RulliStandard - Hight Technology in Extrusion and Coextrusion

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COMPANY

Rulli Standard company was founded in 1961, occupying a space of more than 20 m2, manufacturing parts for different types of machines, but with the firm purpose of manufacturing its own machines.
In 1963, while tending to the first inquiries of customers who were interested in the production of plastics, Rulli Standard invested in new processes in order to begin the manufacturing of equipment for monofilaments and the coating of electric wires.
Rulli Standard, over the years, acquired experience and through large investments and research, developed its very own technology, competing side-by-side with major competitors in the domestic and international market.
The industry was developing around the world and Rulli Standard, always on the forefront, incorporated a new technology into its products' line, seeking the expertise from one of the world's largest machines manufacturer, and in 1965, began to manufacture the first LDPE equipment.
Today, after four decades of development and research, Rulli Standard has become the reference among the major transformers of the global plastic industry, providing not only the best equipment of the films and sheets market, but the best solutions to customers as well.
ISO 9001
In 2007, Rulli Standard implemented the ISO 9001 Quality Management System, with the mission of providing its customers with complete satisfaction, further improving all of its design to manufacturing processes, customer care and technical support services.

PRODUCTS

Sheets Extrusion and Coextrusion Systems

A broad variety of extrusion lines for the processing of the varied resins such as LDPE, HDPE, PP, PVC, ABS, HIPS, PET, Acrylic, etc. They utilie latest generation components, ensuring a better cost-benefit.
Screws
- from to mm diameter
- length ratio up to 34:1
- suited geometry to the most varied resin types, such as LDPE, HDPE, PP, PVC, ABS, HIPS, PET, Arcrylic,etc.
Drive up to 500 hp
Screen-changer - Pneumatic, hydraulic or continuous.
Gear pumps - Latest generation gear pumps with high dosage precision.
Feed block - Coextrusion of several layers.
Flat die head up to 2.400 mm in width.
Rolls Stack
- with high hardness laminating rolls.
- independent cooling and hating system
Guillotines
- for thin or thick sheet cutting
- up to 45 cuts/minute
Winders
- Hydraulic, with DC, or AC motor
- Quick-change pneumatic shafts.
Components control
- by control panel, with micro processed controllers
-solid state relays
- PLCs
- Latest generation components.

Overview of the example of a PP sheets coextrusion line.
Produces from 0.2 to 3.0 mm (thickness) sheets.
Production Capacity: 1.110 to 1.200 Kg/h (with 1,5 mm sheet)

Line composition

Extruders
01 RS- 130 extruder - Ø 130 mm 34:1
02 RS 75 extruders - Ø 75 mm 34:1
The three extruders are driven by DC motors (or AC motors), while the rest of the line is driven by AC controlled by frequency inverters.
The extruders are equipped with pumps and screen-changers with hydraulic command.
The screws are made with 8550 steel, specifically designed for the resins processes, with L/D ratio of 34:1, which results in better homogenization of the processed raw material.
Die Head
“Flat-Die” type
Rolls Stack
With 03 bi-metallic rolls
The rolls are individually driven by an AC motor controlled by a frequency inverter.
The closing of the rolls is made through 04 hydraulic pistons. Micrometric adjustment devices calibrate the openings between the cylinders in a light and smooth operation.
Cooling by closed circuit system, which can use distilled water.
Nip Roll
Puller with 02 neoprene-coated rolls. Actuated by an AC motor controlled by a frequency inverter.
Winders
Individual hydraulic turbine for winding trolley equipped with expansive shaft. Enables three simultaneous webs with the standby trolley.

Line Composition

Extruders
01 RS 130 extruder Ø 130 mm 34:1
Motor: 300 HP DC
Roll: Bi-metallic
Screw: In 8550 steel, with geometry for PP / PS
Screen changer: Hydraulic
1 RS 63,5 extruder Ø 63.5 mm 30:1
Motor: 75 HP AC
Roll: Bi-Metallic
Screw: In 8550 steel geometry for PP / PS
Screen changer: Pneumatic
The extruders are equipped with gear pumps.
Die Head
“Flat-Die” type
Rolls Stack
Three bi-metallic rolls of Ø 500 x 1.600 mm (with), individually driven by motoreducers controlled by frequency inverter.
Closure by 4 hydraulic pistons. Micrometric adjustment devices calibrate the opening between the cylinders in a light and smooth operation.
Cooling by closed circuit system, which can use distilled water.
Conveyor Table
4.200 mm with aluminum rollers.
Sheet Refiling
Enables production of one or more refilled web in longitudinal direction through a knives system.
Winders
Individual hydraulic turbine for winding trolley equipped with expansible shaft. Enables two simultaneous web with a standby trolley.
Control Panel and Integrated Software
An integrated software and hardware system for complete control and monitoring of the entire sheet line.
A color touch screen panel enables the insertion and alteration of the line's entire production parameters.
A PLC installed in the main panel concentrates and commands the line.
A PID system controls all temperature zones (32 zones).
Main resources:
- Memory of all line parameters of each type of service.
- Upload and download of all temperature zones and order receipt (temperatures, speeds, pressures, etc.)
- Possibility to begin heating section by section through PLC programming, reducing the start-up time in an eventual machine stop.
- All motors running in profibus network for better speed performance and monitoring.
- Digital synchronism for acceleration and deceleration of the entire line.
- Enables sheet correction with 10% total line capacity.
- Real sheet thickness control
- Gross and net production information in Kg/h.
- Chart and display of alarms line.

Extruders

All extruder components are assembled in a super-reinforced steel plate structure.
Motorization in DC or AC, and with pulleys transmission and specific coupling. Reinforce-built reducer, double reduction, thermal treatment spiral gears, forced and cooled lubrication, designed rollers for a service life of approximately 225.000 hours at 5.000 PSI, at 100 rpm, in continuous work regime.
The feeder is built in cast iron with open spacer bushing, providing thermal insulation between the reducer and the feed sector.
The rectangular feed in suitably dimensioned, with temperature control provided by cooling of the cast´s internal channels, enables the free down hill of the material until the screw, always keeping it full and preventing plastification in the feeding.
The high hardness barrel is built in bi-metallic alloy, and the screw, which can be nitrated, or built with bi-metallic alloy hardened frames, make up a high resistance combination.
The heating of the barrel can be by tubular heater lined in high efficiency stainless steel, embedded in cast iron semi-bushings, slotted for air-cooling, which are separated by zones, allowing controlled and super stable temperatures in the system.
The water cooling system when running, functions through a closed circuit of demineralized water with a stainless steel tank, pump, solenoid valves, stainless steel piping, heat exchanger and controlled pressure temperatures.

Lamination and cooling system

The system is comprised of 3 smoothening and cooling rolls with layout according to the processing of the material. The surface of the 3 rolls is rectified, and with a bi-metallic stainless steel layer of 55 HRC hardness, rectified with polished hard chrome bath and mirror, with 0,01-micron Ra rugosity.
The central roll is mounted in a fixed position. The upper and lower rolls move vertically over the articulated arms and when in open position, ensure a minimum gap of 100 mm between the rolls.
The closing of the rolls is by 4 hydraulic cylinders with adjustable pressure. The rolls are actuated through solenoid valves and selector switches.
The gap between smoothening rolls is obtained through a micrometric screw and wedge mechanism, which enables centesimal adjustment.
The bearing house of the three cylinders are dismountable, with special high precision bearings, self-centering, and completely sealed.
The three rolls are driven by 3 AC motors with frequency inverters.
A complete individual cooling system for each laminating roll for temperature control, with centrifuge pumps, valves, filters, heaters, heat exchangers, manometers, pressurestats and thermostats, and temperature control, mounted together with other electrical controls in an operations panel, providing a wide range of processing operations.

Screen-Changer

The drawer-type screen-changer is built in special steel, internally polished, equipped with piston and a hydraulic system for changes without interrupting production, and can be supplied with a manual pneumatic driver as well.

Pump

The gear pump, through a pressure controller monitoring the mass pressure before and after the pump, runs in the speed of the extruder´s main motor, automatically keeping the pressure and the volume of the die head constant, according to the indicator set point, substantially reducing pulsations and consequently any thickness variations.

Feed block

Feed block for several layers, internally polished and designed for perfect material distribution. Static mixers can be supplied according to need.

Flat Die

Built in rigid steel, with hard polished chrome bath protection of the surface´s contact areas. It can be supplied in several models or sizes, according to the product extrude.
The fine-tuning of the sheet is made through adjustments screws located on the upper lip, while flow distribution is controlled by the screws of the restriction bar.
Cartridge-type heater with silicone-insulated connection cables and connectors provide the heating. Its perfect distribution provides stable temperatures.
The entire assembly is mounted on a trolley with adjusting and sliding support over rollers, which allow for dilatation without overloading the equipment.

Nip roll

The nip roll has two rubber-coated rolls with 203 mm diameter. They are driven by an AC redactor motor controlled by a frequency inverter.

Winders

Special guillotine and/or winders of specific design, of 1-2-3 or more hydraulic shafts, for jumbo-type winders, or DC drive and pneumatic shafts, fixed on only one side, for high production of webs and quickly-changing tension control, supplying high quality and finish products.

Complete Line for Coextrusion of Tubular Films

2, 3 or 5 layers
The coextrusion process is employed in the conversion of materials of different properties and of specific characteristics in the same equipment. They may have reduced thickness or be manufactured with more economical materials in the internal layers, resulting in a cheaper product, and with the same characteristics. A good example of coextruded film is in the food packing material (high barrier), where we find a material with a barrier against gases and another of high material resistance.

Extruders

The extruders make use of the latest in technology. They were developed to produce with quality and economy, obtaining the best cost-benefit ratio.
The combination of components and engineering enable larger production, better plastification of the processed polymer, and an extremely smooth thermal curve.
They are equipped with separating bushings, which serves as thermal insulation between the gear box and the feeding section.

Barrel

- bi-metallic

Heating

- Ceramic heaters
- PID (Proportional-Integral-Derivative) digital temperature controllers

Feeding zone

- grooved
- cooled water

Screws

- in 8550 steel
- L/D 30:1

Cooling

- blowers

Motors

- AC or CC
- AC high efficiency

Gear Box

- High torque reduction
- Helical gearings
- Forced lubricating for all bearings
- Internal cooling system

Feeder

- in cast iron
- internal water cooling system

Tubular Films LDPE and LLDPE

They have well dimensioned extruders, enabling these lines to work with several demands for a continuous production.
They are equipped with 50 to 150mm screws diameter extruders, L/D 30:1 and are designed according to the polymer to be extruded.
Production capacity can reach up to 800 kg/h.
These machines are able to produce the most varied lay flat and thickness range of films used in several industries. Die heads can be stationary or rotating, like the towers, which can be fixed, or with an oscillating nip rolls.
The blown film machines are equipped with a double-flow aerodynamic cooling ring, enabling substantial production increase, and ensuring higher film thickness uniformity.

Tubular Films HDPE

A complete line of extruders, with dies up to 325 mm (or special), able to produce up to 320 kg/h.
They can be equipped with a rotating or stationary die head, and a new air cooling ring system, where the air inlet is tangential, allowing a perfect air circulation.
The control panel concentrates all of the machine's commands, including extruder, Die head, Roll and winder

Die Heads

Die Heads are designed to provide a perfect spiral distribution of resin, with a passage section that enables a regular flow of extruded resin.
They may be stationary or rotating, specially designed, enable remarkable features in reference to the optical aspect and thickness uniformity. Besides, the electrical project was designed in order to keep the temperature uniformity and minimize the maintenance.
Its perfect construction allows a remarkable features in reference to the optical aspect, and thickness uniformity.
They are equipped with an aerodynamic cooling ring with double airflow. They can also come equipped with the IBC - Internal Bubble Cooling system.
Built with special indeformable steel, nickel or chrome plated.
Heating is by means ceramic heaters for better temperature control.

Winders

Model RS-S
• A winding station that is driven by an AC motor, controlled by a frequency inverter.
• Equipped with a nip roll that enables perfect tension control between the tower and the winder.
Model BAC-2
• Based on the RS-CP Model.
• Equipped with a cutting and automatic roll change over system, able to discharge the roll onto a pallet by a hydraulic system. Can be equipped with a load cell for tension control.
• Layout evaluated according to the system
Model RS-CP
• Two winders stations driven by two independent alternating current motors, controlled by a frequency inverter.
• Equipped with a pre-pulling roller that enables perfect tension control between the tower and the winder.
Model Evolution
• Totally controlled by a PLC (Programmable Logic Controller) and serial communication.
• Enables winding system by contact or GAP.
• Can produce the web without contact, where the expansible shaft is driven and controlled by a load cell and a PLC system.
• Recommended for high quality films, and extra sensitive low thickness films.
• PLC controlled. The load cell is equipped with an automatic roll change over system, and is equipped with a hydraulic unit that enables the discharging of the roll onto a pallet.
• Layout evaluated according to the system.

QUOTE






Technical assistance Equipment

Rigid Flexible | Monolayer Coextrusion

75 100 130 150
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220v 380v 440v 50Hz 60Hz
75 100 130 150
50 2.1/2 70 75 80 100 130
50 2.1/2 70 75 80 100 130
50 2.1/2 70 75 80 100 130
50 2.1/2 70 75 80 100 130
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a

220v 380v 440v 50Hz 60Hz
50 55 2.1/2 70 75 80 100 130
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a

220v 380v 440v 50Hz 60Hz
50 55 2.1/2 70 75 80 100 130
50 55 2.1/2 70 75 80 100 130
50 55 2.1/2 70 75 80 100 130
50 55 2.1/2 70 75 80 100 130
50 55 2.1/2 70 75 80 100 130
a
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220v 380v 440v 50Hz 60Hz

CLIENTS AND REPRESENTATIVES

EVENTS

CONTACT






Av. Amancio Gaiolli, 915, Bonsucesso - Guarulhos SP, Brasil
CEP: 07251-250Tel. (11) 2489-4500
vendas@rullistandard.com.br

Rulli Standard - 2016 - All rights reserved

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