Nordson PPS Has More Than 110 Years of Combined Experience in Polymer Processing

An interview with Mr. Pratik Khanna, Sales Manager of Nordson

How did Nordson PPS become the global leader in plastic processing technology?

Nordson PPS has more than 110 years of combined experience in polymer processing. We use this knowledge to help optimize our customers' overall melt stream processes, increase their productivity, reduce costs, and enhance overall product quality. Nordson uniquely understands all of the components in the melt stream, from the pump for building pressure to the flat extrusion or coating die.

Nordson believes that innovation is critical to support our customers in an ever-changing world and adapt to their technical needs to get the best results possible. With sales organizations in 30 countries, Nordson supports our customers long after a sale is complete, whether by providing ongoing technical services or recommending the best products to optimize the melt stream process and reduce costs.

 

Why is a gear pump so crucial for the process, and what is the BKG® Pump PumpCon Economy Control?

Nordson offers a large selection of gear pumps, designed to optimize processes by offering a high degree of accuracy and constant volumetric output for a variety of applications. By eliminating throughput variations and pressure pulsations, BKG® gear pumps help improve product quality. They reduce stress on the extruder, help save energy, and increase the flexibility of a processing line.

The BKG® gear pump control PumpCon Economy is a compact solution for controlling and regulating a pump and the upstream extruder in an extrusion line. The software processes logical and technical signals to control functions of the extruder speed to maintain a constant melt pressure. We often implement them if a pump is added to a processing line so that the extruder control does not need to be adapted.

Pump controls ease up operation, and the operator needs to intervene less because the controls allow for the automatic starting and stopping process of the gear pump and extruder. The inlet and outlet pressure are monitored and the actual pump- and extruder speed are displayed.

 

How do Nordson PPS filtration systems help make plastics more sustainable?

There are many applications for plastics, but most of them have one thing in common – the need for a clean polymer, since contaminations always have a negative impact on the final product.

For more than 50 years, Nordson has provided customers with advanced technology for filtration systems and related products, offering optimal results and the highest production efficiency.

Nordson can provide engineered solutions that precisely fit the customer's needs, which has enabled Nordson to become the leading international supplier for filtration systems.

Nordson offers discontinuous systems for the quality filtration of virgin polymers and the protection of downstream equipment. The continuous screen changers can be used in direct extrusion processes, as well as compounding applications and raw material production.

The main application for our BKG® HiCon™ self-cleaning systems is recycling. These filters are designed for processes with high contamination levels and strong demand for pressure consistency. We can recycle many different materials and design our systems to meet our customers' needs and requirements. While the BKG® HiCon™ V-Type, a filtration system with power backflush technology, proved to be a state-of-the-art filter for PET recycling, the BKG® HiCon™ R-Type is a proven solution to process highly contaminated polyolefins.

With the BKG® FlexDisc™, we are taking recycling to the next level. The BKG® FlexDisc™ can be implemented into various filters, significantly enlarging the filtration area. The FlexDisc™ allows finer filtration and higher throughputs, helping our customers to reduce their operating costs and make their production more sustainable.

 

Why is a high-quality filtration medium so essential for the process?

The filtration medium is the heart of every filtration process, and high-quality screens guarantee the best results 

The Nordson Screen Pack is designed with all our knowledge of polymer processing. It is made of high-quality weaves combined to ensure the highest filtration efficiency, maximum stability, and unique structural strength. The screen pack and its layers are cleaned ultrasonically to protect the process from contamination.

 

How does a BKG® Jet Cleaner work?

The BKG® Jet Cleaner also helps our customers optimize their polymer processing lines. It removes all types of thermoplastic and thermoset compounds from metal parts safely and efficiently. It enables our customers to reuse components and equipment for a cost-efficient and sustainable operation.

Our Jet Cleaners make use of a principle that people may already know from their household - pyrolysis. With temperatures up to 540°C, polymer is decomposed and thus detaches from the components. The harmful substances are either washed out and separated or split off from the resulting volatile organic compounds and gases by a catalyst. They are easily installed and a great addition to every polymer processing line.

 

What are the advantages of Nordson PPS pelletizing systems?

Producing the perfect pellet is our aspiration when we design and configure our BKG® pelletizing systems. From small to high throughputs, we always strive to find the ideal solution for our customers no matter what material or application.

The heart and soul of our pelletizing systems are our die plates, and a great deal of process knowledge and precision goes into every design. We offer die plates in various diameters and heating options. The die plate holes are precisely drilled and provide the best conditions for a perfect process.

Our water systems transport the freshly cut pellets, separate them from the process water, and dry them for further use. Here we take material characteristics and process conditions into account to offer our customers the right fit. One of the standouts in our portfolio is the BKG® CrystallCut® system. It is mainly used for PET, virgin, and recycled materials, processing the polymer in a low-energy consuming method with exceptional results regarding the pellet quality.

Our pellet dryers can process various throughputs up to 25,000 kg/hr (55,000 lb/hr). Their modular design makes maintenance work easy, allowing quick color and product changes.

 

Why is coextrusion an essential element to polymer processing?

Packaging is a growing end market for the polymer processing industry. Our customers and the consumers call for innovative packaging solutions. The trend goes to consumer-friendly packaging, that offers more convenience and less weight. Sustainable packaging is in great demand. Films need to be thinner, made of cost-effective materials and compounds. EDI® coextrusion feedblock technology is designed to meet these demands.  Coextrusion allows for the combining of materials to create a finished product with unique properties. Whether our customers need to combine multiple layers, encapsulate a product, or enhance the strength or flexibility of a material by combining it with something else, coextrusion is an essential element to polymer processing, and we can help finding the right equipment for every production line.

Coextrusion technology has evolved dramatically in the last few years — with Nordson leading the way. Our EDI® multi-layer dies and coextrusion feedblocks are designed for dedicated structures, optimal layering sequences, the creation of flexible packaging, and more. By utilizing coextrusion technology, processors are able to increase the speed of their process, reduce downtime for maintenance and cleaning, plus provide a precise and uniform final product.

 

Why are Slot Coating Systems so efficient?

The expectations of an efficient coating process are high, especially for products used in the production of batteries and optical displays (mobile phones, TVs, etc.). Increased speed and thinner coatings are requirements of our customers.   Nordson's Premier™ and Ultracoat™ slot die systems are designed to efficiently dispense singular or multiple thin and uniform coatings in one pass. We also offer positioners to accurately place slot dies at the optimum angle, reducing the amount of fluid required and therefore, operational costs.

Nordson custom engineers all coating equipment for each converter's specific fluid and processing parameters. Proprietary design software is used to adapt the slot die's flow channel to ensure all fluids are uniformly distributed onto the substrate within the required thickness tolerance. This results in minimal material usage, saving fluid, and overall operational costs.

Nordson slot dies, die positioning stations, and fluid delivery systems operate in a "closed-loop" set-up, providing the ultimate defense against contamination and volatiles in the coating process. This method also creates a smaller ecological footprint by enabling excess fluid to be reused for future production.

 

What Spare Parts services do you offer?

Nordson Polymer Processing Systems offers a comprehensive spare parts selection.

Our customers can avoid costly shutdowns by relying upon us to supply them with original spare parts for their polymer processing lines. They can order spare parts directly from us and with direct access to engineering records to provide them with the parts per the original specifications.

Our comprehensive inventory of spare parts allows for quick delivery of most parts. We offer spare parts for the following components: coextrusion feedblocks, extrusion and fluid coating dies, gear pumps, pelletizing systems, polymer valves, melt filters, and various auxiliary equipment.

 

How beneficial are the Aftermarket Services of Nordson Polymer Processing System?

As a global leader in high-performance machinery components and equipment for the plastics industry, we have powerful resources to help reduce costs and increase productivity in extrusion and other processes.

At Nordson PPS, we have a dedicated service team to help protect our customers' investment long after the sale with comprehensive aftermarket solutions. This translates into increased productivity, reduced operating costs, and enhanced product quality.

We offer operation and maintenance training provided by our experienced technicians worldwide. Our customers can profit from our years of experience and knowledge of the complete process. We tailor each program to fit our customers' requirements. Training courses can be held at one of our technology centers or a customer’s facility. At our technology centers, customers can explore alternatives without the high raw material costs and loss of production time at their own facility.