A Better Way to Optimize Your Extrusion Process

Since 2001, Diamond America has partnered with pet food and treat manufacturers across North America. Manufacturers work in lockstep with us to review profile requirements, refine their formulations, and optimize production goals. Through extensive research, development, and testing, Diamond America engineers design and manufacture complete extrusion systems while providing customers tailored solutions to meet short- and long-term manufacturing goals. Pet food and treat manufacturers use dried, powdered, and granulated ingredients combined with liquids and oils. Proper mixing is a critical component of successful extrusion. Typically, a pet food and treat manufacturer would adhere to the following mixing procedure:

• Load ingredients into mixer
• Mix materials
• Unload + clean mixer
• Transport mix to the extruder
• Manually load the extruder
• Monitor feeder during extrusion

An Innovative Design that Fosters Consistency & Simplicity

Manufacturers know that downtime negatively impacts critical production requirements. Diamond America’s innovative design for the RF200 reduces manual labor tenfold. This blender seamlessly mounts onto the top of the hopper. Once mounted, ingredients are delivered directly to the RF200
and mixes the formulation to the desired consistency. The blender continuously folds mix back into the center of the 20-liter mixing tub where the discharge cute is located. When all materials have been blended, the discharge gate is manually opened. From there, the blender is continually run,
and the batch is fed directly into the extruder hopper. As a result, a labor-intensive and expensive process produces an affordable and sustainable solution.

RF200 Features + Benefits – Augmenting the Cleaning Process

An easy, efficient process for cleaning machinery is paramount in the food manufacturing industry. The RF200 boasts the following benefits:

• Components comprised of food grade stainless steel
• Open, hygienic modular design for easy cleaning
• Safety grating covet over tub with two hinged dust covers and viewing window
• Blender boasts a split double volute agitator, and one piece polished mixing tub equipped with removable end plates
• Easy assembly + disassembly for minimal downtime to your production line
• Design enables optimal compliance with required food standards, protocols, and procedures

Through our partnerships combined with an educational approach, we empower companies to streamline their operations, meet production requirements, and extrude consistency batch after batch, saving companies time and money.

The post Diamond America’s Ribbon Feeder (RF 200) Reduces Extrusion Labor & Waste appeared first on Diamond America Corporation.

Barrel and Screws

Barrel and screw damage does not get noticed until performance is hindered. Three main factors that impact barrels and screws include abrasion, corrosion, and foreign materials. Check your barrel and screws for irregular wear and damage with each cleaning. If irregular wear and damage occurs, replace the affected part from the Original Equipment Manufacturer (OEM).

Clean Machines Methodically

Machines should be cleaned daily, with a thorough cleaning performed weekly. Dirt and dust can clog seals, cooling fans, and gearbox oil vents, which decreases the overall performance over time.

Conduct Part Inspections

Each extruder part should be inspected carefully. This is a critical step in quality assurance to ensure that each part is functioning properly. The earlier an error can be identified, the quicker the error can be resolved, mitigate further part damage, and production can get back on track.

Check Machines for Wear and Tear

Several factors cause wear and tear over time, which include improper operating habits, accidents, environmental factors, and aging. Aging impacts critical components of the machine. For example, the seals may dry out or crack, bolts may bend, loosen, or stretch out of their original shape. Additionally, the motor and gearbox should be checked for dust/debris.

Along with the mechanical components, check electronics and electrical wires. High temperatures that arise from extended use, vibrations, and environmental factors such as dust and water can damage covered wires and circuits.

Document Your Preventive Maintenance and Service in Detail

Record keeping is a vital part of extrusion preventive maintenance. To ensure successful documentation, a complete record of the following should be maintained:

• Date
• Time
• Technical specifications of the service
• Replacement parts
• Scheduled services

Order Spare Parts from the OEM

Ordering spare parts from the OEM increases the equipment’s lifecycle. Utilization of OEM parts provides easy comparison and equips the user with the exact part dimensions. This provides assurance that equipment parts will continue to perform at maximum capacity with each use.

Regular Lubricant Replacement and Level Checks

Your equipment relies on lubricants to function properly. These liquids reduce friction around moving parts to decrease wear and tear. The lubricants also help keep the interior of machines clean, which prevents debris buildup.

Frequently check the lubricant levels. Regularly look for debris build-up and oil seal leaks. Always use the type of lubricant suggested in the operator’s manual and the right amount of lubricant. With too little use of lubricant, the risk of increased friction and wear and tear will occur. Excessive lubrication builds up pressure and causes performance issues.

Schedule Monthly Performance Checks

Schedule monthly performance checks to confirm that all parts are working correctly, and the extruder is operating at the desired maximum capacity. Moreover, regular checks ensure adherence to the production schedule, minimal downtime, and reduction of workplace accidents.

Temperature Maintenance

Extruders should always be housed in a room or manufacturing facility with temperatures that range between 35-100 degrees Fahrenheit. Machines that are stored in temperatures outside this range risk the breakdown of equipment parts, prevention of the desired shape output, and material inconsistencies.

Train Your Employees

Lack of operator training can cause wear and tear, equipment failures, and injuries. It is important that employees know how the machine works, what the emergency action plan is, where to access the emergency action plan, and the needed safety precautions to take during machine operation.

The post 10 Tips for Maintaining Your Extruder appeared first on Diamond America Corporation.

Diamond America is proud to collaborate with organizations of all sizes to provide a tailored approach that enhances long-term goals. It is important to not only meet objectives but understand the project scope and how that long-term value is added across the supply chain for our customers. How do you know that your manufacturer partner is adding value to your organization? How do you assess that the partnership is a true match?

Improvement of Product Quality

From extruder builds to dies and spare parts, all components should enhance the quality of the extruded materials.

Visit the Facility

Partners can evaluate the manufacturer through an on-site visit. A facility tour provides a behind-the-scenes look into the shop, the manufacturing process, and equipment used.

Level of Expertise

When it comes to making a long-term investment in manufacturing equipment, experience matters. Our team holds a combined 150+ years of expertise and has conducted business in over 70 countries across the globe. Our robust knowledge helps companies make informed decisions. Whether you’re looking to modify a formulation, in the early stages of research and development, or seek to develop a new product for your business portfolio, our lab testing is beneficial for fine tuning products and ensures repeatability prior to implementation on a larger scale.

Equipment Durability

Your manufacturing equipment should be reliable and durable for years to come. Depending on application, all Diamond America machinery is crafted with stainless steel, (300 series, 17-4, and 15-5). Make sure you ask for material certification and heat treat specifications.

Available Resources

One critical factor to consider is the quantity of available resources before, during, and after. For example, how efficient are the manufacturing operations? Operational efficiency and allocation of resources provides better customer service experience through prediction of supply and demand, accurate forecasting, and on-time delivery rates so the customer receives their order in a timely manner.

With business conducted in 70+ countries and counting, manufacturer smarter with Diamond America Corporation.

Contact us today to learn more.

Again, we encourage you to visit our manufacturing facility and see your components being manufactured. Then, we encourage you to visit our competitors to discover The Diamond Difference.

The post Diamond America Adds 3D Printer For Rapid Prototyping appeared first on Diamond America Corporation.

Diamond America is proud to collaborate with organizations of all sizes to provide a tailored approach that enhances long-term goals. It is important to not only meet objectives but understand the project scope and how that long-term value is added across the supply chain for our customers. How do you know that your manufacturer partner is adding value to your organization? How do you assess that the partnership is a true match?

Improvement of Product Quality

From extruder builds to dies and spare parts, all components should enhance the quality of the extruded materials.

Visit the Facility

Partners can evaluate the manufacturer through an on-site visit. A facility tour provides a behind-the-scenes look into the shop, the manufacturing process, and equipment used.

Level of Expertise

When it comes to making a long-term investment in manufacturing equipment, experience matters. Our team holds a combined 150+ years of expertise and has conducted business in over 70 countries across the globe. Our robust knowledge helps companies make informed decisions. Whether you’re looking to modify a formulation, in the early stages of research and development, or seek to develop a new product for your business portfolio, our lab testing is beneficial for fine tuning products and ensures repeatability prior to implementation on a larger scale.

Equipment Durability

Your manufacturing equipment should be reliable and durable for years to come. Depending on application, all Diamond America machinery is crafted with stainless steel, (300 series, 17-4, and 15-5). Make sure you ask for material certification and heat treat specifications.

Available Resources

One critical factor to consider is the quantity of available resources before, during, and after. For example, how efficient are the manufacturing operations? Operational efficiency and allocation of resources provides better customer service experience through prediction of supply and demand, accurate forecasting, and on-time delivery rates so the customer receives their order in a timely manner.

With business conducted in 70+ countries and counting, manufacturer smarter with Diamond America Corporation.

Contact us today to learn more.

Again, we encourage you to visit our manufacturing facility and see your components being manufactured. Then, we encourage you to visit our competitors to discover The Diamond Difference.

The post The Value of Having a True Manufacturing Partner appeared first on Diamond America Corporation.

The Science of pressure flow of fluids through pipes and other non-round conduits has been around for a long time. Hagen and Poiseuille described the basic equation for flow of Newtonian fluids through a pipe back in 1838.^[1]  This basic equation given below describes the pressure needed to push any fluid in laminar flow through any enclosed channel as:

Where  Loss in energy forcing the fluid to flow through the length L of pipe described as pressure drop

             π = pi

             μ = dynamic viscosity

             L = length of flow

             Q = volumetric flow rate

             A = cross-sectional area of the channel

The pressure needed to push the fluid through a full length L of pipe of constant radius R is given by:

Of course any of the variables can be calculated if all of the other variables are known.  As written, the pressure needed to pump a fluid of known viscosity through a known radius of pipe of length L and a given output rate can be calculated.  However, the viscosity of any fluid can be calculated if the force (or pressure) is known to push a given flow rate through a pipe of known radius and length.

The next important point is that the pressure needed to push the fluid through different sections of different lengths or cross sectional areas is additive.  The pressure and resulting flow can be calculated through a very complex die by breaking it down into simple sections and adding the pressure drop through each simple section.

Unlike simple fluids like water, many fluids of interest like polymer melts and food stuffs have complex viscosities that vary with shear rate and temperature. The equation requires a constant viscosity of fluid for the section of flow, however, if the viscosity is known or can be calculated for each of the many different sections of the flow channel, the pressure drop for the flow path through each simple section can be calculated and summed up for all sections making up the flow channel.

Thus for non-Newtonian fluids like polymer melts or food stuffs the equation can still be used if the complex geometry can be broken down into simple, calculatable sections.  This leads to a finite elemental analysis of the flow.  However, it has been demonstrated by the author that using the cells of a spreadsheet as individual elements, an estimate of the flow of almost any desired accuracy can be calculated.

The viscosity of most polymer melts depends on the shear rate during flow.  This can be handled quite simply by breaking the equation into two parts.  First the Shear Rate γ is calculated from the equation:

γ = C₁Q/A                  

where C₁ is a constant dependent on the cross sectional area of the channel.

Then the viscosity of the polymer melt at that Shear Rate (and Temperature) can be obtained from experimental data or a descriptive equation.  The Pressure Drop can then be calculated from the following equation:

 = C₂γμL/R

where C₂ and R will vary dependent on the cross sectional shape of the channel.

This is the basis for most die design programs that are currently on the market, however, they often go into more complex mathematical models that include Finite Element Analysis to calculate pressure drop and flow with improved accuracy and greater versatility.

The original description of this methodology was presented at the SPE ANTEC in 1979^[2].  And a simplified version for profile die design was published in 1981^[3]  

Probably the best example of summing up the pressure through different sections in a die to balance the flow rate across the die is given by that of a sheet die.  The critical requirement is to spread the polymer or other fluid sideways for the desired width of sheet which typically would be 5 or 6 feet, but could be as much as 20 feet.  This is most often done with a manifold type design where a large opening running roughly perpendicular to the desired flow direction allows the fluid to take the easier path (lower pressure drop) down the manifold channel to distribute the flow across the die. The die is balanced by use of a pre-land that gets shorter moving away from the center (entrance) of the die to compensate for the pressure drop going down the manifold. A secondary manifold is often used to allow some side flow to correct any imbalance in the flow channel. Then a uniform land length of constant length and gap opening is used to define the final flow and surface appearance. As shown below:

The extruder builds pressure to force the fluid through the die, starting with the entrance, and then splitting in equal parts through the manifold toward each end of the die. As material leaves the manifold and flows over the Pre-Land toward the die exit, the flow rate of material moving down the manifold decreases so the cross-sectional area of the manifold typically decreases to compensate. The goal is to have the pressure drop be the same for any path that the fluid takes so that the flow rate is the same for each location across the die width.  This is balanced by adjusting the Pre-Land length and gap to yield a pressure drop complementary to the pressure drop through the manifold length taken to reach that position of the Pre-Land. This assures an equal pressure drop and therefore, flow rate for any path that the fluid takes.

More detail and other examples are given in Design of Extrusion Dies by Kostic and Reifschneide.^[4] Question? Should we add links to other die design programs?

Current sheet die manufacturers and all of the die design programs will balance the flow rate across the die face.  That is their purpose and they do a very good job.  However, most do not take into consideration the residence time spent in the die.  For some polymers, like PVC, and most food stuffs that are temperature sensitive, long residence time can cause degradation of the material.  In a wide sheet die using the above equations, balancing the flow can be relatively straightforward, but it takes a long time to flow perpendicular down the manifold to get to the end of the die.  Without consideration for the dwell time the ends of the die can stagnate and burn or cause varying degrees of cure or degradation. In addition, the long residence time for the edges of the sheet will lead to long change over times for color changes or changes in material.

Therefore it is recommended to take a look at a Novel Sheet Die Design Technology that also takes into account the dwell time across the die.  This technology is Excel based and utilizes the simple Rheological equations covered above.  It allows for wide variations in geometry of flow channels and viscosity that is shear rate and temperature dependent.  In addition to balancing the flow across the die, it also allows balancing the residence time across the die to eliminate degradation at the ends of the die and faster change-over times.

Both EDI and Cloeren’s design promoted more flow to the ends of the die in order to help prevent edge burning of the PVC.  As a result the die temperatures on the ends of the dies had to be reduced to slow down the flow of material at the edges.  This causes an uneven heat history of the material across the die.  The Novel design has a much more even flow rate across the die and so the die can be set at a uniform temperature across the die.  The flow rate varies by about 30% between the center of the die and the edges for the other dies, while the Novel die was balanced to within 4% and could be balanced closer if desired.

But even more dramatic is the difference in dwell time between these commercial dies and the Novel design approach:

In these examples, the dwell time at the end of the Cloeren die is 4 times the high dwell time in the center of the die.  The dwell time at the end of the EDI die is 5 times the dwell time at the center. Whereas, the Novel die has a much more even dwell time of only 1.4 times the dwell time for this 5 foot wide sheet die.

The advantages of this Novel approach should be apparent especially for temperature sensitive materials.  As long as the viscosity of the material to be extruded can be characterized with respect to temperature and shear rate, the die can be optimized for that material.

Let us know what we can do for you.

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