Twin Screw Roller
TSR Configuration and Sizing Chart
The TSR-Twin Screw Roller Die
The structure of the Twin Screw Roller Die consists of two (2) portions or machines that work together and share a common base. These two machines or portions are an Extruder and a Calender.
The Extruder portion consists of a Hopper and Twin screws. The hopper is made of cast steel and is jacketed for water cooling. The inside of this hopper assembly is chrome plated as are the twin screws. These twin screws are made of cast steel and are bored for cooling. The screws are fully intermeshing at center for the entire length for better material flow. There is no mixing action taking place in the TSR as these are auger type screws. Each screw is supported by two (2) bearing housings and driven by a special gear reducer and a variable speed motor.
The Calender portion consists of two (2) Rolls that are cored for cooling and sit in a vertical position in their frames. The bottom roll is always in a stationary position and the top roll is adjusted by a gear motor. The roll gap between the top and bottom rolls are monitored by sensors. This roll gap is adjustable so that optimal sheet thickness may be obtained at all times and the rolls can be opened up to an 8" gap for cleaning purposes. Wheels are installed under the housings allowing the Calender to travel away from the Extruder portion for easier cleaning. There are load cells in each of the Calender housings to check the bank load pressure.
The basic operation of the TSR is material being introduced from above the hopper, usually from an Intensive Mixer. The large flights on the augers pull the material in and transfer it to the bank load area just behind the rolls and at the end of the augers. There are level detectors in the Hopper Chute area to detect the level of the material entering the TSR and allow the TSR to adjust its rate of production. As the bank is formed between the Calender rolls and the end of the auger screws, the Bank control system then synchronizes the Extrusion through put with the Calender output. When the bank pressure increases the screw speed is reduced and when the bank pressure decreases the screw speed is increased. A continuous high quality rubber sheet is then produced accordingly. The elimination of a 2-Roll mill under your Mixer can be done when using a Twin Screw Roller Die. Some of the benefits of using a TSR versus a 2-Roll Mill are:
A.) No operator is needed once the material is started through the cooling system from the Calender Rolls
B.) Safer than a 2-Roll Mill since you do not need an operator.
C.) Cleaner environment than the 2-Roll Mill.
D.) Better quality product due to less contamination.
E.) Higher output due to continuous operation.
F.) The TSR uses less energy than the 2-Roll Mill.
G.) Minimal heat generation because of a small compression zone on the screws.
H.) Easier clean-out because of 15 degree incline mounting results in the better flow of material.
I.) Less chance of rubber jams because pressure on the load bank is detected in two (2) areas.
Two load cells-High load and low load.
Photo eyes on Calender between rolls.
Options that are available on the TSR include the following:
A.) Temperature Control Units for cooling water.
B.) Drilled Rolls
C.) Powered Calender Travel.
D.) Brake for quick roll stop.
Maximum through-put from the Mixer
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Size of TSR
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W = W1 x 1.15 x 60 x 1
SG T 1000
W: Required through-put of TSR (ton/hr)
W1: Batch weight of the Mixer (kg)
SG: Specific Gravity of compound ( - )
T: Minimum cycle time including mixing time, charging time and discharging time (min.)See sizes chart: