Melt Filter, Adjustable Flat Die Make U.S. Debut

Making their U.S. debut at NPE2024, from Nordson Corp.’s Polymer Processing Systems (PPS) division, were the BKG HiCon K-SWE-HD/RS melt filter, which helps film and sheet producers use more recycled materials; and the EDI Prodigi automated lip adjustment system for EDI extrusion and fluid coating dies.

The BKG HiCon K-SWE-HD/RS filtration system is based on Nordson’s backflush technology that permits the increased use of recycled material while maintaining process stability and end product quality.

To cope with the high process pressures, especially in blown film applications, the new melt filter is equipped with a patented melt-pressure controlled venting start that fully automates the filling of the screen cavity after a screen change for maximum pressure consistency. Additionally, the filling is done carefully so that no air entrapments endanger the process or the end product. Producers can rely on a stable process and greater quality of the film.

The new melt filter is designed to handle backflushing and venting clean in a maintenance-friendly way. The safety cover can be opened vertically, enabling the operator to reach the filter piston from all sides to facilitate cleaning.

In a highly successful development project, Nordson worked with RKW, a leading blown film producer in Echte, Germany, that focuses on using recycled content in its film packaging products. The new BKG HiCon K-SWE-HD/RS was provided to RKW as part of a user test and installed in a three-layer plant.

Nordson also showcased the new EDI Prodigi motorized lip actuator system, which it says takes extrusion and coating processes to another level by fully automating the lip gap adjustment — making it faster, safer and repeatable. This new patent-pending system achieves saving tolerances four times faster than conventional thermal bolt systems, supporting the processor’s need for increased sustainability.

Instead of using nonautomated, manually-intensive thermal bolts to control the lip adjustment, the Prodigi die relies on a series of motorized actuators connected to the die’s flexible lip. The installed actuators smoothly translate motor rotation into precise linear movement to locally open and close the lip. The system creates a process that is faster, safer and more energy efficient because it is completed away from the hot die, at a user interface.

Another benefit of the Prodigi system is its high energy efficiency because the motorized actuators operate at a significantly lower temperature than thermal bolts. While the thermal bolts need constant heat during a production run, the motorized lip actuator uses little to no power after achieving steady-state operation, reducing overall energy consumption and environmental impact. Projections show that under normal use the Prodigi actuator system would consume less than 1% of the electricity needed annually to operate a comparable thermal die bolt system.