Group photo taken on the day of inauguration, from left to right: Kathrin Portugall, Deputy Production Manager AF-COLOR; Heiko Hornberger, Operations Manager FEDDEM; Thomas Korn, Production Manager AF-COLOR; Michael Mertens, Technical Manager AF-COLOR; Dieter Groß, Managing Director FEDDEM; Dirk Steinbrück, Managing Director AF-COLOR, branch of AKRO-PLASTIC GmbH
As part of a joint project between AF-COLOR, branch of AKRO-PLASTIC GmbH and specialist for masterbatches and mechanical engineering company FEDDEM, both companies of the Feddersen Group, the FED 26 MTS extruder has been successfully handed over and commissioned. The machine is the result of a targeted adaptation project in which key features of the FED 18 MTS laboratory extruder were transferred to the FED 26 MTS extruder.
With this investment, AF-COLOR is expanding its development capacities for additive concentrates within the AF-Complex® product family as well as for colour masterbatches in the AF-Color® range. At the same time, flexibility and capacity for small-scale production runs are being further enhanced.
“It was important for us to implement a solution that not only accelerates our development work but also facilitates transfer into production. This is precisely where the close coordination within the project team proved its value.
The entire workflow was analysed, enabling many potential challenges to be identified and resolved at the concept stage,” explains Kathrin Portugall, Deputy Production Manager at AF-COLOR.
Technical enhancements and customised solutions
Numerous functional modifications were implemented as part of the project.
According to the companies, converting the FSB side feeders from a swivel arm to a movable slide mechanism, results in significantly simplified handling, thereby reducing the effort required for changeover processes. The installation of quick-release fasteners and handles, together with improved mobility on guide rails, enables all work on the FSB side feeders and the FSV side vacuum degassing unit to be carried out from the operator side of the extruder.
At AF-COLOR’s request, the FSB side feeder in the smaller size 26 was designed with a cooling function for the first time. This ensures low-melting materials to be fed reliably without agglomeration or blockage at the feed inlet – a decisive advantage, particularly for sensitive additive systems.
In addition, the extruder height was adjusted to fit optimally beneath the new working platform installed at AF-COLOR. This bespoke modification ensures ideal utilisation of the available space (see Image B).
The new line offers extensive flexibility and is therefore ideally suited to AF-COLOR’s broad product portfolio. Straightforward conversion measures allow for a rapid change between 32 L/D and 42 L/D configurations, as well as between strand and underwater pelletising.
Upgrade of an existing production line
At the same time as the FED 26 MTS was delivered, the existing production line from the FED 43 MTS model series was overhauled. The line was equipped with similar technical capabilities to the new FED 26 MTS, including FSB side feeders, FSV side vacuum degassing, variable process length, and the option to switch between strand and underwater pelletising. This ensures process comparability and transferability to the existing FED 43 MTS production line.
In future, this line will be used for the commercial production of sophisticated additive masterbatches from the AF-Complex® portfolio.
Fully leveraging synergies
Regular coordination meetings were held between the AF-COLOR project team and the FEDDEM team throughout the entire project. The collaboration was characterised by openness, technical exchange and a shared understanding of requirements and solutions.
“The project clearly demonstrates what can be achieved when development, engineering and practical application are closely aligned. The collaborative partnership with AF-COLOR was the key success factor,” adds Heiko Hornberger, Operations Manager at FEDDEM.
During the handover ceremony, the two Managing Directors, Dieter Groß (FEDDEM) and Dirk Steinbrück (AF-COLOR, branch of AKRO-PLASTIC GmbH), expressed their special thanks to all colleagues whose commitment and expertise contributed to the successful completion of this synergy project.
Looking ahead to day-to-day production operations, AF-COLOR anticipates the successful utilisation of the new and modernised lines and values FEDDEM’s technical expertise as reliable support for future challenges.