Process Control Corp.

United States

The GF Series grinders from Process Control Corporation are used as part of an asr Automatic Scrap Recycling system for in-line recycling of production film scrap. GF Series grinders are designed to provide efficient, uniform grinding of film scrap. There are four cutting chamber sizes available along with different horsepower motors to accurately match the grinder to the required scrap rate. The GF Series grinders are available in configurations that accept edge and bleed trims, roll scrap, and loose scrap. Standard carbide-coated knives are employed in the system, increasing the time between sharpening. The rotor knives approach the stationary bed knife, or knives, at a steep angle to ensure a clean scissors-cut. This technique is used for maximum bulk-density and flow of ground scrap. The open rotor design improves airflow for cooling , permitting the highest possible throughput. After the cutting chamber, material passes through a sizing screen that is chosen specifically for the application and material. The ground scrap is pulled through the grinder screen and carried through the process by the scrap conveying fan standard on each GF Series grinder. Reintroduction of roll scrap is achieved with the attachment of an optional RN Series roll feeder. The roll feeder has knurled rolls that provide a strong pull on the film, without wrapping. They are available in several sizes with variable speed DC motors that run at 3 - 32 fpm (1 - 10 mmin). The control panel for the grinders includes a motor starter for the grinder. When purchased as part of a complete asr system, the control panel includes controls for the inducers and roll feeder, as well. Standard FeaturesODP motor with 4-sided belt guard (TEFC motor on GFB)Open rotor cutting chamber with outboard bearings2 HP scrap conveying fan (5 HP on GFD)Mild steel constructionCarbide-coated knivesRemote-mount control panelElectricals: Power requirements 460V3PH60Hz

The GFA with Air Bypass is designed to handle edge andor bleed trims only. This design utilizes a 5 HP fluff conveying fan for both inducing the trims into the grinder cutting chamber and for blowing the ground fluff out of the grinder. There is no need for a separate trim removal inducer or air eliminator. The second version is for handling both trims and off-spec roll scrap. This design does require a separate inducer, eliminator and roll feeder and utilizes a 2 HP fluff conveying fan to blow the ground scrap. Both versions are designed with a single stationary knife and (2) rotating knives.

Designed for use as part of the Gravitrol system, the HGB Series Weigh Hopper incorporates engineering and design breakthroughs to help achieve the optimal result in extrusion: a uniform product within tolerance at the lowest possible manufacturing cost. The Gravitrol system gives you total control over your mono-extrusion or coextrusion processes. The system can be configured to control extruder rate by weight; layer percentages by weight; weight of extrudate by length; average thickness; and pipe or tube diameter. The HGB Series Weigh Hopper is a central part of this system because it precisely monitors the amount of material consumed by the extruder. In effect, the extruder becomes a gravimetric metering device. PCC's HGB mounts directly on the throat of your extruder, requiring no additional support. Standard hopper sizes control an extruder throughput at rates from 10 to 10, 000 PPH. Higher-rate hoppers are available on special order. The HGB Series' clear polycarbonate inspectionclean out door or sight glass allows visual inspection of hopper contents. Each hopper has a PCC-designed and built Weigh Module which connects to the load cell and precisely measures the extruder's material consumption. This information is digitized on the hopper for fast, error-free and noise-immune communications with the central Gravitrol computer. Four-point overload protection on the hopper protects the weighing system from damage due to accidental contact. Standard FeaturesIntegral loader support platformClear polycarbonate inspectioncleanout door (on 2.3 cu. ft. models and larger)Inspection sightglass on 0.3 cu. ft. and 0.6 cu. ft. modelsButterfly drain valve (on 2.3 cu. ft. models and larger)High-resolution DSP weighing systemIntegrates with a complete Gravitrol extrusion control system for precise, consistent throughput controlMild steel construction

Designed for use as part of the Gravitrol system, the HG Series 2 Weigh Hopper incorporates engineering and design breakthroughs to help achieve the optimal result in extrusion: a uniform product within tolerance at the lowest possible manufacturing cost. The Gravitrol system gives you total control over your monoextrusion or coextrusion processes. The system can be configured to control extruder rate by weight; layer percentages by weight; weight of extrudate by length; average thickness; and pipe or tube diameter. The HG Series 2 Weigh Hopper is a central part of this system because it precisely monitors the amount of material consumed by the extruder. In effect, the extruder becomes a gravimetric metering device. PCCs HG2 mounts directly on the throat of your extruder, requiring no additional support. Standard hopper sizes control an extruder throughput at rates from 10 to 10, 000 PPH. Higher-rate hoppers are available on special order. The HG Series 2s clear poly carbonate inspectionclean out door or sight glass allows visual inspection of hopper contents. Each hopper is equipped with a touch screen PLC which connects to the load cell and precisely measures the extruders material consumption. This information is digitized on the hopper for fast, error-free and noise-immune communications with the central Gravitrol computer. Four-point overload protection on the hopper protects the weighing system from damage due to accidental contact. Standard FeaturesIntegral loader support platformClear polycarbonate inspectioncleanout door (on 2.3 cu. ft. models and larger)Inspection sightglass (on 0.3 cu. ft. and 0.6 cu. ft. modelsButterfly drain valve (on 2.3 cu. ft. models and larger)Color touch screen controlIntegrates with a complete Gravitrol extrusion control system for precise, consistent throughput controlMild steel construction

Process Control's IN Series Inducers are designed to pick up and convey edge andor bleed trims generated in the production of plastic film or other thin-gauge products such as foam, tape, paper or foil. These continuous trims are picked up by suction, conveyed into the inducer's venturi section and blown to a destination such as a Process Control film grinder or a waste container. Process Control inducer manifolds are designed to insure that the air velocity at the pickup point is maintained so that trims do not wrap around the cutters. The IN Series inducers feature an adjustable venturi to allow you to tune the inducer for peak performance with your installation. IN Series inducers have a higher induced air to primary air ratio than conventional trim removal systems, providing excellent pickup and conveying performance. IN Series inducers are designed to adapt easily to the installation requirements of your extrusion lines. The unit is shipped with its fan in a top- horizontal arrangement, but can be easily rotated in 90 increments to provide the required fanventuri orientation. The fan may also be mounted remotely from the venturi using additional tubing. Standard Features5 - 20 HP AC, TEFC motorsPower Requirements: 4603PH60HzElectricals: Starter and controls are normally included in a PCC Grinder control panel when purchased as part of a complete asr (Automatic Scrap Recycling system), or can be supplied in a separate standalone panel.Silencer on the fan inletMild steel constructionHigh gloss epoxy paint in PCC standard color

PROCESS CONTROL "X" Series blenders can be equipped with extrusion control software to allow the blender to control the extruder and line speed on mono extrusion lines for consistent output by weight. The only additional hardware needed is an EXD extruder drive control module and, if line speed is to be controlled, an EXL line speed control module. Gravitrol extrusion control offers the benefits of improved product quality, reduced material usage, quicker startups and product changeovers, reduced scrap, and improved product repeatability. At the same time, it reduces the operator's workload by maintaining a consistent output, regardless of screen pack or material variations. The system uses Process Control's proven Gravitrol software to automate the control of the line and hold the extruder output to 0.5% by weight. This tight control of output means that product can be made consistently within tolerance at the lowest possible cost. Process Control "X" Series blenders monitor the extruder usage in order to follow the extruder rate and insure a consistent supply of material. In an extrusion control system, this extruder rate is used to adjust the screw speed by minute amounts to hold the overall throughput to the value entered in the blender operator station. Because the blender already has a powerful computer and equipment necessary to measure the extruder rate, adding extrusion control on a mono extrusion line with a Process Control "X" Series blender is a very cost-effective addition. This feature can be easily retrofitted to existing installations with "X" Series or "B" Series blenders. "X" Series blenders can also be easily integrated into coextrusion applications with extrusion control for controlling product layer ratios and total line throughput. On coextrusion applications the blender computer reports to a master EXB central Gravitrol computer, which also receives weight throughput reading from HG Weigh Hoppers mounted on single-component extruders.

The X Series 2 Gravimetric Continuous Blender offers unsurpassed blend accuracy and blend homogeneity in a wide range of configurations to meet the needs of any application. For extruder throat-mounted applications, the X Series 2 Blender comes equipped with an integral down-comer to preserve the blended material all the way to the extruder without demixing. For mezzanine or off-line mounting, the blender does not include the down-comer and is designed to work with a number of different options for storing the blended material prior to its use. The operator enters the desired blend recipe at the operator station. All ingredients are simultaneously metered in the correct blend ratios by inclined augers from individual weighed material hoppers. The ingredients flow through a cascade chamber which produces the best blend homogeneity.

The XU Series 2 Continuous Gravimetric Powder Blender offers unsurpassed blend accuracy and blend homogeneity in a wide range of configurations to meet the needs of any application by incorporating the PF Series powder feeders. It allows gravimetric blending of non-free-flowing powder materials with free-flowing powder and pellet materials at unprecedented metering and mixing accuracy.The powder feeders allow rates as low as 0.2 PPH and as high as 6, 000 PPH. Metering augers are available in full pitch or 12 pitch configurations with helix diameters from 14 inch to 2-14 inches.The drive system of all blender components utilizes a motor drive with a brushless DC gearmotor and encoder for accurate motor speed feedback. This allows each of the individual feeders to maintain a constant RPM and weight throughput.The weighing system is designed with DSP (digital signal processing) technology (patent pending) to filter out unwanted noise and vibration which can wreak havoc with any feeding system, especially at very low feed rates.Incorporated into the electro-polished stainless steel design is a patented round-to-trough feeding area which provides more consistent mass flow for better metering accuracy. The feeder is designed with a steep wall, removable hopper which features a dust-tight band clamp for easy mounting of hopper extensions and quick disassembly for clean out. The bottom trough design is optimized to provide maximum material exposure to the auger.The XU Series 2 Continuous Powder Blender is also available in food grade stainless steel.The operator enters the desired blend recipe at the operator station. All ingredients are simultaneously metered in the correct blend ratios by augers from individual weighed PF Series powder feeders. The ingredients then flow through a cascade chamber which produces the best blend homogeneity.Standard FeaturesAll mechanical components are disassembled from the drive end, without the uses of tools.Communication protocols supported include: EtherNetIP, Allen Bradley [dh+], CCM, Siemens, Modbus TCP and ModbusExtended, as well as proprietary EPCC and ASCII4 or 6 element frames for mounting a variety of feeder optionsMechanical FeaturesIndividual weighed ingredient hoppers with easy-to-use drainsInterchangeable metering units with quick disconnectBrushless DC gearmotors with drive control and closed-loop speed regulationIntegral loading platform for mounting surge binsvacuum receiversDesigned for easy cleanout and quick changeover, no tools requiredStainless steel construction, food grade optionalStandard 4 and 6 element universal framesControl FeaturesBlender monitors weight loss of each ingredient hopper for precise control of blend ratiosWeighing system resolution is 1:1, 000, 000 for maximum accuracyColor touch screen dispaly for easy viewing of inventory and performance dataStorage for 400 blend recipes in battery-backed memoryMultiple alarm levels with visual display and contact closuresOptionsPelletRegrind elementGravimetric Extrusion ControlSteep-wall surge bins with knife gates for feeder loadingHigh temperature designFDA stainless steelPower115V1PH60Hz or 230V1Ph50HzThe XU Series: designed to produce precise, homogeneous powder blends by weight

The Guardian Series 2 gravimetric batch blender was developed for processors who want the simplicity of operation combined with the most accurate dispensing and superior blend homogeneity at a low cost. For these customers, Process Control designed the Guardian Series 2. The blenders in the 2.5kg Guardian 2 family have been made with redesigned material hoppers to hold each of the ingredients. The 2.5kg can be supplied with up to six separate ingredient hoppers as standard. Both of the designs come equipped with a fast acting V-gate valve for the material hoppers. Each of the materials is dispensed sequentially into a common weighing hopper in the desired proportions. The weighed materials are then released into a separate mixing chamber which provides the most consistent homogeneous blend of any batch type blender. Process Control engineers have developed a highly advanced dispensing and weighing system that accurately controls each ingredient of every batch to the desired amounts and is not averaged over multiple batches as is common in other batch blenders in the industry. At the blenders highest setting, each ingredient can be dispensed to an accuracy of +- 0.02%. In addition to precise batch-to-batch dispensing, the performance of the mixer is just as critical to the end product. The mixer actually determines how uniform the blend will be. Inadequate mixing can lead to inconsistent product characteristics such as color variations or other imperfections. The Guardian Series 2 blenders have incorporated a built in clean-out system in the design. With a pull-out drain chute and separate manual slide-gate controls, the blender can be cleaned out quickly and easily during product changeovers.

The RMX Series Refeed Machine is part of a complete asr Automatic Scrap Recycling System for recycling scrap generated on a film extrusion line. The RMX Series is specifically designed for use with Gravitrol Gravimetric Extrusion Control Systems. The compact size also makes the RMX Series suitable for applications with headroom restrictions without sacrificing the performance that has made the asr Refeed Machine popular for film applications. The unique, double-compartment RMX Series Refeed Machine operates with a variable-speed augerbridge-breaker assembly to compact and meter ground scrap from the inner hopper to the throat of the production extruder. The outer compartment contains virgin material which is gravity-fed to the throat. The virgin material completely surrounds the ground scrap as it enters the extruder. The extruder screw receives a consistent column of compacted ground scrap surrounded by virgin material. This method provides consistent operation without extruder surging or starvation. With the standard extruder follower circuit, refeed machine will increase or decrease the scrap rate in proportion to the extruder speed. This holds scrap percentage constant without additional operator attention. Standard SpecificationsDrive System: DC Motor flanged to hollow-shaft gear box drives the single rotating member used to compact and refeed scrap. An SCR speed control includes adjustable torque limit, extruder screw following and signal isolation circuits. StartStop buttons, load meter and tachometer are mounted and wired in a NEMA-12 enclosure, 15" x 15" for remote mounting and wiring by others. Electricals: Power requirements-230 volt, single phase for drive; 115 volt, single phase for controls. A ground scrap high level switch interfaces with scrap grinder. Materials of Construction: Mild steel. Paint: High-gloss epoxy of PCC standard color. Options Isolation transformer for use with non-230 volt, single phase systemsAdditive feedersTrim Removal InducersFilm Scrap GrindersHigh Efficiency CycloneCyclone Filter AssemblyAC DriveThe RMX Series: for use with asr and Gravitrol systems to recycle edge andor bleed trims, tape, roll scrap and loose scrap, individually or simultaneously