Sacmi CCM001 User manual

TECHNICAL DOCUMENTATION
DOCUMENTATION TECHNIQUE
TECHNISCHE DOKUMENTATION
DOCUMENTACION TECNICA
DOCUMENTAÇÃO TÉCNICA
DOCUMENTAZIONE
TECNICA
USER’S MANUAL
002AZ005A
ROTARY COMPRESSION MOLDING PRESS
CCM001
ENGLISH

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TABLE OF CONTENTS

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TABLE OF CONTENTS
002AZ005A
USER’S MANUAL
ROTARY COMPRESSION MOLDING PRESS
CCM001
MANUFACTURER
SACMI IMOLA
Via Selice Provinciale, 17/A
40026 IMOLA (Bologna) - ITALIA
PUBLISHED ON
February 5, 2003 - December 11, 2003
VERSIONS
CCM001C

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1GENERAL INFORMATION........................................................................................................................1 - 1
1.1 INTRODUCTION ....................................................................................................................1 - 1
1.2 WHERE TO KEEP THE MANUAL ........................................................................................ 1 - 1
1.3 HOW TO USE THE MANUAL ............................................................................................... 1 - 1
1.4 USERS OF THE MANUAL.................................................................................................... 1 - 1
1.5 WARRANTY ...........................................................................................................................1 - 2
1.6 SUPPLEMENTS.................................................................................................................... 1 - 2
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN
THE MANUAL ........................................................................................................................1 - 2
1.8 MACHINE IDENTIFICATION PLATE ................................................................................... 1 - 4
2MACHINE FEATURES ............................................................................................................................. 2 - 1
2.1 MACHINE DESCRIPTION .................................................................................................... 2 - 1
2.1.1 MAIN DEVICES......................................................................................................................2 - 3
2.1.1.1 Plasticization unit .................................................................................................................. 2 - 3
2.1.1.2 Drive unit ............................................................................................................................. 2 - 10
2.1.1.3 Insertion drum unit .............................................................................................................. 2 - 11
2.1.1.4 Forming unit ........................................................................................................................ 2 - 13
2.1.1.5 Exit channel ......................................................................................................................... 2 - 16
2.1.1.6 Pneumatic system ............................................................................................................... 2 - 16
2.1.1.7 Hydraulic system ................................................................................................................. 2 - 16
2.1.1.8 Cooling system .................................................................................................................... 2 - 16
2.1.1.9 Electric system: control board ............................................................................................. 2 - 16
2.1.1.10 Tooling................................................................................................................................. 2 - 16
2.1.2 INTENDED, PROHIBITED AND MISUSE OF THE MACHINE .......................................... 2 - 18
2.2 OVERALL DIMENSIONS .................................................................................................... 2 - 19
2.3 TECHNICAL DATA ............................................................................................................. 2 - 26
2.3.1 SPECIFICATIONS .............................................................................................................. 2 - 26
2.3.2 OPERATIONAL CHARACTERISTICS ............................................................................... 2 - 27
2.3.3 AIRBORNE NOISE EMISSION LEVELS ............................................................................ 2 - 28
2.3.3.1 Sound pressure level (ISO/DIS 11202) .............................................................................. 2 - 28
2.3.3.2 Livello di potenza sonora (ISO 3746) ................................................................................. 2 - 28
2.4 DIAGRAMS ......................................................................................................................... 2 - 30
2.4.1 PNEUMATIC SYSTEM DIAGRAM ..................................................................................... 2 - 30
2.4.2 HYDRAULIC SYSTEM DIAGRAM ...................................................................................... 2 - 33
2.4.3 COOLING SYSTEM DIAGRAM .......................................................................................... 2 - 36

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3SAFETY EQUIPMENT AND PRECAUTIONS .......................................................................................... 3 - 1
3.1 SAFETY DEVICES AND GUARDS ...................................................................................... 3 - 1
3.1.1 GENERAL SAFETY RULES ................................................................................................. 3 - 1
3.1.2 SAFETY DEVICES INSTALLED ........................................................................................... 3 - 1
3.1.2.1 Shutdown devices ................................................................................................................. 3 - 1
3.1.2.2 Indicating a shutdown ........................................................................................................... 3 - 1
3.1.2.3 Devices to safeguard the operator ........................................................................................3-1
3.1.2.4 Emergency stop buttons ........................................................................................................3 - 2
3.2 SAFETY RULES FOR HANDLING ........................................................................................3 - 3
3.2.1 LIFTING PROCEDURES ...................................................................................................... 3 - 3
3.2.2 HANDLING PROCEDURES ................................................................................................. 3 - 3
3.2.3 PLACING THE LOAD ...........................................................................................................3-3
3.3 INSTALLATION......................................................................................................................3 - 4
3.3.1 GENERAL RULES ................................................................................................................ 3 - 4
3.4 OPERATOR TRAINING ........................................................................................................ 3 - 5
3.4.1 END-USER.............................................................................................................................3 - 5
3.4.2 OPERATORS ........................................................................................................................ 3 - 5
3.4.3 MAINTENANCE STAFF........................................................................................................ 3 - 5
3.5 SAFETY PRECAUTIONS FOR OPERATING, ADJUSTING AND SERVICING
THE MACHINE...................................................................................................................... 3 - 6
3.5.1 GENERAL SAFETY RULES ................................................................................................. 3 - 6
3.5.2 GUIDELINES FOR OPERATION AND MAINTENANCE ..................................................... 3 - 7
3.5.2.1 Risks deriving from high temperatures ................................................................................. 3 - 7
3.5.2.2 Risk of explosion ....................................................................................................................3 - 7
3.6 WHAT TO DO WHEN THE MACHINE IS NO LONGER USED ............................................3 - 8
3.6.1 GENERAL ............................................................................................................................. 3 - 8
4INSTALLATION ........................................................................................................................................ 4 - 1
4.1 SHIPPING AND HANDLING ................................................................................................. 4 - 1
4.2 POSITIONING ........................................................................................................................4 - 4
4.3 CONNECTIONS AND HOOK UPS ........................................................................................4 - 5
4.3.1 CONNECTING THE EXTRUDER TO THE PRESS ............................................................. 4 - 5
4.3.2 HYDRAULIC CONNECTION: FROM THE POWER UNIT TO THE PRESS ....................... 4 - 6
4.3.3 HOOKING UP THE COOLANT SYSTEM............................................................................. 4 - 7
4.3.4 HOOKING UP THE PNEUMATIC SYSTEM ..........................................................................4 - 8
4.3.5 ELECTRIC HOOK UP ...........................................................................................................4-9
5START UP ............................................................................................................................................... 5 - 1
5.1 INTRODUCTION ....................................................................................................................5 - 1
5.2 PRELIMINARY CHECKS ...................................................................................................... 5 - 1
5.3 CHECKING OPERATION ......................................................................................................5 - 2
5.4 PRELIMINARY OPERATIONS ............................................................................................. 5 - 3
5.5 STARTING THE AUTOMATIC CYCLE .................................................................................5 - 4
5.6 SUBSEQUENT START UPS .................................................................................................5 - 4

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6OPERATING INSTRUCTIONS ................................................................................................................. 6 - 1
6.1 CONTROL AND MONITORING UNIT .................................................................................. 6 - 1
6.2 STARTING AND STOPPING THE MACHINE ...................................................................... 6 - 4
6.3 AUTOMATIC CYCLE .............................................................................................................6 - 5
6.4 PRODUCTION CYCLE ......................................................................................................... 6 - 6
6.5 EMERGENCY CYCLES AND RESET OPERATIONS ..........................................................6 - 9
6.5.1 ACTUATOR DOWNSTROKE CONTROL ............................................................................ 6 - 9
6.5.2 ACTUATOR UPSTROKE / BROKEN ROD CONTROL ..................................................... 6 - 10
6.5.3 DOUBLE PRODUCT DETECTION ..................................................................................... 6 - 11
6.5.4 EMPTY DIE CONTROL ...................................................................................................... 6 - 12
6.5.5 DETECTION OF PRODUCTS HEAVIER OF LIGHTER THAN NORMAL WEIGHT ......... 6 - 12
6.5.6 CORRECT POSITION FOR START OF FORMING CONTROL ........................................ 6 - 13
6.5.7 ACTUATOR UPSTROKE CONTROL ................................................................................. 6 - 13
6.6 PRODUCT SAMPLING ....................................................................................................... 6 - 14
7ADJUSTMENTS ........................................................................................................................................ 7 - 1
7.1 PLASTICIZATION UNIT........................................................................................................ 7 - 1
7.1.1 EXTRUDER........................................................................................................................... 7 - 1
7.1.2 METERING PUMP ................................................................................................................ 7 - 1
7.1.3 FEED TUBE ...........................................................................................................................7 - 2
7.1.4 BY-PASS SYSTEM ............................................................................................................... 7 - 2
7.2 INSERTION DRUM ...............................................................................................................7-3
7.2.1 ADJUSTING THE PRE-LOAD OF THE DRUM’S CONNECTING ROD .............................. 7 - 3
7.2.1.1 Adjusting the drum’s connecting rod precharge ...................................................................7 - 3
7.2.1.2 Checking the drum’s connecting rod precharge ................................................................... 7 - 4
7.2.2 ADJUSTING THE CUTTER .................................................................................................. 7 - 4
7.2.3 ADJUSTING PELLET INSERTION TIMING ..........................................................................7 - 6
7.3 FORMING UNIT .................................................................................................................... 7 - 9
7.3.1 PRODUCT REMOVAL ADJUSTMENT .................................................................................7 - 9
7.3.2 ADJUSTING THE QUALITY CONTROL UNIT ................................................................... 7 - 10
7.4 PNEUMATIC SYSTEM ....................................................................................................... 7 - 12
7.5 HYDRAULIC SYSTEM........................................................................................................ 7 - 12
7.5.1 ADJUSTING THE OIL FLOW UNDER LOW PRESSURE ................................................. 7 - 12
7.5.2 ADJUSTING THE FORMING STAGE (HIGH PRESSURE) ............................................... 7 - 12
7.5.3 ADJUSTING THE ACTUATOR DOWNSTROKE ............................................................... 7 - 12
7.6 COOLING SYSTEM ............................................................................................................ 7 - 14
7.7 INSTALLING AND REMOVING THE TOOLING ................................................................ 7 - 14
7.8 ADJUSTING THE EXIT CONVEYOR BELT ....................................................................... 7 - 16
7.9 REPLACING THE INDUCTIVE SENSORS ........................................................................ 7 - 17
7.10 RESETTING THE ENCODERS .......................................................................................... 7 - 17

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8MAINTENANCE ........................................................................................................................................ 8 - 1
8.1 SCHEDULED MAINTENANCE ............................................................................................. 8 - 2
8.1.1 SCHEDULED MAINTENANCE CHART ............................................................................... 8 - 2
8.1.2 PERIODIC MAINTENANCE OPERATIONS ..........................................................................8 - 8
8.1.2.1 Drive unit ............................................................................................................................... 8 - 8
8.1.2.1.1 Checking the condition of the drive belts ...............................................................................8 - 8
8.1.2.1.2 Tensioning the forming unit transmission belts .................................................................... 8 - 8
8.1.2.1.3 Replacing the forming unit transmission belts ...................................................................... 8 - 8
8.1.2.1.4 Tensioning the insertion unit transmission belt......................................................................8 - 8
8.1.2.1.5 Replacing the insertion unit transmission belt ...................................................................... 8 - 9
8.1.2.1.6 Checking the oil level in the forming unit’s geared motor ..................................................... 8 - 9
8.1.2.1.7 Changing the oil in the forming unit’s geared motor ............................................................. 8 - 9
8.1.2.2 50 kg/h Extruder .................................................................................................................. 8 - 11
8.1.2.2.1 Overhauling the extruder auger .......................................................................................... 8 - 11
8.1.2.2.2 Checking the oil level in the extruder geared motor and topping up .................................. 8 - 12
8.1.2.2.3 Changing the oil in the extruder geared motor ................................................................... 8 - 12
8.1.2.2.4 Cleaning the nozzle............................................................................................................. 8 - 12
8.1.2.2.5 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 14
8.1.2.3 100 kg/h Extruder ................................................................................................................ 8 - 16
8.1.2.3.1 Overhauling the extruder auger .......................................................................................... 8 - 17
8.1.2.3.2 Checking the oil level in the extruder geared motor and topping up .................................. 8 - 18
8.1.2.3.3 Changing the oil in the extruder geared motor ................................................................... 8 - 18
8.1.2.3.4 Cleaning the polymer metering pump ................................................................................. 8-18
8.1.2.3.5 Replacing/overhauling the polymer metering pump ........................................................... 8 - 18
8.1.2.3.6 Lubricating the universal joint ............................................................................................. 8 - 19
8.1.2.3.7 Cleaning the nozzle............................................................................................................. 8 - 19
8.1.2.3.8 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 19
8.1.2.3.9 Checking the condition and tensioning the extruder drive belt ........................................... 8 - 21
8.1.2.3.10 Tensioning the extruder drive belt....................................................................................... 8 - 21
8.1.2.3.11 Replacing the extruder drive belt ........................................................................................ 8 - 21
8.1.2.3.12 Lubricating the extruder motor’s bearings .......................................................................... 8 - 21
8.1.2.4 150-200 kg/h Extruder......................................................................................................... 8 - 22
8.1.2.4.1 Overhauling the extruder auger .......................................................................................... 8 - 23
8.1.2.4.2 Checking the oil level in the polymer metering pump geared motor and topping up ......... 8 - 24
8.1.2.4.3 Changing the oil in the polymer metering pump geared motor .......................................... 8 - 24
8.1.2.4.4 Checking the oil level in the extruder thrust block and topping up ..................................... 8 - 24
8.1.2.4.5 Changing the oil in the extruder thrust block ...................................................................... 8 - 25
8.1.2.4.6 Cleaning the polymer metering pump ................................................................................. 8-25
8.1.2.4.7 Replacing/overhauling the polymer metering pump ........................................................... 8 - 25
8.1.2.4.8 Lubricating the universal joint ............................................................................................. 8 - 26
8.1.2.4.9 Cleaning the nozzle............................................................................................................. 8 - 26
8.1.2.4.10 Checking and setting pressure transducers BP1 and BP2................................................. 8 - 26
8.1.2.4.11 Setting pressure switch SP8 and pressure relief valve YV8 .............................................. 8 - 28
8.1.2.5 Insertion drum ..................................................................................................................... 8 - 30
8.1.2.5.1 Sharpening the blades ........................................................................................................ 8 - 30
8.1.2.5.2 Replacing the blades........................................................................................................... 8 - 30
8.1.2.5.3 Cleaning the cutters ............................................................................................................ 8 - 30
8.1.2.5.4 Replacing the cutters .......................................................................................................... 8 - 30
8.1.2.5.5 Cleaning the nozzles ........................................................................................................... 8 - 30
8.1.2.5.6 Replacing the nozzles ......................................................................................................... 8 - 32
8.1.2.5.7 Cleaning the compressed air distributor ............................................................................. 8 - 32
8.1.2.5.8 Replacing the compressed air distributor ........................................................................... 8 - 32
8.1.2.5.9 Checking the pre-load of the drum’s connecting rod .......................................................... 8 - 32
8.1.2.5.10 Adjusting the pre-load of the drum’s connecting rod .......................................................... 8 - 32
8.1.2.5.11 Replacing pulley A .............................................................................................................. 8 - 32
8.1.2.5.12 Removing cogged wheel B ................................................................................................. 8 - 34
8.1.2.5.13 Replacing cogged wheel C ................................................................................................. 8 - 34
8.1.2.5.14 Removing pulley D .............................................................................................................. 8 - 34

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8.1.2.5.15 Replacing toothed belt E ..................................................................................................... 8 - 36
8.1.2.5.16 Tensioning belt E ................................................................................................................ 8 - 36
8.1.2.5.17 Lubricating the gears........................................................................................................... 8 - 36
8.1.2.6 Forming unit ........................................................................................................................ 8 - 38
8.1.2.6.1 Cleaning .............................................................................................................................. 8 - 39
8.1.2.6.2 Overhauling the actuator valve ........................................................................................... 8 - 39
8.1.2.6.3 Greasing the roller............................................................................................................... 8 - 39
8.1.2.6.4 Replacing the hydraulic actuator gasket ............................................................................. 8 - 39
8.1.2.6.5 Replacing the upper flange gaskets.................................................................................... 8 - 40
8.1.2.6.6 Replacing the lower flange gaskets .................................................................................... 8 - 40
8.1.2.6.7 Greasing the roller and stripper rod pin .............................................................................. 8 - 41
8.1.2.6.8 Lubricating the stripper rod guide bushes........................................................................... 8 - 41
8.1.2.6.9 Greasing the central tool wheel (optional) .......................................................................... 8 - 41
8.1.2.7 Cams ................................................................................................................................... 8 - 42
8.1.2.7.1 Greasing and checking ....................................................................................................... 8 - 43
8.1.2.7.2 Replacing the stripper cams (central movement) (optional) ............................................... 8 - 43
8.1.2.7.3 Replacing the stripper cams (side movement) ................................................................... 8 - 43
8.1.2.7.4 Replacing the actuator control cams .................................................................................. 8 - 43
8.1.2.7.5 Replacing the cams for injecting air in the punches ........................................................... 8 - 43
8.1.2.8 Rotary distributor ................................................................................................................. 8 - 44
8.1.2.8.1 Replacing the gaskets ......................................................................................................... 8 - 44
8.1.2.9 Hydraulic system ................................................................................................................. 8 - 44
8.1.2.9.1 Checking the oil level in the hydraulic power unit ............................................................... 8 - 46
8.1.2.9.2 Changing the oil in the hydraulic power unit ....................................................................... 8 - 46
8.1.2.9.3 Replacing the flexible coupling in the hydraulic power unit ................................................ 8 - 46
8.1.2.9.4 Replacing the filter in the hydraulic power unit ................................................................... 8 - 46
8.1.2.9.5 Checking the oil level in the hydraulic power unit for 150/200 kg/h extruders ................... 8 - 46
8.1.2.9.6 Changing the oil in the hydraulic power unit for 150/200 kg/h extruders ........................... 8 - 46
8.1.2.9.7 Replacing the flexible coupling for the 150/200 kg/h extruder motor-pump unit ................ 8 - 46
8.1.2.9.8 Replacing the filter in the hydraulic power unit for the 150/200 kg/h extruder ................... 8 - 46
8.1.2.9.9 Cleaning control valve Pb ................................................................................................... 8 - 47
8.1.2.9.10 Cleaning control valve Ph ................................................................................................... 8 - 47
8.1.2.9.11 Cleaning solenoid control valves Pb and Ph ...................................................................... 8 - 47
8.1.2.9.12 Checking for condensate on the bottom of the tank ........................................................... 8 - 47
8.1.2.9.13 Checking the accumulator’s precharge .............................................................................. 8 - 47
8.1.2.10 Air supply system ................................................................................................................ 8 - 48
8.1.2.10.1 Cleaning the filter ................................................................................................................ 8 - 48
8.1.2.10.2 Cleaning and replacing the silencers ..................................................................................8- 48
8.1.2.11 Cooling system .................................................................................................................... 8 - 49
8.1.2.11.1 Checking the coolant level .................................................................................................. 8 - 49
8.1.2.11.2 Adding coolant .................................................................................................................... 8 - 49
8.1.2.11.3 Cleaning the filters .............................................................................................................. 8 - 49
8.1.2.11.4 Changing the coolant .......................................................................................................... 8 - 49
8.1.2.12 Safety devices ..................................................................................................................... 8 - 50
8.1.2.12.1 Checking the efficiency of the safety devices ..................................................................... 8 - 50
8.1.2.13 Air injection device .............................................................................................................. 8 - 51
8.1.2.13.1 Checking the valves ............................................................................................................ 8 - 51
8.1.2.13.2 Replacing the valves ........................................................................................................... 8 - 51
8.1.2.14 Product exit conveyor belt................................................................................................... 8 - 52
8.1.2.14.1 Replacing the conveyor belt................................................................................................ 8 - 52
8.1.2.14.2 Cleaning the counter photocell ........................................................................................... 8 - 52
8.1.2.14.3 Cleaning the slots in the exit conveyor belt slide surface ................................................... 8 - 52
8.1.3 LUBRICATION .................................................................................................................... 8 - 54
8.1.3.1 Lubricant specifications ....................................................................................................... 8 - 54
8.1.4 SETTINGS FOR TIGHTENING THE NUTS AND BOLTS.................................................. 8 - 55
8.2 TROUBLESHOOTING ........................................................................................................ 8 - 56

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9DECOMMISSIONING................................................................................................................................ 9 - 1

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GENERAL INFORMATION 1
1GENERAL INFORMATION
1.1 INTRODUCTION
E0004P
WARNING!
Carefully read the entire User’s Manual before working on the machine and/or the packaging of the various parts.
This manual contains important information for safeguarding the operators, the maintenance staff as well as the
machine itself.
SACMI reserves the right to make changes to the machine and in the manual without giving prior notice.
Copyright. All rights reserved. Unauthorized reproduction can result in civil damages and criminal prosecution on the
part of SACMI.
The contents of the manual and drawings are valuable trade secrets and must not be given to third parties, copied,
reproduced, disclosed or transferred.
Additional copies of this manual can be obtained by contacting SACMI’s Customer Service Department.
1.2 WHERE TO KEEP THE MANUAL
E0004P
WARNING!
This manual is to be considered an essential part of the machine and must be kept along with it even if the machine
is sold. Always keep the manual near the machine where it can be easily consulted. The manual must always be at
hand so that the operator and maintenance staff are able to consult it rapidly at any time.
1.3 HOW TO USE THE MANUAL
The lay out of this manual allows it to be easily consulted as all the information and instructions provided are grouped
together and divided into chapters and paragraphs. The user has to simply refer to the table of contents.
The information provided with alert, warning or danger symbols must be carefully read. The notes pertinent to the
operator’s safety or health are given inside a block and are pointed out by alert, warning and/or danger symbols and
are written in italics, as shown below.
E0004P
IMPORTANT!
Chapter 3 - SAFETY EQUIPMENT AND PRECAUTIONS must be carefully read in its entirety several times as it
contains important information and warnings regarding safety.
1.4 USERS OF THE MANUAL
In this manual the machine operators are categorized as follows:
-Operator: this is the person responsible for supervising and operating the machine.
-Routine maintenance men.
For a more detailed description, see the OPERATOR TRAINING paragraph in chapter 3 - SAFETY EQUIPMENT AND
PRECAUTIONS.

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1 GENERAL INFORMATION
1.5 WARRANTY
SACMI shall be held responsible only for the machine as it was configured at the time of delivery.
Any operations that alter the configuration of the machine or operating cycle must be carried out by SACMI personnel
or duly authorized by SACMI S Engineering Dept.
SACMI shall not be held responsible for damages deriving from the use of non-original spare parts.
E0004P
ATTENTION!
The machine operator or maintenance staff are not responsible for carrying out operations under warranty, special
maintenance and repairs. These operations are to be performed only by the manufacturers specially trained
technicians. For this reason, these operations are not dealt with in this manual.
1.6 SUPPLEMENTS
Information regarding the electric and electronic components of the machine is given in four handbooks provided under
separate cover, entitled:
- USE OF THE MICROPROCESSOR CONTROL SYSTEM (Instructions B manual)
- DESCRIPTION OF THE ELECTRONIC CARDS
- LIST OF DEVICES
These handbooks are supplied with this manual.
1.7 LEGEND OF THE SAFETY SYMBOLS USED ON THE MACHINE AND/OR IN THE
MANUAL
DANGER SYMBOLS
E0004
General hazard
E0002
Danger of being burnt on hot surfaces
E0003
Danger of hands being crushed
E0007
High tension. Risk of electrical shock
E0011
Risk of entanglement, amputation

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GENERAL INFORMATION 1
E0010
Risk of entanglement in moving parts
E0017
Risk of falling
E0035P
Risk of explosion
E0015 Keep a safe distance away
WARNING SIGNS
E0001
Do not lubricate or work on moving parts under any circumstances
E0034D
O2
Do not use oxygen to recharge the accumulators
ALERT SYMBOLS
E0005
Always wear heavy duty work gloves
E0006
Machine must be connected to an effectively grounded power point

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1 GENERAL INFORMATION
1.8 MACHINE IDENTIFICATION PLATE
T2927

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MACHINE FEATURES 2
2MACHINE FEATURES
2.1 MACHINE DESCRIPTION
The CCM series of hydraulic presses is specially designed to produce thermoplastic products by means of
compression.
A continuous work-cycle is carried out during which plastic material is fed from an extruder, cut into suitably gauged
pellets and then inserted inside the dies. A hydraulic system is employed to close the dies at a pressure that can be
regulated while the production cycle is being performed. The time required for cooling down is strictly related to the
speed at which the forming unit runs.
The machine basically consists of the following parts:
-Unit for plasticizing and extruding the material
-Unit for inserting the plastic pellets
-Forming unit
-Electrical cabinet with control system for the production cycle
-Pneumatic system
-Hydraulic system
-Temperature control system

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2 MACHINE FEATURES
1281059
Figure 2.1 - OVERALL VIEW
1
7
14
6
41311 3 2
1Extruder
2Metering pump
3Feed tube
4By-pass system
5Drive unit
6Insertion drum
7Forming unit
8Pneumatic system
9Hydraulic system
10 Cooling system
11 Electrical cabinet
12 Tooling
13 Control panel
14 Exit channel
T2928
T2929

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MACHINE FEATURES 2
2.1.1 MAIN DEVICES
2.1.1.1 Plasticization unit
The function of this unit is to melt down the plastic compound and then push it out through the nozzles. The temperature
and flow rate of these operations are controlled. The unit includes an extruder (1), metering pump (2), a heated feed
tube (3) and a by-pass system (4).
In order to compensate for any thermal expansion and to allow maintenance to be carried out the unit is mounted on
tracks.
According to how they are installed the tracks may allow the extruder to be removed lengthwise or crosswise.
The machine may be equipped with various extrusion devices, depending on the flow rate required for the plastic
material.
Figure 2.1.1.1 - PLASTICIZATION UNIT
1Extruder
2Metering pump
3Feed tube
4By-pass system
1
3
4
2
T2930

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2 MACHINE FEATURES
Extruder
The extruder melts down the plastic compound and homogenizes it with any colorings and lubricants that may have
been added.
The granular material is let in through a hopper (1) and is pushed into the cylinder (2) by the auger (3) through the
various thermal conditioning zones. The auger is driven by a geared motor (4) or by a hydraulic motor. The zones are
supplied with heating elements and electric cooling fans. The temperature in each individual zone is measured by
thermocouples provided for this purpose.
Figure 2.1.1.1/A - 50 kg/h EXTRUDER
1Hopper
2Cylinder
3Auger
4Extruder gearbox
T1701
2
1
3
4
T1701

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MACHINE FEATURES 2
Figure 2.1.1.1/B - 100 kg/h EXTRUDER
1Hopper
2Cylinder
3Auger
4Extruder gearbox
T1544
2
1
3
4
T1544

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2 MACHINE FEATURES
T1702
Figure 2.1.1.1/C - 150/200 kg/h EXTRUDER
1Hopper
2Cylinder
3Auger
4Hydraulic motor
5Motor-pump unit
6Tank
1
3
4
2
6
5
T1702