Integrated Process Control Systems Extrol · Precise Gauge Control Extrol constantly monitors average thickness and/or thickness profile utilizing infrared, Beta, Gamma or capacitance

ExtrolIntegrated Process Control Systems

Tradition of Excellence

EXTROL®

Extrusion Specific Process Control

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The Battenfeld GloucesterExtrol® 6000 Series wasdesigned from the verybeginning as a process control system specificallyfor extrusion. It has beenrefined and optimized byengineers who have a deep understanding of theextrusion process and therelationship of different variables to the quality of thefinished film, sheet or shape.

Microcomputer based, theExtrol system gives youdirect digital control ofevery phase of the extru-sion processing line fromresin loading and melting to finished product, all atone central station that has been designed for easy operator interface. Itconstantly monitors thou-sands of process variablesand reports both absolutevalues and trends in easy toread, highly understandablegraphic form.

Used to control hundreds ofextrusion lines around theworld, the Extrol system isso successful because of its

unique concept. Based onthe most advanced computerhardware available, itincludes a powerful 32-bitoperating system capable of running equally powerfulsoftware programs. But thereal key to its success is the fact that these softwareprograms were createdspecifically to control extrusion processes. What’smore, the system’s controllogic, algorithms, displaysand reports have been created by Gloucester engineers with years of experience and expertise in:

• Blown film

• Cast film

• Rigid sheet

• Foam sheet

• Coating & laminating

• Profile extrusion

Diagnostics

Complete Control of Process Functions

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The Extrol system controlsall process functions fromthe beginning to the end ofthe production line, including:

• Resin loading

• Materials blending

• Gravimetric/volumetricfeeding

• Resin melting

• Extrusion pressure & temperature

• Film or sheet gauge

• Flat or round die profiling

• Web cooling

• Hauloff

• Auxiliary Equipment

But the Extrol system is not only ready to begin controlling your processfrom the moment your production line is installed.It’s also very easy to customize it to fit your operating conditions and

procedures. You can setparameters, limits andalarms simply by pushing a few buttons, and onlinemonitoring is equally easy.

More than just a processcontroller, Extrol is a complete management information system as well.The system automaticallyprovides managementreports, audit trails, SPC statistics, and a wealth ofother valuable information.

Hundreds of satisfied Extrolsystem users have realizedincreased uptime, sustainedmaximum throughput, con-sistently higher quality andminimum operator interven-tion. These benefits flowdirectly to your bottom lineand immediately increaseyour profitability.

Extrol 6032 Microcomputer Control System

A Powerful, Yet User Friendly System

Reliable Hardware

The Extrol control system is designed for maximumoperator convenience. User-defined system parametersare clearly displayed as easyto understand color graphicson a high-resolution monitor.A logical, easy to use colorcoded function keyboardmakes setup and monitoringfast and easy, eliminating

time consuming menusearches.

Programming can be easilycustomized to meet therequirements of yourprocess and procedures. Allmodifications are thoroughlytested by trained Gloucestertechnicians before the system goes online.

The Extrol System incorpo-rates the most advancedhardware available, including:

• The Motorola 68020 (32 bit) for the Extrol6032 and 68000 (16 bit)for the Extrol 6016P.These powerful proces-sors provide excellent reliability at high operating speeds.

• One megabyte of DRAMmemory (512K for6016P) for virtuallyunlimited processingpower.

• EEPROM memory for storage of productrecipes and tuning parameters.

The entire system featuresrugged construction for continuous use indemanding production environments.

A Complete ManagementInformation System

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The Extrol 6000 Series notonly provides informationrequired by the operator,but also generates reportsthat help managementmake better informed decisions. And it presentsthis information in the formof visual color graphics thatare easy to recognize andunderstand. For example:

• Up to three variables canbe tracked and displayedsimultaneously as multi-colored trend plots, withSPC data plotted as anX-bar graph alongside.

• Trends, alarms, eventsand operator parametersare not only recorded,but also identified as tothe time and the point ofthe operation at whichthey occurred.

• Product and shift reportson variables such asmaterial and energy con-sumption, quantities ofacceptable product versus scrap, percentageof downtime, and averagedrive speed can all begenerated on command.

• Product recipes and tuning parameters arestored in reliable, non-volatile EEPROM memory.

Alarm and Event

Constant, True Controlof All Process Functions

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Because the slightest changein a process variable in onesection of the production linecan instantly affect other sections of the line and ultimately the quality of theproduct, it is imperative thata single system monitor andcontrol the entire productionprocess. The Extrol systemis designed to do exactlythis, resulting in increasedthroughput and tighter conformity to specifications.

Gravimetric Feeding and BlendingThe Extrol system preciselycontrols both the output ofthe gravimetric hoppers andthe speed of the screw tomaintain uniform thicknessand accurate layer-to-layerratios. It also controlsIntegrated GravimetricBlending by monitoringeither loss-in-weight, batchweight/mix, or feed throatblend systems to ensureaccurate formulations andresin inventory control.

Gravimetric Blending

From a single control stationon the production floor, theoperator commands:

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Precise Gauge ControlExtrol constantlymonitors averagethickness and/orthickness profile utilizing infrared,Beta, Gamma or capacitancegauges.

Temperature ControlTrue set point control of allheating and cooling zonesfor extruders, dies,adapters, meltpumps and coolingrolls is achievedthrough the use ofpreprogrammed non-linear PID controlalgorithms. Thisallows the Extroloperator to expertlymanage the entireprocess by using indepen-dent temperature tuningparameters.

Drive ControlThe Extrol system regulatesthe output of an extruderwith gravimetric feedby VolumetricControl, setting thespeed of the screwat a constant RPM.When a melt pump is used, a pressurefeedback loop controls output. Forcoextrusion applica-tions, Tandem SpeedControl synchronizesextruder ramp up rates tomaintain product uniformityand reduce scrap.

Extrol works in conjunctionwith Gloucester’sAutoprofile™ Air Ring inblown film applications toautomatically ensure gaugeconsistency forimproved yieldsand reducedscrap. In blownfilm as well ascast film, sheet, orextrusion coating/laminating applica-tions, the Extrolsystem automati-cally controls average sheet and film thickness by constantly regulating either extruderoutput or line speed.

The Extrol system controlstransverse gaugeby regulating diebolt operationswith no additionalcomputer required.Full profile displaysas well as compos-ite roll and distribu-tion curves areincluded in roll orbatch reports.

Isometric Plot

Polar Plot

Gauge Plot

Temperature Set Point and Data

Speed/Temperature/Amp Page with Gravimetrics

Useful Management Reports

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The Extrol system includesa host of managementreports that provide usefulinformation such as:

• Product and ShiftReports

• Trend Charts andNumerical Data

• Alarm and Event Audits

• Statistical Process Control (SPC) Data

• Storage of MaterialRecipes and TuningParameters

• Interactive Link toPersonal Computer

• Electronic MailCommunication

With Extrol, managementhas the constantly updatedsupport and documentationneeded to validate the manufacturing process as required by regulatoryagencies such as GMP, FDAor ISO 9000.

SPC Data

Trend Analysis

Shift to Shift Consistency

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Several features of theExtrol system are designedto assure shift to shift production consistency. For instance:

• Self-calibrating diagnosticscontinually troubleshootthe computer system tocorrect problems beforethey occur.

• Automatic orderly startupand shutdown proceduresprotect the process, thesystem and the operator.

• An audible and visualalarm network alerts theoperator immediately toany variance in pre-pro-grammed system operation variables.

• High/low deviation and safety alarms areprovided for all controlzones, including:• Temperature

control zones• Drives• Amps and pressure

control zones• Gauge control• Feeding and

blending control Shift Report

Production Report

Extrol 6032Control System

CPU (Central Processing Unit)

ServoReference

Digital OutputGauge Control

FunctionsEncoder

Input Pos.

Gauge DriverBoard

EEPROMMemory Board

(Recipes & Setup Parameters)

RS232Communication Board

High ResolutionGraphics Controller

Board

Isolated Inputs

Digital Input Board

Drive – Start/Stop

Alarm Inputs

Process Inputs

Analog Input

Thickness Gauge(Linear or Non-Linear)

Signal Conditioner

Linear Signals(Drive, Amps, Etc.)

Strain GaugeTransducers

Thermocouple

IsolationDevice

Frequency InputBoard

Digital OutputBoard

Analog OutputBoard

Elec. Pot.

Drive Reference

Optically IsolatedElectronic Relays

Heater Device Cooling Device

Blending Drive Ref.

Process Setpoints

Motorola68020-32 Bit

Microprocessor

To Remote I/O

CPU(Central Processing Unit)

Fiber Optic Converter

Digital PulseGenerator/Encoder Etc.

Gloucester I/O Bus(Interface Card)

High Resolution Monitor (CRT)

IBM-PC

Printer

256 KProgram Memory

1MbyteRAM

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Battenfeld Gloucester Engineering

Outstanding Service and Superior Support

• Fully inclusive process consultation

• Comprehensive engineering services

• Use of Gloucester’s dedicated TechnicalCenter for material and equipment testing

• Gloucester’s worldwidenetwork of skilled, knowledgeable serviceengineers

• Our extensive inventory of parts and supplies

Battenfeld GloucesterEngineering provides thetools and the technology for completed integratedextrusion and control systems. We serve as a

single source for requiredtechnical expertise, engineer-ing and process knowledgethat always delivers the endproduct. Support includes:

From its headquarters inGloucester, Massachusetts,USA, Battenfeld GloucesterEngineering is a worldwideleader in extrusion basedplastics production systems. In addition to integrated microcomputercontrol systems, Gloucestersupplies production lines,including tandem foam,blown film, cast film, rigidsheet, extrusion coating,bag making and reclaimprocessing.

A member of the BattenfeldGroup, a leading worldwidesupplier of plastics processing systems,Gloucester has led in thedevelopment, engineering,manufacture and support of individual productioncomponents and completeextrusion lines since 1961.

Total production facilities ofalmost 360,000 squarefeet include CAD/CAM/CAEand CNC equipment for precision manufacturing ofcomponents such as extrusion screws and dies.Complete integration ofdesign and engineeringenable BattenfeldGloucester to stay at the forefront of the latest technologies.

Battenfeld Gloucester • USA

Battenfeld Gloucester Europe • UK

Battenfeld Gloucester Engineering Co., Inc.Blackburn Industrial Park/Post Office Box 900Gloucester, Massachusetts 01931-0900 USA

Tel: 978-281-1800 Fax: 978-282-9111 www.bge.battenfeld.comSMS Plastics Technology

Tradition of Excellence