- GENERAL EXTRUDER INFORMATION
- Model: 2C105 HTS 52D
- Manufacturing Year: 2013
- Type: Twin-screw, co-rotating
- Manufacturer: Costruzioni Meccaniche Luigi Bandera S.p.A.
- Application: Processing post-consumer PET bottle flakes into melt for sheet/film lines
- TECHNICAL SPECIFICATIONS (Extruder Machine Data)
Mechanical Parameters
| Parameter | Value |
| Screw diameter | 105 mm |
| L/D ratio | 52:1 |
| Screw material | Stainless steel XDBD |
| Barrel construction | 6 modular sections |
| Heating zones | 12 + 1 adapter |
| Degassing | 2 vacuum chimneys + 1 vent |
| Max extrusion pressure | 200 bar |
| Screw speed | 35–350 rpm (constant torque) |
| Torque | 2 × 6500 Nm |
| Motor power | 450 kW (limited to 400 kW) |
Thermal & Cooling System
- Barrel heated by electrical resistances
- Barrel cooled by diathermic oil circulation
- Thermocouples and electronic temperature control
- Full safety guarding over heated surfaces
Drive & Gearbox
- Heavy-duty welded steel baseplate on rails
- Elastic torque limiter between motor & gearbox
- Forced-lubrication system with pump, filter, heat exchanger & indicators
Outlet & Downstream Interface
- Heated adapter → Filter changer → Melt pump
- Melt pump driven by independent motor
- EXTRUDER OUTPUT CAPACITY
- PET flakes output: 960 kg/h ±5%
- Based on 2C105mm 52D extruder configuration
- RAW MATERIAL & PROCESS REQUIREMENTS
PET Flake Type
- Post-consumer bottle flakes and/or skeleton thermoforming flakes
- Preforms ground flakes, or virgin pellets
- Flakes drying NOT required due to high-efficiency degassing system
Indicative PET Flake Quality (UNI 10667/7)
| Feature | Limit |
| Fines < 0.6 mm | ≤ 0.5% |
| Oversize > 8 mm | ≤ 1% |
| Residual PVC | ≤ 50 ppm |
| Polyolefins | ≤ 25 ppm |
| Metals | ≤ 20 ppm |
| Paper/cellulose | ≤ 15 ppm |
| Moisture | ≤ 0.7% (or ≤1.0%) |
| Min density | 0.28 kg/dm³ |
| Colour | Transparent |
Intrinsic Viscosity (IV) Requirements
- Initial IV: 0.75 – 0.78 dl/g
- pH ≤ 9
IV Drop During Extrusion
- If moisture ≤0.7% → IV drop ≤10%
- If moisture ≤1.0% → IV drop ≤12%
Guaranteed IV at Extruder Exit
- For moisture ≤0.7% → IV ≥ 0.66 dl/g
- For moisture ≤1.0% → IV ≥ 0.64 dl/g
- DEGASSING SYSTEM (PROCESS-CRITICAL)
- Two liquid-ring vacuum pumps
- Ejector booster for higher vacuum
- Separator tank with heat exchangers
- Dual water-level control
- Impurity decantation baskets
- Degassing designed to remove:
- Moisture
- Volatile monomers
- Acetaldehyde
- Other low-molecular-weight byproducts
- ENERGY CONSUMPTION (PER KG OF PET OUTPUT)
| System Component | Specific Energy |
| Extruder motor only | 0.18 kWh/kg |
| Full extrusion system (dosing + extruder + vacuum + melt pump + thermoregulation) | 0.22–0.25 kWh/kg |
Values based on 900 kg/h PET post-consumer flake throughput.
- UTILITY REQUIREMENTS
Electrical
- 400 V – 3 Ph + N – 50 Hz
- Voltage variation: ±5%
- Frequency variation: ±2%
Cooling Water
- Filtered
- Inlet temp: 10–20°C
- Pressure: 2–3 bar
- Hardness: ≤ 15°f
Ambient Conditions
- Temperature: +5°C → +40°C
- Humidity: ≤70%
- Installation altitude: ≤1000 m
- COMPLETE ONE-PAGE SUMMARY
Machine: Bandera 2C105 HTS 52D Twin-Screw
Material: Post-consumer PET flakes (no drying)
Output: ~960 kg/h
Motor Power: 450 kW (limited to 400)
Screws: 105 mm, L/D 52:1, co-rotating
Pressure: Up to 200 bar
Degassing: 2 vacuum chimneys + 1 vent
Energy: 0.18–0.25 kWh/kg
Final IV: 0.64–0.66 dl/g depending on moisture
Required Flake Moisture: ≤0.7–1.0%
Required Flake Purity: PVC ≤50 ppm, PO ≤25 ppm, Metals ≤20 ppm
Thermal: 12 zones, electric heaters + oil cooling
Gearbox: Dual-output, forced lubrication
Downstream: Filter changer → Melt pump → Die
Upgrades and replacements:
Replaced both screws with new ones in 2020
New VSD for main motor installed in 2025
