Newsletter 01/2023
Special production: Production line for manufacturing of ceramic injection molded feedstocks
Most of our equipment is developed and produced specifically to customer requirements. This was also the case with a production line for the manufacture of ceramic injection molded feedstocks, which was recently delivered. Although the customer initially wanted to procure a shear roll, trials in our laboratory convinced him of the suitability of our twin-screw extruders for his requirements.
The first contact with the customer, the Zurich University of Applied Sciences (ZHAW), came about as a result of a recommendation from an existing customer. The customer was looking for a shear roll for the production of ceramic injection molding (CIM) feedstocks in laboratory scale. This was to be used to produce batches of one to ten kilograms from a mixing unit.
As a specialist for customized solutions, we wanted to offer the customer a hand, even though we had not manufactured shear rolls ourselves before. Since the technology of shear rolls and extruders is related, it was agreed in a first step to carry out trials on an existing twin screw extruder in the Three-Tec laboratory to test whether an extruder would also be suitable for the application as an alternative. Although the customer already had a laboratory extruder from a competitor, it was unsuitable due to the low torque and insufficient mixing effect, which led the customer to focus on a shear roll.
The trials at Three-Tec were carried out using a ZE 18 extruder with a screw diameter of 18 mm and a process length of L/D 40 (720 mm) to test its performance in terms of compounding and homogenization. For this purpose, a powder feeder was used for the pre-mix of three solid components, a pellet feeder for the pre-mix of two binder components, a conveyor belt for uniform discharge and cooling of the extrudate, and a pelletizer. Following the tests, the extruder was cleaned with cleaning granules, whereby the cleaning time could be massively reduced compared to normal manual cleaning.
The extruded and granulated materials from the tests were collected by the customer for further analysis.
The successful tests, which exceeded the customer's expectations, led to the order of the complete set of equipment with which the tests were carried out.
The main reasons for the decision in favor of the extruder were:
- extrusion as a continuous process incl. automated feeding of raw materials
- very good melting, homogenizing, dispersing properties
- a lower throughput time and a single-stage instead of a multi-stage process, compared to the existing laboratory extruder
- the resulting highly efficient production of ceramic injection molded feedstocks and significant simplification of work in the laboratory
The plant was specifically developed and produced by Three-Tec's specialists according to ZHAW's requirements. After efficient manufacturing time following the order, the new plant could finally be put into operation at the customer's site.
"In our search for a device for the homogenization of ceramic injection molding or 3D printing feedstocks, we contacted Three-Tec and were quickly convinced during initial tests on site that a high-performance extruder is more versatile for us in the area of research and development and easier to clean/maintain than a shear roll, which we had also considered. Finally, the competent advice and the good and uncomplicated service from Three-Tec were also decisive in ordering a ZE 18 extruder, which is now being used at the ZHAW for current and hopefully many future projects."
Dr. René Wick-Joliat, Laboratory for Ceramic Materials, ZHAW
Are you also looking for a device or system that meets your specific needs? Then we look forward to hearing from you. You can also find the steps involved in creating a customised unit on our webseite.
More efficient feeding with flat-tray feeders
For poorly flowing materials and for maximum utilisation of the material to be fed, Three-Tec offers feeders with flat-trays. The flat-tray feeders convince with up to ten times less residual quantity remaining in the hopper.
Three-Tec's flat-tray feeders guarantee precise volumetric and gravimetric feeding of good to poor-flowing, moist or bridging products with flowabilities of ffc 1-5. We often use flat-tray feeders, especially for projects in the pharmaceutical and food industries, because they often work with poor-flowing powders, have high cleaning requirements, and only a minimum of material should remain in the hopper.
In tests in our internal test laboratory with poorly flowing micronized paracetamol, for example, the residual quantity in a normal hopper was 540 g, whereas in a device with a flat-tray with the same product and the same hopper volume and base, it was only 48 g. Thanks to the flat-tray, around ten times less material remained in the hopper. This difference is particularly decisive for feeding applications with expensive active ingredients.
Other features of flat-tray feeders:
- precise feeding even with complex product behavior
- extension with scale and control possible at any time
- easily exchangeable feeding tools
- various feeding tools such as solid-blade, concave or spiral screws facilitate adaptation to the product to be fed
- very easy to clean
- stable feeding thanks to gentle transport of the bulk material
- feeding screws easy to replace thanks to bayonet fasteners
- tray scrapers can be designed and manufactured according to customer requirements
- very uniform feeding thanks to wide-open screw channel and constant filling through bottom scraper
For free-flowing products such as granules or free-flowing powders such as sugar or semolina, our feeders with standard hoppers can also be used.
Are you unsure which hopper is suitable for your feeding application? In the know-how section on our website you will find an overview of the different hoppers and their suitability for the nature of the product to be fed. We would also be happy to provide you with further information in person. We look forward to hearing from you!
Current Projects
Most of our devices are designed and produced according to specific requirements of customers especially for their purposes and are unique pieces. Here are some examples of devices and equipment completed and delivered in the past year:
Laboratory and pilot plant for the production of meat substitutes
Devices:
ZE 50 extruder (twin-screw, co-rotating) as laboratory and pilot plant incl. downstream cooling die, gravimetric feeding (ZD 32 FB twin-screw feeder), gravimetric refilling (ZD 55 FB twin-screw feeder)
Industry/Use:
Food, production of plant-based meat analogues/substitutes.
Special feature:
- flat-tray feeders for continuous feeding of poorly flowing powders
- cooling die with continuously adjustable slot height from 4 to 25 mm on mobile stand
- platform for refilling the ZD 55 feeder incl. stairs
- split barrel (horizontal) incl. opening mechanism for simplified process analysis
- modular extruder screws
- a large number of closable barrel openings for the addition of powder or liquids
ZE 50 extruder for coloring and marking of wood repair compound
Devices:
ZE 50 extruder for the production of approx. 100 to 500 kg/h, with connection to a pelletizing unit. Cooling of the drops on a conveyor belt, collection and packing into 25 kg bags.
Industry/Use:
Wood repair compound, coloring and marking
Special feature:
- customized cover of the barrel for thermal insulation
- connection to granulating unit for drops
- temperature control in pressurized water mode at 160 °C
Hybrid extruder for the production of films containing active ingredients
Devices:
Hybrid extruder ZE 5 /12, gravimetric twin-screw feeder ZD 9 with flat-tray, temperature-controlled film roller
Industry/Use:
Pharmaceuticals, production of films containing active ingredients
Special feature:
GMP plant
Laboratory extruder for the production of meat substitutes
Devices:
ZE 12 extruder (twin screw, co-rotating) as laboratory unit incl. downstream cooling nozzle, volumetric metering (ZD 9 FB twin screw metering unit)
Industry/Use:
University, production of plant-based meat analogues/substitutes
Special feature:
- flat-tottom feeder for continuous feeding of poorly flowing powders
- cooling die upper part with sight glass for optical analysis of the extrudate, additional closed cooling die upper part
- split barrel (horizontal) for simplified process analysis
- modular extruder screws
- braker plate can be installed as needed
- a large number of closable barrel openings for the addition of powder or liquids
- a variety of additional sensor connection options
Exhibitions 2022 and 2023
After a three-year break due to the coronavirus, we were finally able to welcome you back on site at trade fairs last year. At the ACHEMA in Frankfurt in August and the POWTECH in Nuremberg in September we had many interesting conversations with interested parties and existing customers. In 2023, we will exhibit our equipment at two trade shows: At SOLIDS in Parma from June 14 to 15 and at POWTECH in Nuremberg from September 26 to 28.
We are already looking forward to your visit in Parma or Nuremberg! Until then, we would like to show you some impressions of our trade show appearances from last year:
ACHEMA in Frankfurt a. Main, August 22 to 26, 2022
POWTECH in Nuremberg, September 27-29, 2022
