PEKUTECH - Powdering Machines – Powdering for cables, rubber and silicone strips

Services

From the technical service located in Germany, all technical enquiries related to are managed:

Assessment and solution of specific problems

Commissioning of new equipment

Periodic maintenance

Spare parts

Support, inspection, and overhaul visits

Upgrades of existing equipment

Die Heads

Unicor extrusion heads offer a perfect synergy between extruder and corrugator, guaranteeing excellent quality, flexibility and a perfect flow and distribution of the material, in order to achieve the objective of manufacturing more robust, flexible and energy efficient pipes. The main features are:

Easy handling

Excellent material flow distribution

Quick tool change without the need for readjustment

The range of models consists of:

DDH (Disc Die Head) – The powerful ones for big diameters
CDH (Compact Die Head) – The compact ones for mid-sized diameters
SWESY (Schnell Wechsel System) – The productive ones for small and mid-sized diameters and mono as well as dual layer pipes
DWP (Double Wall Pipe) – The traditional ones for small and mid-sized diameters and dual layer pipes
SWP (Single Wall Pipe) – The variable ones for small and mid-sized diameters and mono layer pipes

Large-sized Corrugators

The range of large corrugators covers a diameter range from 200 mm (inside) to 1800 mm (outside). The main features are:

Additional extensions

Cost-effectiveness

High stability

Reduced number of mold blocks

Common applications are:

Drainage
Sewage

The range of models consists of:

UC 1200 – The pioneer
UC 1800 – The giant

Mid-sized corrugators

The medium corrugators range covers a diameter range from 32 mm (inside) to 800 mm (outside). The main features are:

Continuous water cooling (UNICOR system)

Easy in-line integration

High flexibility

High production speeds

Process stability

The most common applications are:

Cable protection on the ground
Drainage
Sewage
Support and ventilation

The model range consists of:

UC 210 – The efficient one
UC 280 – The powerhouse
UC 5XX – The new one
UC 800 – The traditional one

Small-sized corrugators

These are high-performance flexible corrugators for a diameter range of 3 mm (inside) up to 135 mm (outside). This type of corrugators are characterized by:

Compact design

Cost-effectiveness

High flexibility

Longevity

Process stability

Water cooling (UNICOR system)

The most common applications are:

Automotive
Cable protection in ground or electrical installation
Drainage
Medical
Pre-wired or pre-piped tubes
Support and ventilation

The range of models consists of:

UC 15 vario – The tiny one
UC 36 – The fastest
UC 58 – The most popular
UC 58 vario – The versatile one
UC 90 – The multi talent
UC 135 – The biggest of the smallest

Aftermarket

Whether you need to retrofit a feedscrew, add new capabilities, upgrade existing equipment or do preventive maintenance, the Service Team is here to support you.

Some of the global services are:

Die and head upgrades
Process control upgrades
Lines upgrades
Air-to-water conversions
Internal Diameter Increase (IDI) conversion
Operator training
Equipment install and relocation
Feedscrew replacement and rebuilds
Gearcase retrofits
etc.

Adjustable Calibration sleeve

The four-point adjustable calibration sleeves have the following properties:

Four adjustment points allow adjustment of both the diameter and the ovality
Easy handling with high flexibility
Readable adjustment via numeric counter
Make larger or smaller adjustments during ongoing production
Adjustment range for all SDR classes
System based on the Patent no’s. DE 10 2009 041 628 and DE 10 2015 119 328

Adjustable Calibration sleeve

The two-point adjustable calibration sleeves have the following properties:

Greater adjustment range with two adjustment points
Easy handling with high flexibility
Readable adjustment via numeric counter
Sturdy adjustment with minimum effort
Make larger or smaller adjustments during ongoing production
Adjustment range for all SDR classes
System based on the Patent No. DE 10 2009 041 628

Adjustable Calibration sleeve

The one-point adjustable calibration sleeves have the following properties:

Easier handling with only one adjustment axis
Readable adjustment via numeric counter
Make larger or smaller adjustments during ongoing production
Control via motor possible: manual or automatic motor control
Fast reaction time for inline diameter adjustment
Adjustment range for all SDR classes
System based on the Patent No. DE 10 2009 041 628

Conventional Calibration sleeve

Overlapping slots mean outstanding sliding properties
Retrofitting is easy with the adjustable calibration sleeve
Run a different diameter just by opening the end slots and retrofitting a ring
Good value for money

Unwinding and Winding

Davis-Standard unwinders and winders provide the uncompromising quality and reliability demanded in today’s competitive marketplace for web production and/or converted products.

Some of the benefits are:

Reliable web transfers without tension upsets for high productivity
Consistent production of quality rolls with uniform inwound tension and minimum scrap
Programmable operational setpoints for high versatility and fast changeovers

Cast Film

Davis-Standard is the technology leader for flat and embossed cast film processes. Depending on your end market and production targets, the extruder layout, casting sections, winder and automated winding and roll handling systems are engineered to meet the customer standards.

Typical specifications depending on the type of line are as follows:

Embossed Cast Film Lines

Widths: 2082 – 3550 mm
Outputs: 315 – 825 MT / month
Line Speeds: 185 – 460 m / min
Film Thickness: 15 – 30 µm

Cast Polypropylene Lines

Widths: 2000 – 5300 mm
Outputs: 650 – 1675 kg / hr
Line Speeds: 50 – 300 m/min
Film Thickness: 15 – 20 µm

Stretch Cast Film Lines

Widths: 2000 – 4500 mm
Outputs: 1100 – 3000 kg / hr
Line Speeds: 300 – 600 m/min
Film Thickness: 8 – 80 µm

Service & Maintenance

Among others the plugs of peripherally bored calender rolls, irrespective of their plug system, can be replaced. And also calender rolls with different kind of seals can be treated (opened, cleaned and closed again).

The tightness will be checked by pressure test at ambient or working temperature.

Finishing

To obtain the best possible quality, once ground to the desired diameter, the roll can be polished or matted.

By polishing of the roll’s surface, the roughness will be reduced to the requested value. This can be done either by simple polishing or superfinish polishing.

By matting of the roll’s surface, the roughness will be raised to the requested value. The kind of blasting material determines the shape of roughness.

Both ways of processing are independent of the roll’s material. All common types of steel and cast iron can be polished or matted. The same goes for rolls which have been chrome-plated or nickel-plated.

The combination of both types of processing is also possible.

Turning

Available turning machines enable to provide all services on workpieces with dimensions Ø 1100 mm (above slide) / Ø 1600 mm (without slide) x 12000 mm total length and a weight of up to 25 tons.

Nickel Plating

In case of heavy wear, the original diameter of the roll can be restored through the nickel-plating process.

Since the nickel layer is almost as hard as the chrome layer, a roll with nickel beneath the covering chrome layer does not have any limitations during the production process.

Chrome Plating

Vertical chrome plating tubs offer sufficient capacity to treat any size of roll.

Any demanded thickness of a layer will be precipitated with the best possible structure. In particular applications of the chrome-plating technique electrolytical mattings can be produced.

Upon request, the hydrogen produced during the chrome plating, which has been stored in the chromium layer due to the process, is outgassed by heating the roll. This process is known as dehydration.

Grinding

With the available grinding machines very big and heavy rolls can be ground with maximum precision. Rolls up to 3500 mm in diameter and a maximum face length of 10000 mm can be worked with great accuracy.

The CNC technique gives the ability to produce any requested profile of the face. The deviation of the profile’s target can be limited to 1 µm. The result of grinding including run-out and concentricity is made out and printed electronically.

Possibility to do grinding of rolls with exactly the temperature the customer uses during the production process.

Liquid Coating and Laminating

Davis-Standard offers highly efficient liquid coating systems tailored to meet specific product requirements for your customers. These systems can be anything from a complete standard coating line to a new custom coating line, or just a coater head that can be retrofitted into your existing line.

Typical specifications:

Width range depending on the application: 1016 – 2974 mm
Process speed depending on the application: 15- 457 m/min

The BOPP Tape line uses the versatility of the Series 4000 Cartridge Coater, advanced drying technology, and renowned winding technology to ensure converters run faster and still produce the highest quality tape product possible. This process is available for testing and evaluation at the R&D Center in Fulton, NY, USA.

Coating weight depending on the material (kg / m2)

Film: 0.5 – 3
Film: 3.6 – 9.5
PE Coated Scrim: 5.4 – 13.6
Paper: 3.6 – 13.6

Extrusion Coating and Laminating

The dsX flex-pack™ 300S offers cost efficiency, flexibility in operations, short product changeovers and the Davis-Standard know-how and experience in the converting industry.

Design features:

Reduced product variability and improved product quality
Greater uptime and productivity for quick and frequent change-overs to meet market demands
Less waste and lower overall cost allows for optimizing production cost

Technical Specifications:

Extrusion coating and laminating of film, foil and paper
Chemical priming for surface treatment of film
Co-extrusion as standard utilizing Davis-Standard proven extrusion technology for the flexible packaging market

The extrusion coating machinery fulfills even the most demanding flexible packaging, non-wovens, paper and board coating and laminating applications. This includes everything from laboratory-size systems for R&D to 5m-wide systems for industrial materials.

Width range depending on the application: 650 – 5100 mm
Process speed depending on the application: 6 – 760 m/min
Coating thickness depending on the application: 12 – 2500 µm

Wall Thickness for CV Lines

X-RAY 8000 NXT devices for CV lines continuously measure the concentricity, diameter, wall thickness and ovality of cables up to three layers in a pressurized environment.

Direct line integration.

Wall Thickness

X-RAY 6000 / X-RAY 6000 PRO equipment measures continuously the concentricity, diameter, wall thickness and ovality during the cable sheathing process of up to three layers. They contain no moving parts, so they do not require any calibration.

Direct line integration.
Different sizes depending on the cable diameter.

Lump and Neck Detection

LUMP 2000 devices detect non-conformities on the product surface regardless of line speed.

Depending on the model, it can measure in 2 or 3 axes.
Direct line integration.

Concentricity

The CENTERVIEW 8000 unit measures the eccentricity, diameter and ovality of cables, regardless of line speed. Non-contact measurement based on an inductive and optical laser principle.

Graphical visualization of measuring values as a scatter plot for showing short-term variations of eccentricity.
Automatic centering of the gauge head to cable position.
Direct line integration. Different sizes depending on the cable diameter.
Depending on the model, they measure in 2 or 3 axes, in addition to detecting possible defects such as lumps and necks.
Direct integration in the line or as an independent device.
Different sizes depending on the cable diameter.

Diameter and Ovality

LASER Series 2000/6000 devices measure diameter and ovality continuously and without contact. They do not contain moving parts or lenses, so they do not suffer wear or require annual calibration.

Depending on the model, they measure in 2 or 3 axes, in addition to detecting possible defects such as lumps and necks.
Direct integration in the line or as an independent device.
Different sizes depending on the cable diameter.

Upgrades & Service

Maillefer offers upgrades for all types of wire and cable lines as well as continuous maintenance and training of operators to continue improving and increasing production capacity.

Maintenance Solutions
Performance Solutions
Service Level Agreements
Support Services
Upgrade Solutions

Components Pipe & Tube

Maillefer offers a wide range of components either to increase production capacity or flexibility, or to replace or upgrade the existing production line.

Coilers and Reelers
Downstream Equipment
Extruders
Extrusion Heads

Components Wire & Cable

Maillefer offers a wide range of components either to increase production capacity or flexibility, or to replace or upgrade the existing production line:

Accumulators
Cable Guiding and Measuring
Capstans and Caterpillars
Cooling Systems
Crossheads
CV Line Equipment
Extruders
FO Line Equipment
Line Control
Reel Handling
Stranders

Lines Pipe & Tube

Maillefer offers a wide selection of tube and hose extrusion lines for different applications:

Automotive
Heating and Plumbing
Irrigation
Medical
Micro-Duct
Off-Shore
Special

Lines Wire & Cable

Maillefer offers a wide selection of wire and cable extrusion lines for different applications:

Automotive
Building Wire
Coaxial Cable
Fiber Optic Cable
LAN
Low Voltage Cable
MV, HV & EHV
Rubber Cable
Special Cable
Telecom Cable

Factories & Consultation

Maillefer offers a wide range of consulting services to acquire and update needed production competence and R&D capabilities, and to improve the performance and productivity of your current factory. Also, Maillefer can partner with you in the conceptualization and realization of a new factory.

Factory System
Piloting
Production Competence
Production Optimization

Profile powdering

Profile powdering is applied in extrusion lines for rubber or silicone strips, hoses or profiles.

Calendered sheet powdering

Calendered sheet powdering allows the adhesion to be avoided during the winding process of the sheet.

Suitable for a useful width of 500 – 3000 mm.

Rubber parts powdering

Rubber parts powdering is done by means of a grooved conveyor belt, which allows continuous adjustment of the powdering grade as well as of the speed of the line.

Cable powdering

Cable powdering is based on a mechanical and electrostatic system, so that the powder adheres only to the cable.

A wide variety of available powder materials can be used, some of them without the need of explosion-proof measures.

Interlock Armouring Lines

Interlock Strip Armouring machines are used for the production of armored cables and flexible conduits. They are suitable for building cables (MC & AC), ESP cable (Electrical Submersible Pump), data, fiber optic, safety & fire alarm cables.

They represent a low-cost solution for the physical protection of energy, instrumentation, coaxial, data and optical fiber cables.

Cable constructed with strip armouring of aluminum, steel or copper is also known as BX, Interlock or MC cable and offers a combination of high tensile strength, crush and impact resistance making it the preferred choice for demanding installations.

Rigid or Planetary Stranders

Rigid Stranders are cage type machines without backtwist. They are suitable to produce multiple wire combination strands of copper or aluminum for low, medium and high voltage applications, cabling insulated conductors for control cables, screened power cables and steel wire armouring.

Typical lines include the capability to strand 37 or 61 elements in a single pass with tandemizing options to further enhance the line’s capabilities.

Planetary Stranders are cage type machines with backtwist. They minimize the twisting of bare wire/insulated conductors around their own axis by utilizing an eccentric ring principle to maintain the axis of the bobbins parallel as the cage rotates.

These machines are designed in two versions, light duty, for cabling insulated conductors with low bobbin weight, and heavy duty, for stranding bare wire with high bobbin weight.

Single or Double Twist Stranders

Single Twist Stranders are suitable for stranding, cabling and armouring bare or insulated conductors (with or without taping).

Double Twist Strander is an “outside/in” configuration with bow, capstan, take-up, traverse and loading platform.

Depending on the strand construction and number of wires, either a single or double twist strander will be used, in order to optimize the tension and straightness of each conductor.

Roll Form Strander Systems

The Roll Form Strander program covers machines designed to accommodate reels up to 2240 mm. The scope of the products that can be manufactured includes:

Copper and aluminium stranded conductors between 10 mm2 and 300 mm2
The process is capable of manufacturing bunched conductors to compact strand with Fill Factors between 76% and 97%
Aluminium Conductors Steel Reinforced (ACSR) using a single steel wire core
All Aluminium and Aluminium alloy Conductors (AAC & AAAC)
Cabling of insulated conductors

The aim of this system is to shape individual wire of single diameter and present the material to the strander in the optimum format depending on the desired strand construction.

High-speed Twinners

High speed Twinners are ideal for the manufacturing of shielded and unshielded pairs up to 5 mm diameter with a bow speed of up to 2500 rpm and line speeds of up to 600 m/min. A digital drive package ensures precise lay control of the finished pair. This line is suitable to assemble with solid HDPE, FRPE, Foam HDPE and FEP insulations.

The major components of the line include the following:

Dual driven payoff or Backtwist Pay-off for LAN pairs
High Speed Twinner

Machine parameters are digitally monitored and controlled via a Programmable Logic Controller (PLC) and a menu driven touch screen so that at each stage the operator is guided to obtain the desired machine operation.

Laboratory mixers

For laboratory solutions and small-scale blends, MTI offers the Laboratory Mixers Type M, which offer high mixing capacity on a smaller scale, are mobile and can be quickly cleaned.

Heating and cooling mixers

As a complete solution, MTI offers combined heating and cooling mixers. Two series are available, the Heating / Cooling Mixer Combination Type M/K Flex-Line, which offers customized solutions for the best possible performance, and the Heating / Cooling Mixer Combination Type M/K Eco-Line, which offers more affordable standardized solutions. In both series, the mixer comprises a top-up heating mixer and a cooling mixer at the bottom.

Horizontal Mixers

MTI offers horizontal mixers, such as the Horizontal Cooling Mixer Type K, for the cooling of mixtures. For greater flexibility and variety of products, Horizontal Universal Mixers Type H are suitable, as they are ideal for mixing, dispersing, granulating or coating, heating / cooling and drying of products for virtually all applications and industrial sectors.

Vertical Mixers

MTI offers two types of vertical mixers, the High Speed Mixer Type M, with peripheral speeds of 10 m/s up to 40 m/s, and the Universal Mixer Typ UT UniTec®, with peripheral speeds up to 8 m/s. Both are friction mixers for powder materials with the option of adding liquids and offer a wide variety of processes ranging from heating and tempering by reaction, melting, and coating to agglomeration and dispersion, even under pressure or vacuum.

Mobile Container Mixers

The latest innovation of MTI is the Container Mixer C tecPRO, a robot with mobility in six axes and individual containers of up to 600 l capacity. It allows to make different subsequent mixtures in less time, since it is not necessary to wait for a previous cleaning. In addition, each container can have different tools, as these are not attached to the robot. The flexibility of the robot allows working with containers of different sizes, so you can adapt the production of each mix to the needs and thus achieve maximum productivity.

Wall Thickness for CV Lines

X-RAY 8000 NXT / ADVANCED devices for CV lines continuously measure the concentricity, diameter, wall thickness and ovality of cables up to three layers in a pressurized environment.

Direct line integration.

Example of a representation of the measured values with the ECOCONTROL 6000:

Wall Thickness

X-RAY 6000 / X-RAY 6000 PRO equipment measures continuously the concentricity, diameter, wall thickness and ovality during the cable sheathing process of up to three layers (X-RAY 6000 PRO).

They contain no moving parts, so they do not require any calibration.
Direct line integration.
Different sizes depending on the cable diameter.

Example of a representation of the measured values with the ECOCONTROL 6000:

Lump and Neck Detection

LUMP 2000 devices detect non-conformities on the product surface regardless of line speed.

Depending on the model, it can measure in 2 or 3 axes.
Direct line integration.

Example of a representation of the measured values with the REMOTE 2000:

Concentricity

The CENTERVIEW 8000 unit measures the eccentricity, diameter and ovality of cables, regardless of line speed.

Non-contact measurement based on an inductive and optical laser principle.
Graphical visualization of measuring values as a scatter plot for showing short-term variations of eccentricity.
Automatic centering of the gauge head to cable position.
Direct line integration.
Different sizes depending on the cable diameter.

Example of a representation of the measured values with the ECOCONTROL 6000:

Diameter and Ovality

LASER Series 2000/6000 devices measure diameter and ovality continuously and without contact.

They do not contain moving parts or lenses, so they do not suffer wear or require annual calibration.
Depending on the model, they measure in 2 or 3 axes, in addition to detecting possible defects such as lumps and necks.
Direct integration in the line or as an independent device.
Different sizes depending on the cable diameter.

Example of a representation of the measured values with the ECOCONTROL 600:

Experience

Location

Services

Experience

Location

Services