of the injection molding machine. You can rely on an experienced partner replacing your existing nozzle with the suitable complete Mixing nozzle from our extensive mixing nozzle portfolio. Most of the mixing nozzles can be delivered within 1 to 2 weeks.
â–ºMixing nozzle inquiry form
Melt blenders for extrusion
Do you wish to optimize your extrusion process? Promix offers you effective static mixer and melt blender solutions including extrusion housings at low investment cost.
Promix melt blenders offer you
• Higher throughput
• Excellent distribution of all additives
• Consistent quality and optimal inflow of melt into the die
• Elimination of flow lines
• Homogenious temperature and velocity
Application examples:
For more information please click on the links below:
• Cable sheathing
• Compounding
• Extrusion blow molding
• Pipe extrusion
• Rigid PVC & rubber extrusion
• Sheet & profile extrusion
• Thin film & blown film extrusion
• XPS foam boards
Promix melt blenders for effective temperature homogenization
Thermoscan of PE coating film with and without Promix melt blender
What we offer
• Design, layout and manufacturing of melt blenders / static mixers
• Custom-made housings including heater bands and thermocouples
• Short delivery times
• High quality standard
â–ºMelt blender inquiry forms extrusion
Promix foam extrusion - Retrofit solution for physical foaming in extrusion
Promix foam extrusion is a unique, licence free technical concept for foam extrusion. Promix foam extrusion allows to cut production cost of semi-finished products due to reduced raw material consumption. It is also used to substitute chemical foaming additives with eco-friendly blowing agents as CO2 or Nitrogen.
What we offer
Promix foam extrusion is a comprehensive solution including all required equipment and services to achieve your microcellular foam product:
• Thorough analysis of your current extrusion process and your targeted foam application
• Foaming systems for precise injection and effective solving of supercritical blowing agents including melt
cooling
• Reliable and very accurate gas dosing stations
• Foam dies and die modifications, annular dies for light foam applications
• Melt coolers for optimized foaming results
• Pilot testing and sample production on site or in our test facilities
Microcellular foams with Promix foam extrusion system
Examples of use
Promix foam extrusion systems are in industrial use for many different applications and products. Mono- and multilayer foam lines are in operation with capacities of 5 kg/h up to 2000 kg/h producing superior foam products including microcellular foams. Here below are a few examples.
Your benefits
• Significant cost savings due to density reductions by 10 - 70 %
• Lower running costs and further reduced foam densities compared to chemical foaming
• Eco-friendly light weight products, use of natural blowing agents such as CO2 or N2
• Superior foam properties and process consistency
• Easy switch from foamed to non-foamed products
• Fast and easy installation, quick start up
• No licence fees, no running royalties
CO2 and N2 Gas dosing stations for physical foaming
Promix Gas Dosing Stations for physical foaming have been developed to suit the specific needs of foam extrusion applications. Extremly high dosing accuracy, reliability and easy operation are the key features of Promix gas dosing systems. No matter if process monitoring with trend charts and user settable alarms, data acquisition, flow match with extruder output and many more, Promix gas dosing units provide all the required features for state of the art foam production. Furthermore, implementation in extruder control via fieldbus system is also possible.
Promix gas dosing system for physical foaming
Main characteristics Promix gas dosing stations
• Massflow from 1 g/h up to 3000 g/h
• Delivery pressure up to 700 bar
• Convenient operation via 12,1” Touch Screen
• User settable limits for full process control
• Trend charts for pressure and flow over time
• “Flow match” function to synchronize mass flow with extruder output
• Implementation in extruder control via fieldbus system possible
• Data acquisition via USB port
• Remote maintenance capability
Melt Coolers and Heat Exchangers
Do you wish to cool down your polymer melt? Promix offers you very efficient melt coolers and heat exchangers for viscous and high viscous fluids and melts.
Promix Melt Coolers improve your process
- Very high cooling efficiency and accurate outlet melt temperature control
- No fouling or blocking problems due to a well-mixed single flow
- Narrow residence time distribution
- Short installation length
- Low pressure drop
Melt Cooler for highest efficiency
Melt Cooler concept
In cooling processes viscous fluids tend to deposit at the cooling wall sections (fouling) leading to reduced cooling efficiency. In the Promix Melt Cooler (PMC) the melt flows in a single stream through the cooler. The cooling media flows in special pipe bundles arranged similar to those of the Promix mixing elements. The intense mixing together with the very high heat exchange surface area leads to effective cooling with very limited risk of fouling. Due to a void volume of about 75 % the resulting pressure drop in a PMC is rather low. The PMC can as well be used for gentle heating with only small temperature difference between heating media and fluid.
Fill in the PMC inquiry in order to get an offer or contact our experts for further questions.
Promix Melt Cooler in operation
Key components for the production of XPS, XPE, XPP, XPET low density foams
Promix offers relevant key components to optimize production of low density foams as for example fabrication of XPS insulation boards, XPE foam film or XPP, EPE thermoforming sheet. Implementing Promix key equipment generally results in lower foam densities, improved cell structure and an increased line output, leading altogether to significantly lower production cost. Whether it is a tandem or long single screw line, thermal insulation boards, packaging film or insulation for tubes or pipes: we will analyse your current line concept and are going to propose a solution to increase your profitability.
Benefits of Promix key components for low density foams
XPS Insulating board
 • Uniform cell size and more consistent foam structure
• Increased throughput, especially for thick boards
• Lower foam density
• Faster start-up time
• Savings of blowing agent
XPE foam film and profile
 • Lower foam density
• Uniform cell structure
• More narrow thickness tolerances
PS foam for food packaging (XPE)
 • Lower foam density
• Increased stiffness/rigidity
• Improved thermoformability
• More narrow thickness tolerances
Viscosity measurement, accurate and inline - true real time quality control
Control the production quality of your extrusion line with Promix Visco-P continuously and in real time. Avoid poor production quality issues and scrap. Visco-P is a true inline viscometer which measures viscosity directly in the melt stream and requires no bypass. The Visco-P continuously monitors raw material quality and process conditions. Convince yourself. Ask us for a test unit.
Your benefits
• Continuous real time control of raw material quality and process conditions
• Very accurate inline viscosity measurement without bypass
• Suitable for all viscous fluids
• MFI / IV-calculation mode
• Will be used in combination with Promix static mixers leading to additional value by improved melt and
temperature homogeneity
How it works
A special Promix static mixer module, installed in the extrusion line, is the physical point for measuring process variables. The calculated results are displayed continuously and in real time on an industrial PC with touch screen. In addition to measuring the melt viscosity, the Visco-P will also calculate the MFI or IV value of the real melt.
The Promix static mixer module creates excellent blending of the polymer melt which improves thermal homogeneity and surface quality, reduces thickness tolerance variations of the extrudates, and often leads to an increased output rate. Visco-P is in operation in many applications such as PET and PE extrusion and for the processing of polymer melts containing blowing fluids.
Promix® Visco-P for accurate inline viscosity measurement in extrusion
Visit us at the K fair. We would be pleased to meet you on our booth:
Hall A9 / Booth A32
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Promix Solutions AG
