Apex Modular Extrusion
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Apex Engineering presents its new AME modular extrusion line series. The standardized lines come in 60mm, 70mm, and 90mm sizes, can produce 600-5500 lbs/hr, and cost less than $2.5-3.5 million. The pre-engineered and pre-tested modules integrate equipment like feeders, extruders, melt filters, and pelletizers. Optional equipment and automation solutions are also available. Apex handles design, assembly, installation, and startup to provide a turnkey solution while requiring minimal resources from customers.
Apex Modular Extrusion
- 1. Apex Controls Specialists, LLC Apex Modular Extrusion™ AME-Series Presentation AME SERIES
- 2. Corporate Office Apex Engineering PLLC P.O. Box 621 326 East Avenue Calvert City, KY 42029 (270) 395-4121 Regional Office Apex Engineering PLLC Apex Controls Specialists LLC P.O Box 687 5521 Industrial Rd. Mt. Vernon, IN 47620 (812) 838-0148
- 3. Apex Engineering, Inc. is a full-service engineering firm headquartered in Calvert City, Kentucky. Apex was incorporated in 1974 to provide multi-discipline engineering services for industrial clients. Our clients include major producers of specialty chemicals, refrigerants, polymers, nonferrous metals, coal, aggregates, electric power generation, rubber and elastomer products, and pulp and paper manufacturers. From small engineering tasks to large-scale projects, Apex Engineering provides unsurpassed quality resources to the client. As a result of superior client services, Apex has built continuing relationships that have lasted over 40 years. In 1988, Apex included an office in Mt. Vernon, Indiana. Today Apex Engineering is a multi- disciplined firm, providing a wide range of services to U.S and International clients. Apex Engineering’s continued success is attributed to long-term, confidential relationships we maintain with our clients. This is achieved through quality management, fast response and engineering excellence. From small engineering tasks to large-scale projects, Apex Engineering provides unsurpassed quality resources to the client.
- 4. Introduction In 1995 Apex Engineering established a sister company, Apex Controls Specialists (ACS). ACS allowed a dedicated entity to concentrate on controls and related services only. This gave Apex a one-stop opportunity for our clients and allowed for a more seamless efficient projects. In 2000 Apex used this Cinergy to develop Apex Modular Extrusion Systems™ and other process design / build systems. Process Engineering Network and SCADA solutions PLC and HMI Training Control Panel Fabrication Continuous Process Control PLC /DCS Engineering Electrical Engineering Mechanical Engineering Civil / Structural Engineering Design / Build / Procure Project Management
- 5. SHORT CIRCUIT, ARC FLASH AND COORDINATION STUDIES POWER STUDIES FIELD INSTALLATION SUPERVISION CONSTRUCTION MANAGEMENT DESIGN-BUILD CONTRACTING DOCUMENT MANAGEMENT PRELIMINARY CEP’s AND BEP’S SCOPING & FEASIBILITY STUDY PROCESS ENGINEERING PROCUREMENT SERVICES ESTIMATING PROJECT MANAGEMENT CIVIL ENGINEERING STRUCTURAL ENGINEERING MECHANICAL ENGINEERING ELECTRICAL ENGINEERING INSTRUMENT DESIGN PLANT UTILITIES DESIGN & SUPPORT
- 7. Primary Compounding Raw Material Transfer Systems Storage / Feeding Systems Formulation /Verification Off Line Mixers Hi-intensity Mixers Lo-intensity Mixers Extrusion Densifier/Compactor Melt Filters Die Face Pelletizing Conventional Pelletizing Classifying / Cooling Packaging / AGV / SGV / ATL De-metallization Control Integration Data Collection System Turnkey Systems / Modules Metering Skids Vapor Recovery Skid (Marine Offloading) Coating Skids Compactors In-LineColor Detectors Modular Electrical Building Modular Extrusion Closed Loop NitrogenTransfer System Long Glass Fiber (LGF) System Mercury Abatement System Nylon Extrusion System Sheet CoatingThickness / ColorTesting Modules Secondary Processes Dust Collection Fume Collection Clean Rooms Apex Modular Extrusion™ Systems
- 8. Modular Extrusion Experience Two (2) – Mexico - 2000 One (1) – Argentina - 2001 Five (5) – Brazil – 2001, 2004, 2006, (2008 , 2013 2nd Generation) One (1) – Indiana (USA) – 2003 – 70mm One (1) – Brazil 2010, “2nd Generation” – 40mm One (1) – Saudi Arabia 2012, “2nd Generation” – 50mm One (1) – Saudi Arabia 2012, “2nd Generation” – 58mm Four (4) – China – 2013, “2nd Generation” One (1) – Brazil – 2013, “2nd Generation Two (2) – US – 2014 “3rd Generation Controls” Two (2) – US – 2015 “1st Generation CCC” Above are all custom designed, client requested systems With Compounding Control Centers (CCC) Various Modules supplied with complete engineering services Multi-Floor / Multi-Level Feed Systems Two (2) or more levels and up to 11 feed streams The Evolution of Apex Modular Extrusion™ Systems
- 9. Introducing the all new AME series, Apex Modular Extrusion™ Line Apex Engineering PLLC and Apex Controls Specialists LLC are pleased to present three low cost, high value, standardized modular extrusion lines, the AME 60mm, AME 70mm, and the AME90mm. The system is provided with two resin pellet feeders and one powder resin feeder. Pigment, fiberglass and mineral feeders are all optional adders. The Modules are pre-wired and pre-tested and designed to easily ship over the road. Connecting the electrical system is truly plug and play through the use of disconnect rated power plugs. A state of the art Allen Bradley controls system is standard for all AME lines. Ethernet and remote I/O provide an efficient and clean electrical system. The AME series differs from our Custom designed modular lines in that the equipment is pre selected by Apex Engineering. Doing so allows us even lower pricing while still using robust equipment. Apex Controls Specialists, LLC
- 10. AME series – Sizes and Rates AME Model # AME – 60 AME-70 AME-90 Base Rate (lbs./hr.) 600-1700 1700-3500 3500-5500 Base Cost (USD) Less than $2.5MM Less than $2.9MM Less than $3.5MM
- 11. The AME Series – 3D View Operators Side
- 12. The AME Series 3D View Non-Operators Side
- 13. AME Series – Process Equipment Scope of Supply • Raw material debagging and pressure transfer (Pneu-Con) • One powder and two pellet resin feed streams • Extruder – Steer America MS series, 10 or 11 barrel machine with two ATM vents and one vacuum vent • Barrel heaters and barrel cooling manifold • Barrel cooling skid • Vacuum pump with dual knock out pots • High torque gearbox with clutch • Max screw speed 750 rpm (1360Nm/screw) • Melt and temp probe at die head • Clamped die with swivel support • Fume collection system • Brabender Feeders • Vortex Feeder RefillValves • Feed throat hopper • Reduction Engineering - Water bath with heat exchanger/pump • Reduction Engineering - Strand dryer • Reduction Engineering Pelletizer • Witter Classifier • Packaging blower • Packaging receiver/valves • Packaging hopper 2000 lb. – AME-60 and 3500 lb. for AME-70/90 • Vibratory tray with dribble mode (No valve for contamination) • Packaging Magnet • Weight Scale (0-2000 lb.) • Pellet hang-up points minimized • 4500 lb./hr. pack out rate for AME-60 andAME-70 • 7500 lb./hr. pack out rate for AME-90 • Packaging into box or bulk bag • Allen-Bradley CompactLogixs PLC • Allen-Bradley PF 5 series drives • Allen-Bradley RSVIEW ME HMI • All electrical components are skid mounted with forced ventilation
- 14. AME Series – Optional Equipment Fiber glass feed stream $ 173,300 Talc or mineral feed stream $ 156,600 Included equipment for each system: 1. Bulk bag unloader with massage paddles, electric hoist/trolley 2. Inclined auger to perform feeder refill 3. Loss-in-weight feeder 4. Side feeder
- 15. AME Series – Optional Equipment One master batch feed stream $ 109,300 Included equipment for each system: 1. Three container bowls - 600 liter 2. Container docking station 3. Loss-in-weight feeder
- 16. AME Series – Optional Equipment One liquid feed stream Coriolis flow meter, gear pump, pressure and temperature gauge, steel skid with containment pan, pre-piped and pre-wired Hydraulic dual screen changer 25 kg valve body bagger Dust collector Sized for powder feeder and feed throat source points. Dust collector must be located outside. Price includes 50 feet of ductwork. Additional fees apply for further distances. $ 97,800 $ 64,600 $ 156,800 $ 48,500
- 17. AME series – Project Execution What doesTurn-key supply mean? Answer: Apex will provide the keys to the system after the system is operational in your plant! How we execute the AME Modular Lines: • Review 3D views and P&ID’s after receipt of contract • Design drawings • Purchase material • Assembly in our shop as pre-fabricated modules • Pre-piped and pre-wired • Functionally tested in our shop • Break down and ship • Re-assembly of all systems in customer facility • Start-up of systems in customer facility • System operational
- 18. AME series – Customer Scope of Supply 1. Building with an internal clear span height of 22 ft. 2. Concrete floor with a rating of 600 lb./sf 3. Area lighting (note: Apex supplies lighting under the mezzanine) 4. Fire suppression/sprinkler systems for area and for Apex mezzanines 5. Building ventilation 6. Clean, dry compressed air for instrumentation 7. De-Ionized water for barrel cooling skid 8. Cooling tower water 9. Process drain(s) or sewer 10. Electrical power to extruder drive cabinet 11. Electrical power to system load center 12. Ground grid connection to bond modular system
- 19. Building Mixers Silos / DayTanks / Bulk Bag Unloaders / BoxTilters Transfer Pipe to Modules Fume Duct to Hoods Dust Collection System Dust Collection Duct to Modules CoolingTower to Modules Air Compressor to Modules Nitrogen to Modules Utility Power to Modules and Main Drive Utility Power to Auxiliaries (Mixers / Packaging / etc.) Lighting Fire Suppression Potential Engineering Services by Apex Floor LoadingAdequate for Modules HEAF (if necessary) for Fume Collection Packaging CableTray from CCS to Modules Labor and Equipment to erect / assembly Modules VPN Communication to CCS Floor Drains Screener / Pelletizer /Water bath / Strand Dryer
- 20. AME Series Advantages: Proven Performance: E-stop circuits, programming interlocks, electrical designs, etc… are not reinvented for each project, providing hardy/proven designs. Shorter schedules: Standardized lines can be built in parallel with building construction and / or minimize disruption to existing plant production. Standardization: Engineering reduced, cost reduced, schedule reduced Lower costs: Shop construction has proven to be 20 – 30% lower in costs with less risk of scope changes. Faster ROI: Reassembly is typically 2 weeks, no welding required.The client can make product faster than traditional construction as described above. Client resources minimized: Single source responsibility and standardization reduces resources. Robust equipment : 40 years of compounding experience with plastics equipment manufactures and vendors.
- 21. AME Automation Philosophy PLC is master controller. Allen-Bradley CompactLogixs PLC. Entire system utilizes Ethernet/IP communications. Feeders are connected for Ethernet communication, set points, actual values and diagnostics. Start/Stop of feeders is by I/O. HMI Allen-Bradley RSVIEW ME All Allen-Bradley PowerFlex drives are controlled over Ethernet communications with a hardwired E- stop. Main Extruder Drive is a PowerFlex 755. Programming software is RSLOGIX Studio forAllen-Bradley. A stand alone temperature controller is used for precise temperature control of extruder barrels. A Eurotherm MINI 8 is used. All Control Panels and Main drive are mounted next to Extruder.
- 22. High Speed Ethernet controls network. Tightly integrated drive systems, simple Ethernet connection with Estop. Real Time data for process analysis to support a quality product. Reduced wiring with Intelligent MCC and remote Ethernet I/O. Feeders are connected to the PLC over Ethernet for easy interlock and setup.
- 23. Process data historian. Recipe management systems. Material verification systems. Packaging systems – material weight and labeling. Lot tracking – Materials used –Yield calculation -Waste tracking. EDM Extrusion Data Management Options
- 24. To request a modular extruder system formal quotation, please contact: Steve Spahn PH: 812-838-0148 ext. 2102 E: sspahn@apex-engineering.com To request a modular control system or a control system upgrade, please contact: Jeff West PH: 812-838-0148 ext. 2113 E: jwest@apex-engineering.com To request a site visit by the Apex Modular Extrusion team, please contact: Mike Walker PH: 270-395-4121 ext. 1105 E: mwalker@apex-engineering.com Contacts – Additional Requests