ir lac) MAW ie eg Weta lg FARREL The Farrel Twin-Screw Sheeter is designed for high volume conversion of batch form product to quality rubber sheet. The TSS line is engineered for integration with Farrel’s Banbury: and Farrel Shaw Intermix batch mixers in both new and existing process lines. The TSS combines processing, mechanical, and contro! innovations which overcome the limitations of other types of roller die extruders. The TSS represents the new standard for batch to sheet conversion.Farrel Twin-Screw Sheeter Superior batch to sheet conversion General Description ‘The Twin-Serew Sheeter (TSS) integrates a specially engineered twin-screw extruder with a matching two-roll calender The counter-rotating tapered twin-screws Of the extruder ingest the batch discharged ‘rom either a Banbury? Mixer or Intermix with no need for mechanical pushers. The design of the scraws, and the machine's billy to contrl the temperature of material-contacting surfaces, generally allows feeding of material to the calender with a temperature decrease. The matching {wo-roll calender uses high heat transfer ‘capacity rolls far ational material cooling. Feedpath The entre fosdipath fram the twin-screw extruder inlet to the calender rll discharge is set at a downward incline to facilitate self-omptying of maton Drive Options The two main components of the TSS. are directly drivon by independent variable speed drives mounted on the respective input shafts of the extruder and calender. Electric motors with gear reducer dives, as well as cirect coupled high- torque, low-speed hydraulic motor drive options aro availabe, Control Systems System star-up, intial speed synchraniza tion, and optimum performance are attained rapialy through a responsive Programmable Logic Control (PLO) Based control system, The system, by sensing materia lovel in the hopper and materiel pressure In the extruder/calenderintertace, synchronizes the extrucier screw speed and the calendar roll speed to the mixer output. Operating variables are automaticaly adjusted 10 provide a continuous, full wcth sheet Primary Advantages + Counter-rotating, selt-feeding ‘tapered twin screws eliminate the need for mechanical pushers. ‘+ Non-contact serews minimize ‘equipment wear. + Water-cooled screws and jacketed housing provide means to control product temperature. + Modular design and movable roller head for ease of maintenance. + Low profile for retrofit under existing mixers. + Integrated controls for the automatic synchronization of batch mixer feed rate, extruder, calender, and cooling line speeds. + Reduced operating expen: + Lower capital cost. Inclined extruder axis lows for self-cleaning,in and Engineering Profile Twin-Screw Extruder The tapered, intermeshing, and counter- rotating extaider screws are supported by ntiriction bearings in the gear housing, ‘One screw is driven by a directly mounted motor and gear reducer. The second sorow is driven from the frst screw by Connecting gears. With the hydraulic drive ‘option, each screw is directly driven by alhycirauic moter, with connecting gears ‘maintaining synchvonization of the sores, Large Hopper Opening A large hopper opening allows unrestricted movement of the batch riding on top of the screws. The screw geometry anc counter-rotation insures a high rate of batch ingestion, providing a consistent discharge to the two-rll calender. Process Action ‘The large open volume of the serew fights, fon the large diameter feed and, insures ‘hat suficent rubber is cut from the batch with every cavolution to fil the discharge fond of the seraws. Dract interaction between the sereus, and eortralled backflow in the screws and hopper section generates a beneficial stock blending effect, ‘Wear Resistance Since screw tips do not contact the housing, ‘surface wear fs minimized. The screw and hhousing surfaces which come in contact, \with processed material are chrome-plated for corrosion and wear protection. ‘Temperature Control Screw shafts are drilled and the housing Is ackoted for temperature contro Emcee reducer and (Glenda ger reducer’ ‘onnected fo ootom rok ‘Two-Roll Calender The calenider's fix2d-position bottom roll is directly driven by a ral mounted gear reducer and motor assembly, or by a hydraulic motor. The moveable top rol is driven from the bottom roll by connecting gears, The rolls are steel, shell-ype construction for heat wansfor and are hardened for wear ‘Adjustable Roll Gap The rol gap is adjustable for gauge control. ‘The standard design allows ga changes \with the machine stopped. An option for in-production gauge changes, by ether mechanical sorew-down davices or hydraulic oylinders, is available FARREL Seamless Mixer Interface ‘The Farrel TSS system can be inked without intermediary systems to Farral’s {wo mixer tochnologies, the Banbury” Mixer and the Farrel Shaw Intermix The Banbury Mixer ‘The key process elements of the Banbury Mixer are tangential ST™ Rotors featuring ‘unique helical four-wing geometry, a closed loop water termpering system for cooling (of chamber and rotors, including the rotor tips, and variable speed crives, ‘Synchronous rotation exposes the entire batch to superior cistibutive and dispersive mixing. The angular alignment af the rotare can also be adjusted fo specific mixing requirements, Farrol Shaw Intermix ‘The Intermix, featuring intarmeshing NR Rotors, has demonstrated top performance in rubber and plastics compounding ‘woridwide, ‘The NRS rotor's newest interlocking nog goomtry assures even distnbution and dispersion of ingredionts in materials through shear and elongation. The mixer is designed {or exact process repeatabilty for product quality and uniformityFarrel Twin-Screw Sheeter FARREL Sees ‘TSS Model 1583 Extrcer Motor ize 80H (Calender Motor Size 0H oll Diameter x Length: = 460% 700 in wer x278 Maximum sheet width ‘mn 00 in 236 Nominal production ate: Kaine 3000 User 6800 Matching Banbury Mixer Mode 80 nee nen 1ss7 1589 125 Hp 180 Hp ‘esto ‘*90H0 500% 900 00 1150 1972354 1975453, 750 os 205 200 7.000 9000 35.400 16.00 200 P70 S812 18825 200 Hp 400 Hp 2000. 400 Hp 590. 1159 500% 1600, 19.7453, 8x60 ons +400 0 ‘561 +2000 27.500 25400 000 F370) Fs20 ‘width mm 560 4400 400 in 138 78 104 ‘Lengthy mm 400) 100 300 in 13 200 328 Height mm 2100 7900 2100 in a 4 3 Weight — Ka 18;000) 22,000) 26,000) be. 40.000, 48,000, 7.000 ‘i.dta ar nominal and may vary Yo suit specie appteaons Specifeatens er subject fo charge winaxt nots. TSS Control Systems The Twin-Screw Shecter’s control system ig based upon a Programmable Logie CControler (PLC) with a touchsereen for operator interface. The control system is housed in two panels: a Local Panel ‘and an Operator Pane! ‘The Local Panel, mounted directly on the calender frame, is used for adjusting the roll gap. The Operator Panel, located near the TSS, contains the touchscreen {or operator access to the TSS control meng, un parameters, and alarm status, Sensor Arrays for Process Control Level sensors jn the feed hopper adjust the roll speed to balance the materia lscharge rate with the material Input rate from the baten mixer. A load eel atthe discharge end of the ‘extruder moasuring the stock pressure in the closed guide section is used to regulate the screw speed. This provides consistent, controled materia flow to the rol nip area. {A dancer rall generating a potentiometer posiion feedback signal is mounted on the discharge side of the calender This allowe synchronization of the cooling lina wath the shet output speed. Farrel: Leadership in Process Technology, Systems, and Service ‘Advanced Processing Equiomant “The F-Series Banbury Mixer and Mark 5 Series Igri pole super ihe tah ng. Fam pressure and ram position inelentor bach See mixing patern tracing Eeo-Gland™ boos ‘dsttens for he stmnatin of contra 1 Intrni inernmsting NR Rotor, mov anc hear ‘rough slangaton cea fr technica goes ertect mise integration with the TSS fide range of customizane Ml, Calenders, ne Eatrston oystems: Computer Assistes Remote Diagnostics ean" System The GARD Sst enables the on- and offsite remote contel diagnosis, and mentering of quip tment and process performance = Asse cx pestonDetwes equ ogre age transmission of sata i ea ime for mmerte {eouback and response ‘Customer Service Dison Worldwide customer support = Genuine pat, nou iid semen scupment rector, rihing ae unions Process Engneoring and Procose Consuting ' Tumkay facies analysis, planning end design 2) pps Process abe supa este Sin teat ‘00 1a 200 2300 0 29,000 52,000 4.000 14.000 Farrel Corporation 2b tan Svea Anson, C1 G6801 Tet +1 eas) ra 5500, Franc +1200) 7956287 | Farrel Asia Ltd. Surong, Singopere 6263 epic of Singapore | ase 188 8619129 Farrel Ltd./Farrel Shaw Lid. ‘Queencway.Castoton P.O on 2 Rocha Lancashire, OUT 2 Une inggern Tot +44 cpim6 erase Fens 2441) 708 698 982