ASC TE Guide

Fluff Feed System •882.00209.00 •01/02/2019 1
FLUFF FEED SYSTEM
Part Number: 882.00209.00
Revision: 01.02.2019
Revision: C
OPERATION AND INSTRUCTION MANUAL
TE / TFH / TFH-HP

Fluff Feed System •882.00209.00 •01/02/2019 ii
Write Down Your Serial Numbers Here For Future Reference:
_________________________ _________________________
_________________________ _________________________
_________________________ _________________________
We are committed to product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without
notice.
DCN No. ____________
© Copyright 2019 All rights reserved.

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Shipping Info
Inspecting Packaging and Equipment
Please inspect all packaging for any damage prior to unpacking. If you see any damage to
the packaging, please take pictures of the packaging prior to unpacking the equipment.
Once the pictures are taken of the packaging, take pictures of the equipment as well.
If the packaging is damaged, write Damaged Freight on the delivery receipt. If we find the
equipment is damaged, a claim can be filed.
Thoroughly check the equipment for any damage that might have occurred in transit, such
as broken or loose wiring and components, loose hardware and mounting screws, etc.
Please take pictures of the damage.
In the Event of Shipping Damage
According to the contract terms and conditions of the Carrier, the freight claims are filed by
the terms below.
If the order is prepaid, ACS Group is responsible for the freight payment. ACS will file the
claim with the truck line. We need pictures of the damaged freight and a copy of the
delivery receipt marked Damaged Freight. ACS must be notified within 24 hours of any
damage. The driver should give you a claim number before they leave your facility.
If the order is collect or third party billing to a customer’s account, the customer is
responsible to file the claim with the truck line. You will need pictures of the damaged
freight and a copy of the delivery receipt marked Damaged Freight to file the claim. The
driver should give you a claim number before they leave your facility.
Advise customer service regarding your wish for assistance and to obtain an RMA (Return
Material Authorization) number. If you need assistance, contact the shipping supervisor at
262-641-8600.
Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods before the transportation company’s inspection and authorization and,
you have received your RMA (Return Material Authorization) number from ACS.
A certified copy of our invoice is available upon request. The original Bill of Lading is
attached to our original invoice. If the shipment was prepaid and ACS is responsible for the
freight, we will submit the claim. You will need pictures of the freight, a copy of the delivery
receipt marked damaged freight and the claim number.

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If the Shipment is Not Complete
Check the packing list as back-ordered items are noted on the packing list. You should have:
Machine
Bill of lading
Packing list
Operating and Installation manual
Electrical schematic and panel layout drawings
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking.
If the Shipment is Not Correct
If the shipment is not what you ordered, contact the shipping department immediately.
Please call 262-641-8600. Have the order number and item number available.
Hold the items until you receive shipping instructions. Do not return any goods before
receiving your RMA (Return Material Authorization) number from ACS.
Returns
Do not return any goods before receiving your RMA (Return Material Authorization)
number and shipping instructions from ACS.

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Table of Contents
CHAPTER 1: SAFETY................................................................6
1-1 How to Use This Manual ........................................................................................................... 6
Safety Symbols Used in this Manual ................................................................................... 6
1-2 General Safety Regulations ....................................................................................................... 7
1-3 Responsibility ............................................................................................................................ 7
Safety Tags and Warning Labels......................................................................................... 6
1-4 Warnings and Precautions ...................................................................................................... 10
CHAPTER 2: FUNCTIONAL DESCRIPTION...........................12
2-1 Models Covered in This Manual.............................................................................................. 12
2-2 General Description................................................................................................................. 12
2-3 Typical Features and Components .......................................................................................... 12
2-4 Safety Features........................................................................... Error! Bookmark not defined.
CHAPTER 3: INSTALLATION..................................................16
3-1 Uncrating the Equipment ........................................................................................................ 16
3-2 Electrical Connections ............................................................................................................. 16
3-3 Making Electrical Connections ................................................................................................ 19
3-4 Initial Start-up.......................................................................................................................... 19
CHAPTER 4: OPERATION.......................................................22
4-1 Start-up....................................................................................... Error! Bookmark not defined.
4-2 Operation Procedures ............................................................................................................. 22
4-3 Shut-down .................................................................................. Error! Bookmark not defined.
CHAPTER 5: MAINTENANCE..................................................24
5-1 Preventative Maintenance Schedule ...................................................................................... 24
5-2 Preventative Maintenance......................................................... Error! Bookmark not defined.
5-3 Corrective Maintenance............................................................. Error! Bookmark not defined.
CHAPTER 6: TROUBLESHOOTING........................................25
6-1 Introduction............................................................................................................................. 29
CHAPTER 7: APPENDIX..........................................................31
7-1 Customer Satisfaction Warranty Program .............................................................................. 31
7-2 Technical Specifications.............................................................. Error! Bookmark not defined.
7-3 Drawings and Diagrams.............................................................. Error! Bookmark not defined.
7-4 Spare Parts List ........................................................................... Error! Bookmark not defined.
7-5 Technical Assistance.................................................................................................................. 3
Parts Department ............................................................................................................... 3
Service Department............................................................................................................. 3
Sales Department................................................................................................................ 3

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Chapter 1: Safety
1-1 How to Use This Manual
Use this manual as a guide and reference for installing, operating, and maintaining your
machine. The purpose is to assist you in applying efficient, proven techniques that enhance
equipment productivity.
This manual covers only light corrective maintenance. No other maintenance should be
undertaken without first contacting a service engineer.
The Functional Description section outlines models covered, standard features, and safety
features. Additional sections within the manual provide instructions for installation, pre-
operational procedures, operation, preventive maintenance, and corrective maintenance.
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup
of the machine. We can also provide the assistance of a factory-trained technician to help train
your operator(s) for a nominal charge. This section includes instructions, checks, and
adjustments that should be followed before commencing with operation of the machine.
These instructions are intended to supplement standard shop procedures performed at shift,
daily, and weekly intervals.
The Operation chapter includes a description of electrical and mechanical controls, in addition
to information for operating the machine safely and efficiently.
The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly
instructions for those areas of the equipment requiring service. Preventive maintenance sections
are included to ensure that your machine provides excellent, long service.
The Troubleshooting chapter serves as a guide for identification of most common problems.
Potential problems are listed, along with possible causes and related solutions.
The Appendix contains technical specifications, drawings, schematics, parts lists, and available
options. A spare parts list with part numbers specific to your machine is provided with your
shipping paperwork package. Refer to this section for a listing of spare parts for purchase.
Have your serial number and model number ready when ordering.
Safety Symbols Used in this Manual
The following safety alert symbols are used to alert you to potential personal injury hazards.
Obey all safety messages that follow these symbols to avoid possible injury or death.
DANGER indicates an imminently hazardous situation that, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially hazardous situation or practice that, if
not avoided, could result in death or serious injury.
CAUTION! CAUTION indicates a potentially hazardous situation or practice that, if
not avoided, may result in minor or moderate injury or in property
damage.

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1-2 General Safety Regulations
These regulations should be read, understood and periodically reviewed by all personnel
involved in any way with this machine.
Never operate or remove any machine components that are secured by mechanical fasteners
unless the motor is electrically locked out and all moving parts are motionless.
Do not circumvent the safety interlocks.
Extreme care should be taken to see that all bolts are properly tightened at all times during the
operation of the machine.
Service personnel should observe PPE (Personal Protective Equipment) requirements for Arc
Flash per OSHA1910 and NEC70 standards.
1-3 Responsibility
These machines are constructed for maximum operator safety when used under standard
operating conditions and when recommended instructions are followed in the maintenance
and operation of the machine.
All personnel engaged in the use of the machine should become familiar with its operation as
described in this manual.
Proper operation of the machine promotes safety for the operator and all workers in its
vicinity.
Become familiar with materials, inspection, speed limitations, guard maintenance, and total
user responsibility while using or servicing the equipment.
Each individual must take responsibility for observing the prescribed safety rules as outlined.
All caution, warning and danger signs must be observed and obeyed. Any actual or potential
dangerous conditions must be reported to your immediate supervisor.

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Figure 1: Safety Tags and Warning Labels
Hazard Alert Symbol
Description/Explanation
Preventative Maintenance
High Voltage Hazard. The
electrical enclosure is supplied
with 3-phase electrical power.
Use caution when using or
maintaining this product.
Every six months inspect all electrical
connections for secure attachment.
For further information see the
Maintenance Chapter in this manual.
Hands could be exposed to a
crushing movement.
Every month inspect the
shear/blades for any type of wear.
For further information see the
Maintenance Chapter in this manual.
When equipped with belts and
sheaves, hands could become
entangled.
Every month inspect the belt(s) for
any type of wear. For further
information see the Maintenance
Chapter in the manual.
Hands can become entangled or
cut if they enter the danger zone
of gears or cutting shears.
Every month inspect the
shears/blades for any type of wear.
For further information see the
Maintenance Chapter in the manual.
The unit can produce continuous
noise above 85 dBA and/or
produce projectiles under normal
operating conditions.
Always wear eye and ear protection
when the machine is in operation or
performing maintenance.

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Mandatory Symbol
Description/Explanation
Read operators Manual. This equipment must be operated
and maintained by properly trained personnel. The
information contained within this manual must be read and
understood prior to operating this equipment.
Lock Out. This equipment is operated with 3-phase electrical
power. Therefore, when performing any maintenance
operations, we recommend following the local standards for
performing a lock-out/tag-out procedure. Lock out power
whenever worked on to prevent electrical shock.
Safety Gloves Required. Wear gloves to prevent injury when
performing maintenance work to avoid serious injury.
Eye & Ear protection required. This unit may produce loud
and continuous noise and may produce projectiles.
Do not reach into unit. Reaching into a unit is prohibited
while the unit is in operation and may cause serious injury.
Do not step. Stepping on the unit is prohibited and may cause
serious injury.
Do not operate the unit without guards. Operating the unit
with guards removed is prohibited and may cause serious
injury.

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1-4 Warnings and Precautions
Our machines are designed to provide safe and reliable operation when installed and operated
within design specifications, and follow national and local safety codes.
To avoid possible personal injury or equipment damage when installing, operating, or
maintaining this machine, use good judgment and follow these safe practices:
LEARN AND OBEY your company’s safety policy regarding mechanical and electrical
equipment.
MOVING OR LIFTING THE MACHINE: Although our equipment is built and engineered
for great ruggedness in operation, care must be taken when moving the machine along
the floor or lifting it. Damage may occur to sheet metal covers, electrical cabinets, or
small brackets if pressure is applied to them when moving the machine. When lifting
the machine, be certain the total machine weight does not exceed the capability of the
lifting equipment.
EQUIPMENT LOCATION: Adequate area for routine maintenance should be provided in
order to open the machine for service. Proper service area clearances also should allow
people who are working on the machine to be clearly visible to others, thereby
reducing the potential safety hazards.
SAFE HOUSEKEEPING: The work area must be kept clean and uncluttered during
periods of operation or maintenance. No hand tools or other metal objects should be
left on or around the machine.
SAFETY GLASSES OR A FACE SHIELD MUST ALWAYS BE WORN
when servicing or operating the machine.
EAR PROTECTION: The Occupational Safety and Health Act of 1970 has established
guidelines for Permissible Noise Exposures (OSHA 1910.95) that should be followed.
CUT RESISTANT GLOVES MUST ALWAYS BE WORN when servicing or handling knives.
NEVER attempt to operate the machine unless it is fully assembled with all guards and
interlocks in place and functional.
OBSERVE all danger, warning, caution and safety labels on the equipment.
Upon completion of any machine maintenance, be certain ALL SAFETY GUARDS AND
COVERS are securely and properly fastened prior to resuming machine operation. All
fasteners must be in place and properly tightened. ANY SHORTCUTS MAY RESULT IN
INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT.
NEVER wear any loose fitting clothes, neckties, or dangling items such as earrings,
belts, or shoestrings. Jewelry, such as wristwatches, bracelets, or rings should NEVER
be worn. Long hair must be tied back or placed in a tight fitting hairnet. NEVER lean
against or rest hands or feet on the equipment when it is in operation or open for
maintenance. NEVER stand on the machine when it is in operation.

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ROTATION OF MOTORS: The correct rotating direction for the machine motor is clearly
marked on the machine. Always check for proper rotation of motors. Incorrect rotation
direction can cause severe damage.
ELECTRICAL GROUNDING: All electrical equipment on the machine must be grounded
in accordance to all local codes and Article 250 of the National Electric Code.
ALWAYS DISCONNECT AND LOCKOUT the main electrical power to the machine before
performing any service.
SAFETY INTERLOCKS MUST NOT BE BYPASSED. The mechanical and electrical safety
interlocks ensure the safety of personnel. They should never be tampered with or
removed for ANY reason. They should be checked frequently by a qualified mechanic
for proper operation.
NEVER modify the machine configuration or any individual component without written
notice from the factory.
We have long recognized the importance of safety and have designed and manufactured our
equipment with operator safety as a prime consideration. We expect you, as a user, to abide by
the foregoing recommendations in order to make operator safety a reality.

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Chapter 2: Functional Description
2-1 Models Covered in This Manual
This manual provides operation, installation, and maintenance instructions for
Fluff Feed Systems. Model numbers are listed on the serial tag. Make sure
you know the model and serial number of your equipment before contacting
the manufacturer for parts or service. TE fluff feed hoppers are used to feed
up to 20% film edge trim into the throat of a 2.5” extruder. They cannot be
used on extruders equipped with a grooved feed throat. TFH and TFH-HP
fluff feed hoppers are used to feed up to 50% film edge into the throat of 3.5”
to 10” extruder. They cannot be used on extruders equipped with a grooved
feed throat.
2-2 General Description
The TE direct recycle fluff reclaim systems provide the processor with a
simple, easy to operate method of reclaiming edge trim and unprinted roll
stock.
The system generally consists of:
An edge trim venturi blower to convey the edge trim from the winder trim
station to the grinder on the TE system.
An edge trim air exhauster designed to exhaust the majority of the trim
conveying air and direct the edge trim into the grinder chamber.
A single or dual stage film grinder with small hole size screen.
A centrifugal fluff-conveying blower.
A high efficiency cyclone separator installed on top of the TE fluff feed
hopper assembly, to exhaust the majority of the conveying air from the fluff
blower.
A dual stage SCR drive fluff feed hopper to meter and mix the ground film
scrap with virgin material. The fluff hopper is mounted directly on the extruder
throat, mixing the ground scrap with virgin pellets.
2-3 Typical Features and Components
Mechanical Features (All Models)
IR Compensation.
Machine-mount flange.
Dependable auger metering.
Mild steel material contact surfaces.

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Mechanical Features (TE Models)
Up to 20% fluff re-feed rate (Re-feed rate is based on feeding 1 mil medium
slip LDPE film scrap to a die limited extrusion system. If the system is limited
by the extruder, some loss in output rate may occur when feeding higher
percentages of fluff.).
Vertical Mix Auger, horizontal fluff metering auger.
Individual speed adjustments on fluff auger and Verti-Blend mixer.
Mechanical Features (TFH / TFH-HP Models)
Up to 30% maximum fluff re-feed rate (Fluff feedback rate is based on a
non-extruder limited line, recycling 1.25 mil LDPE medium slip film. Extruder
screw speed increase may be required to obtain maximum quoted feed rate.
If extruder is running 100% plasticizing capacity on virgin material, loss in
output may occur during fluff feeding.
Note: Typical TFH-HP Models fluff feed rates exceed 30% of
extruder output and are known to be as high as 50%. Maximum fluff
feed percentages will vary depending on application.
Independently-adjustable dual control utilizing separate vertical mix
auger and separate horizontal fluff metering auger. Eliminates extruder
surging.
Individual speed adjustments using variable frequency drives.
Additional Mechanical Features (TFH-HP Models)
High performance “Verti-Blend” vertical feed auger incorporates vertical
compaction and mixing design to allow maximum fluff feeding.
Vertical side access door on pedestal for easier cleaning and
maintenance.
Heavy-duty ICS100 gearbox assemblies.
Electrical Features (All Models)
• 230/1/60 (unless otherwise noted) supply voltage
• Extruder following signal isolator
• Fully accessible NEMA 12 electrical control enclosure
Electrical Features (TE Models)
• Horizontal and vertical drive DC motors (SCR) 180 VDC
• Individual voltmeters

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Electrical Features (TFH / TFH-HP Models)
• AC inverter-duty motors
• Ammeters to monitor both drives
• Fluff hopper bridge breaker
• Optical level sensor with delay timer, with field connection to grinder feed
rolls or alarm device
• Precision speed regulation
• 98% displacement power factor
• 98% drive efficiency
• Internal overload protection
• Programmable auto restart
• Adjustable acceleration and deceleration
Additional Electrical Features (TFH-HP Models)
• Heavy-duty fan-cooled brushless VFD AC vector duty motors with
Delta VFD-E variable-frequency Vector drives
• 460/3/60 supply voltage
2-4 Optional Features
Options marked with “*” indicate options that can be factory installed or
retrofitted in the field.
Special Voltage Operation.
90° feed pedestal.
Fluff hopper with bottom clean-out door, including safety switch.
Special mounting flange or throat adapter.
Special cyclone hole in fluff hopper cover.
Cyclone separators.
High level sensor with delay timer (TE Series only).
2-5 Safety Features
This section includes information on safety devices and procedures that are
inherent to the Fluff Feed System. This manual is not intended to supersede
or alter safety standards established by the user of this equipment. Instead,
the material contained in this section is recommended to supplement these
procedures in order to provide a safer working environment.

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At the completion of this section, the operator and maintenance personnel will
be able to do the following:
• Identify and locate specific safety devices.
• Understand the proper use of the safety devices provided.
• Describe the function of the safety device.
Safety Circuit Standards
Safety circuits used in industrial systems protect the operator and
maintenance personnel from dangerous energy. They also provide a means
of locking out or isolating the energy for servicing equipment.
Various agencies have contributed to the establishment of safety standards
that apply to the design and manufacture of automated equipment. The
Occupational Safety and Health Administration (OSHA) and the Joint
Industrial council (JIC) are just a few of the organizations that have joined
with the plastics industry to develop safety standards.
Every effort has been made to incorporate these standards into the design of
the conveying system; however, it is the responsibility of the personnel
operating and maintaining the equipment to familiarize themselves with the
safety procedures and the proper use of any safety devices.
Fail Safe Operation
If a safety device or circuit should fail, the design must be such that the failure
causes a “Safe” condition. As an example, a safety switch must be a normally
open switch. The switch must be held closed with the device it is to protect. If
the switch fails, it will go to the open condition, tripping out the safety circuit.
At no time should the safety device fail and allow the operation to continue.
For example, if a safety switch is guarding a motor, and the safety switch
fails, the motor should not be able to run.
Safety Device Lock-Outs
Some safety devices disconnect electrical energy from a circuit. The safety
devices that are used in this fluff feed system are primarily concerned with
electrical power disconnection.
WARNING! Always disconnect and lockout all electrical power and
pneumatic (i.e. compressed air) sources prior to servicing the Fluff
Feed System. Failure to do so may result in serious injury. No one
but the person who installed the lockout may remove it.

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Chapter 3: Installation
3-1 Uncrating the Equipment
Fluff feed systems are shipped mounted on a skid, enclosed in a plastic
wrapper, and contained in a cardboard box.
1. Pry the crating away from the skid.
Note: Remove the nails holding the box to the skid and lift the box
off carefully; avoiding staples in the 1’ x 4’ wood supports. Cut
the steel banding.
2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift unit from sides. Use a pry bar if necessary to carefully remove the
skid from the unit.
4. Lower slowly.
3-2 Mounting Hopper (Units with Remote Grinders)
1. Remove the material supply hopper from the extruder.
2. Install the fluff feed hopper assembly on the extruder throat. The holes
will normally have to be drilled to match the extruder flange.
Note: When installing, check the vertical segmented flight auger
to ensure that it is within ½” to ¾” from the top of the extruder
screw flight (See figure 1). This will ensure proper feeding of the
fluff / pellet mixture without bridging.

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Figure 1: Mounting Clearance
3-3 Setup of System (Units with Remote Grinder)
This section provides the procedures for configuring your fluff feed system.
We recommend that you carry out these procedures in the order given here.
Note: If the extruder is equipped with any type of throat other than a
cylindrical one, the fluff feed system should be equipped with a
custom fitted adapter to provide the proper throat configuration to
allow for proper feeding. A fluff system should never be installed on a
square or tangential throat extruder without an adapter. (CONSULT
FACTORY)
1. After the hopper has been installed, replace the virgin supply hopper
on top of the angled virgin feed pedestal pipe.
2. If the fluff feed hopper is equipped with a photo cell level switch used
for controlling grinder feed rolls, ensure that a compressed air line is
connected to the air blow offs that keep the photo cell heads clean.
This air should be regulated to about 1 P.S.I. Too much air blowing in

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these cleanoffs can cause the blower cyclone to carryover blowing fluff
particles out of the cyclone.
3. Install the cyclone separator on top of the fluff feed hopper cover. The
bolt circle will allow rotation in 15 degree increments. If the cyclone has
to be oriented at a special angle, new holes will have to be drilled in
the cyclone flange to fit.
4. Install the grinder at a convenient location adjacent to the extruder.
5. When installing, open the grinder chamber and inspect to ensure it is
clean and empty. At this time, check the grinder blade gap. The rotor
blades and bed knife should have a gap of .002”. This is preset at the
factory when the unit was test run. However, this gap can change
during shipping, and should be rechecked. If a feeler gauge is not
available, adjust the blades so they will cut through one or two pieces
of notebook paper placed between the blades. The grinder will operate
with a larger gap, however it will run quieter and more efficient with
sharp blades and the recommended gap of .002-.004”.
6. Install the edge trim exhauster on top of the grinder and orient just as
was done with the cyclone.
7. Install the fluff conveying tubing between the fluff blower on the grinder
and the fluff feed hopper cyclone inlet. The interconnecting tubing is
normally not furnished with the system and must be purchased locally.
We recommend that the system be piped with standard thin wall
aluminum conveying tubing. The blower outlet and cyclone inlet are
sized to match and are usually 3”, 4”, or 5” O.D. depending on the
system size. We recommend the use of long sweep elbows close to
the cyclone. If flex is used to connect to the cyclone, it can create poor
flow and cause some carryover of fines out of the top of the cyclone.
Improper air flow velocity can also cause some carryover.
8. If the grinder is equipped with feed rolls, ensure that a proper set up is
provided to allow the rolls to be unrolled easily and not put excessive
loading on the feed roll drive. This can result in premature failure of the
gearbox or SCR drive.
9. Install the edge trim venturi blower adjacent to the extruder system
winder. Place the two (2) pickup bellmouths close to the trim knives
and connect the flex hose from the bellmouth to the “Y” tube. Connect
the flex from the “Y” tube to the venturi inlet. The system will perform
more efficiently with aluminum conveying tubing and long sweep
elbows piped from the venturi outlet to the air exhauster on top of the
grinder.

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10.When installing the edge trim conveying tube from the venturi to the
grinder air exhauster, leave an airgap between the end of the tubing
and the exhauster inlet. We recommend a gap of at least 3-6”, and
more if possible. This will allow the grinder to be opened for blade
maintenance easily, and will prevent the cutting chamber from being
overpressurized by the trim blower air. Recheck the edge trim piping to
ensure there are no sharp edges, rivets, etc. protruding into any of the
trim conveying pipes. This will cause intermittent trim hangups and can
cause the grinder to jam up with wads of trim or cause the winder trims
to wrap.
3-4 Making Electrical Connections
Refer to local electrical codes, the schematic and connection diagrams
supplied with this unit and the serial tag for wiring considerations. Run all
wiring in conduit if codes require it.
1. After the system is mechanically installed, field connect all the
appropriate power leads.
2. The fluff feed hopper control signal isolator will have to be connected
to the extruder DC drive circuit to allow slaved in performance to keep
the fluff feed hopper speeds in relation to the extruder screw speed.
CONSULT THE FACTORY IF YOU HAVE ANY QUESTIONS.
Caution!
If this is done improperly with the SCR drive units, blown fuses and
ultimate drive failures will occur on the vertical mixer and the fluff
metering auger devices.
3-5 Initial Start-up
Once the mechanical and electrical components of the fluff feed system have
been installed, the following will need to be checked prior to startup:
1. On systems equipped with hydraulic drives, check the cooling water
flow. Do not run the unit without cooling water or damage to the seals
will occur.
2. After the electrical wiring has been completed, check all motor
rotations for proper rotation. Motor rotations must be counter-clockwise
from drive end.
Upon Startup:
1. When the extruder has reached production speed, turn on the reclaim
system fluff feed hopper. Adjust the SCR speed on the vertical mixer to
approximately 75%. Watch the drive meter to see that it is not

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fluctuating and is operating smoothly. If the meter is fluctuating, slow
the drive speed adjustment. If the meter is still fluctuating, re-inspect
the vertical mixing auger for binding. If there is no binding, the material
being fed probably has a very low slip coefficient (such as stretch
wrap). The mixer auger should be turned down to a smaller diameter to
allow easier movement. This will have to be done on a trial and error
basis to find the proper clearance between the mixer auger and the
fluff feed vertical mixer throat that will allow this particular material to
be mixed easily.
In some cases, an additional mixer auger will have to be purchased
and switched if a wide range of products are to be run on the same
extruder. Good performance on a hard to feed resin might cause a
lesser performance on an easy to feed resin. The fluff feed unit has
more adjustments than competitive single screw units, however there
are extreme cases where a mixer change may be necessary.
2. After the vertical mixer has been started properly, start the film grinder
and the edge trim blower. When the edge trim is started, position the
bellmouth as close to the knife and align as straight as possible. This
will provide good performance on conveying the trim away from the
winder trim roller.
After the edge trim has reached the grinder exhauster, adjust the upper
exhauster baffle to blow only as much air as necessary to convey the
edge trim down the exhauster into the grinder chamber. Adjust the
lower grinder outlet tube air adjustment to provide as much suction as
possible without screen blinding. Watch the fluff movement through the
screen to ensure it is coming out O.K. If fluff is blowing out of the
clearance hole between the grinder rotor shaft and the chamber side,
this indicates that the airflow into the top of the grinder chamber is
excessive. Adjust the upper exhauster baffle and the lower suction
adjustment to ensure that the chamber I under slightly negative
pressure.
3. When the ground fluff is being conveyed into the fluff hopper (if the
hopper is equipped with a photo cell level switch), let the fluff build up
in the fluff feed hopper by running the horizontal auger slower than
needed to feed the amount of fluff being conveyed. This sensor should
be checked for operation and adjustment. Adjust the sensitivity as
necessary (Don’t forget to shut off the edge trim blower and grinder
when doing this or a mess will be created.).
4. After the level switch has been adjusted and is operating properly, start
the horizontal metering auger. This auger should be started slowly and