KraussMaffei Technologies GmbH
With the flexible ZE BluePower and optimized process technology, KraussMaffei Extrusion offers a machine technology that processes formulations with halogen-free flame retardants in polyolefins – as an alternative to conventional cable formulations based on halogenated flame retardants. The specially configured extruder is used to produce high-quality HFFR compounds (HFFR – Halogen Free Flame Retardant) with ATH (ATH – aluminum (tri)hydroxide) contents of up to 65%. The ZE BluePower can also be adapted to various process tasks and formulations, giving
customers a high degree of flexibility to meet their individual requirements.
With the innovative ZE BluePower, KraussMaffei Extrusion offers an efficient complete solution for the production of high-quality HFFR cable compounds based on halogen-free flame retardants. The specially configured machine at
provides customers with an alternative to conventional cable compounds and is therefore ideally positioned to participate successfully in the fast-growing market for HFFR cable compounds.
In Europe, halogen-free flame retardants are increasingly being used as an alternative to halogenated flame retardants in cable compounds. HFFR cable compounds not only meet the requirements for good insulation with simultaneous fire resistance, but also comply with the more stringent Construction Products Regulation (CPR). For this reason, cables with a sheath made of HFFR compounds are particularly in demand for public buildings and in the transportation sector and are also attracting increasing interest worldwide.
Advantages of a wider process window during processing
With the innovative ZE BluePower extruder technology, KraussMaffei Extrusion now offers a solution with a number of advantages. The ZE BluePower can be flexibly adapted to different processing tasks and formulations, it is characterized by a gentle yet effective mixing effect and convinces with reasonable investment costs.
An optimized screw configuration, using the special Multi Process elements from KraussMaffei Extrusion, allows the compound to be processed even more gently. This results in a significant reduction in melt temperature. The flame retardant is processed more gently than in conventional screw geometries due to the increase in axial mixing. The axial mixing effect, i.e. the longitudinal mixing by the Multi Process elements, extends the process window which can be used to achieve higher filling levels and/or higher throughputs.
For compound manufacturers who want to participate in the growth market of HFFR cable compounds, the purchase of a specially configured ZE BluePower extruder is therefore very lucrative. With its Da/Di ratio of 1.65 and a torque density of 16 Nm/cm³, the series impresses with an optimum ratio of large free volume and high specific torque.
In combination with special Multi Process screw elements, the ZE BluePower ensures intensive mixing of the flame retardant at a low melt temperature, resulting in a melt temperature reduction of up to 30 Kelvin. Five sizes with screw diameters of 28 to 80 mm and output rates of 50 to 1,500 kg/h will be available for HFFR cable compounds in the future. Higher throughputs are possible on request. The process length can vary between 48 and 56L/D and depends on the MFI of the base polymer and the specific surfaces of the flame retardants used.
Development with ExxonMobil Signature Polymers and flame retardants from Huber Advanced Materials
For the development, the KraussMaffei extrusion team used a ZE BluePower with a length of 48L/D and processed a formulation with ExxonMobil Performance Polymers and an ATH-based flame retardant from Huber Advanced Materials. Various screw configurations and different ATH contents were tested. The results were clear: the ZE BluePower not only met the required mechanical properties, but even exceeded them. For the tests, the extruder was equipped with a twin-screw side unit (ZSA).
Bilal Ilhan explains: “Flame retardants can have a high specific surface area. The higher the specific surface area, the longer we select the process length of the extruder to ensure optimum mixing and therefore excellent mechanical and flame retardant properties. ” An underwater pelletizer has proven itself as a pelletizing unit for the reliable production of the compounds. The pressure-reduced die plates specially developed for highly filled formulations take into account the temperature and shear sensitivity of the HFFR compounds produced. The use of underwater pelletizing increases the stability of the pelletizing process.
Efficient complete solution from KraussMaffei Extrusion
With the innovative ZE BluePower, KraussMaffei Extrusion from Laatzen offers an efficient complete solution for the production of high-quality HFFR cable compounds based on halogen-free flame retardants. The specially configured machine provides customers with an optimum system setup to position themselves successfully in the fast-growing market for HFFR cable compounds.
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