The gain in efficiency with KryoSys is achieved by a combination of a high-speed extruder with a newly developed die, a highly efficient cooling section and a heat system. Kryosys lines lend themselves to the production of smooth mono-layer and multi-layer or pipes with diameters ranging from 110 to 2,000 mm. They are also suitable for the production of corrugated pipes. The length of the cooling section can be halved compared to conventional extrusion lines, even for large diameters. At the same time, the for a KryoSys line is highly competitive compared to conventional extrusion equipment.
To ensure optimal melt distribution, the KryoS die, specially developed for Kryosys, has been designed on the basis of a spiral mandrel die. The great advantage of this particular die is an innovative melt cooling system inside the die. Thanks to this system, it has become possible to start cooling the melt in the die, which allows a substantial reduction in the length of the cooling section. The lower melt temperature also brings about a significant increase in viscosity at the point of exit from the die, which counteracts sagging especially in thick-walled pipes.
Moreover, KryoS features a large internal aperture, which allows air cooling of the extruded melt. The KryoSys system is rounded off by a highly efficient cooling section. In this aggregate, the is cooled simultaneously from the outside and the inside by an ingenious combination of water and air cooling, which permits a further shortening of the cooling section.
Another advantage of KryoSys, which is just as vital in times of soaring costs, is the system's great in-production saving potential. Thanks to its direct drive, the Rapidex high-speed extruder operates with an extremely high level of -efficiency. Through a reduction in the number of vacuum and spray cooling baths required for the downstream aggregates and the optimized cooling system consisting of water and air cooling, consumption can be cut by up to 71kW (about 27 kW are saved by the reduction in the number of circulation pumps, and about 44 kW by the fact the less water is circulated). Another source of savings is utilization of the heat set free by the cooling system in the die. With KryoSys, this can be used for material pre-heating. Thus the torque of the extruder can be reduced, resulting in savings of up to 95 kW. By combining all of these measures, a reduction in consumption of roughly 186 kW can be achieved. With costs of 0.10 /kWh and 6,000 operating hours per year, this adds up to about 100,000 in annual savings for a single extrusion line.
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