Mastic adhesives present a number of challenges when being extruded, but none more critical to the bottom-line than the downtime production lines face when extruders need to be cleaned. Diamond America was recently presented with such a challenge by a customer in the aerospace adhesives industry.
Diamond America has been invited by Rutgers University to take part in its Catalyst Manufacturing Science and Engineering Consortium (CMSEC). The partnership includes Diamond America loaning one of its extruders to the consortium and the appearance of the company’s president, Terry Hendershot, at the CMSECs April meeting.
Hookahs are water pipes that are used to smoke specially made tobacco that comes in different flavors. A premium hookah shisha brand, located on the West Coast, specializing in cocktail drink and party life flavors, currently assembles its product by hand — forming it into shape and then packaging it for distribution. That is 7,000 pounds of product per day.
A company that manufactures coatings for the aeronautical industry looked to Diamond America recently to develop a catalyst extrusion process to replace the plastic extruders they were currently using. The plastic extruders were unable to sustain a consistent feed of a resin material that is solid when fed into the extruder.
A manufacturer of a caulk free peel-and-stick trim for bathtubs, showers and countertops was looking for an improved extrusion process to both upgrade their product and eliminate third-party costs. Previously, the caulking tape was composed of two separate pieces — butyl and adhesive tape. Diamond America engineered a heated, precision application process that allowed for the butyl to be formed inline with the tape in a single V-shape. The company is currently testing the process with the Diamond America TT100 extruder and forming die in a production atmosphere.
What once took a crane and weeks of time-intensive labor — not to mention costly downtime — is now a seamless process. Diamond America’s customer in the catalyst industry has an extruder spanning three decks that required regular maintenance due to heavy wear of components. A complete disassembly was required, often resulting in days, if not weeks, that the extruder was off-line.
Diamond America was recently called in to consult a manufacturer of acid-proof brick and ceramic packing media. The customer was looking to improve its extrusion process to for better consistency of output while reducing downtime to complete persistent maintenance. Our research and analysis of the customer’s process led us to recommend several design and equipment improvements.