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AIMPLAS has more than 20 pilot plants with different processes for plastic processingThe plants’ equipment covers all the plastic transformation processes, both thermoplastics and thermostables, or composites.

Materials processing

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COMPOUNDING

FILM BLOWING GRAVURE PRINTING

THERMOFORMING

FLAT SHEET

FOAMS

PIPE

PROFILE

CONVENTIONAL

MULTICOMPONENT

MICRO-INJECTION

EXTRUSION BLOW MOULDING

PREFORM BLOWING

EXTRUSION

INJECTION

BLOW MOULDING

COMPRESSION

PULTRUSION

RTM - INFUSION

PU FOAMING RIM

SOLID SURFACE

MICROWAVE CURING

SMC

COMPRESSION

LAMINATION

CO-ROTATING TWIN SCREW

COUNTER-ROTATING TWIN SCREW

PLANETARY ROLLER EXTRUDER

COATING

COMPOUNDING

NANOMATERIALS

Rooms especially equipped to work with nanomaterials and produce compounds with: graphene, graphene oxides, carbon nanotubes, carbon nanofibres, nanoclays, nano metal-oxides and others.Viability validation of new nanomaterials, such as additives in plastics.

FORMULATION OF PVC & WPC[pilot plant scale]

Co-rotating and counter-rotating twin screw extrusion to process shear-sensitive materials, such as PVC and obtain wood plastic composites (WPC).Possibility of head pelletizing (water or air cooled) and of direct extrusion of profiles, pipes and sheets by putting together the proper headstocks.Production of 10-20 kg/h.

MASTERBATCH, REACTIVE EXTRUSION, BIOPLASTICS[pilot plant scale]

Co-rotating twin screw extrusion to obtain highly-filled plastic compounds, formulate bioplastics, reactive extrusion and produce colour masterbatch or additivesDesign of screws adapted to the materials to be processed and optimization of processing parameters by validating dispersionPossibility of multiple fillers/fibres and liquids addition.Several degassing ports.Production up to 50-70 kg/h.

FIBRES, FILLERS, FLAME RETARDANTS AND OTHER ADDITIVES [pilot plant scale]

Co-rotating twin screw extrusion especially modifiable to work with nanomaterials (CNT, graphene, nanoclays) and obtain compounds with fibres, fillers, fire resistant, etc. Design of screws adapted to the materials to be processed and optimization of processing parameters by validating dispersionPossibility of multiple fillers/fibres and liquids addition.Large “stock” of screw elements, possibility of designing screws with different shear rates, thus obtaining excellent dispersions for all kinds of fillers and additives.Production up to 30 kg/h.

FORMULATION OF PLASTICS [laboratory scale]

Modular extruder with a vertical gate (with forced feeding).Designed to process small amounts of material required by price and availability.Productions up to 0.5-2 kg/h.Equipped with high-precision gravimetric feeders, both for pellets and powder for materials with different apparent density and format.

PERIPHERALS

In the compounding lines we have also quenching baths and the following auxiliary equipments:· Gravimetric dosing feeder for solids

0.1-80kg/h.· Gravimetric dosing feeder for liquids.· Turbo-mixers.· Head Pelletizer (water cooled).

FOAMING EXTRUSIONProduction of foamed plastic (rods, profiles and sheets) using chemical and physical foaming agents (supercritical CO

2).

BLOWN FILM EXTRUSION

Structures from a single-layer up to 5 layers.Vertical unit with maximum height of 4 m. Maximum film width of 300 mm.Film thickness range from 30 to 200 microns.

AUXILIAR EQUIPMENTPRESS MACHINE AND TWO-ROLL MILLPreparation of blends in batches with tempered two-roll mill.Manufacturing of sheets in a hot platen press. Sample thickness from 0.2 to 4 mm, maximum area of 200 x 200 mm.

FLAT SHEET EXTRUSION

Structures from a single-layer up to 5 layers. Maximum film width of 480 mm.Film thickness range from 50 up to 900 microns. Tempered calender from 5 to 90 ºC.

PROFILE AND PIPE EXTRUSIONProfile extrusion to work with amorphous polymers (PC, PMMA), semi-cristaline polymers (HDPE, PP) and PVC. Various dies with different shapes.Pipe extrusion of 16 mm diameter pipes with different thickness.Vacuum assisted calibration system and water cooling bath.

LAMINATION UNITSemi-industrial lamination unit to obtain flexible structures using solvent-less adhesives and solvent adhesives.Coating and print additional modules.Elimination of static electricity. Corona treatment.

EXTRUSION

THERMOFORMING AND PACKAGING

EXTRUSION

TANDEM EXTRUSION LINE

REACTIVE EXTRUSION (REX)Continuous chemical modification of polymers. Polymer functionalisation.Solid-liquid mixtures.Long residence times.

PROCESSING OF POST-INDUSTRIAL SCRAP. IMPROVEMENT OF QUALITY OF RECYCLED MATERIALRemoval of volatile compounds, including odours, by injection of gases at high pressure and vacuum-assissted degasification.Filtering for removal of solid contaminants.

THERMOFORMING AND PACKAGING

ROD FOR 3D PRINTING

Extrusion of rods with thicknesses of 1.75 mm and 2.85 mm. Controlled cooling (water and air).Automatic winding system.Formulation and processing of wide range of materials.

EXTRUSION-COATING

Coating of plastic films in line with the extrusion process.Different types of substrates (paper, aluminum foil, fabrics, plastic films, etc.).Adhesion by temperature and pressure. Maximum coating width of 450 mm.

THERMOFORMING

Thermoforming by pre-blowing and vacuum.Dual heating of the sheet (upper and lower).Moulding area up to 400 x 400 mm.Moulds with different shapes and materials.

VERTICAL FORM FILLING SEALING SYSTEM (VFFS)Automatic forming, filling and sealing process for pouches and bags.Control of temperature, sealing time, clamps pressure, etc.Pouches width: 90 mm or 150 mm. Lenght up to 250 mm.Different types of welding, depending on the compatibility of the materials.

SEALING MACHINE

Semi-automatic pre-industrial equipment, suitable for preformed trays. Wide range of films (top) and trays: laminated, foamed and monomaterials.Different packaging options: vacuum and modified atmosphere packaging (MAP) with single or tailored combination of gases.

CONVENTIONAL INJECTIONThree injectors with a clamping force of 50, 100 and 160 t.Different type of nozzles, depending on mould. Maximum plasticization capacity (in PS) of 343 g, and possibility of intrusion.Maximum mould size: 520 x 520 mm, with heights between 160 and 450 mm.Temperature regulation systems that allow mould temperature of anything from -5 ºC to 250 ºC.More than 15 moulds for tests and prototypes.

MULTI-COMPONENT INJECTIONInjection machine with clamping force of 100 t, and two plasticization units. Part injection capacity of up to 182 g (in PS).Maximum mould size: 420 x 420 mm, and minimum heights of 250 mm.Possibility of mounting different nozzles in machine. Temperature regulation systems that enable mould temperatures from -5 ºC to 250 ºC.Possibility of conventional injection.Processes of bi-injection, co-injection and overmoulding.

STANDARDIZED TEST PIECE MOULDS Moulds with quick change plates.Geometries available: ISO A, ISO B, ISO F, ISO A2, ISO D2.UL-94 standardized test part moulds for inflammability tests with thicknesses of 3.2, 1.6 and 0.8 mm.Standardized spiral mould for determining en route flow/thickness ratios.Injection of sheets for flammabilities with 150x75x4 mm and 150x150x2 mm dimensions.

MICRO-INJECTIONMaximum clamping force of 12 t.Maximum part weight (in PS) of 9.64 g.Temperature regulation systems that enable mould temperatures from -5 ºC to 250 ºC.Maximum mould size of 259 x 259 mm.

BLOW MOULDING

EXTRUSION BLOW MOULDING Automatic blow moulding for bottles of 125 and 200 ml.Equipment for obtaining single-layer, two-layer and three-layer bottles. Tempered mould.Cut of parison by hot cutter.

INJECTION

PREFORM BLOWINGPreform blowing from 0.5 to 5l.Preform thickness of between 1 and 4mm.Carrousel with 58 preforms loading capacity.Standard mould dimensions: 260 x 220 mm.

PULTRUSION PILOT PLANT

For obtaining constant section composite profiles. Injection or resin impregnation. Special resin injection.Maximum width of profile: 350 mm.Pulling system by pressing.

SOLID SURFACE FORMULATION

Intensive mixer of 5l. capacity.Programmable control of mix times, speed and temperature. Manufacture of prototypes by injection or moulding.

STUDY OF ALTERNATIVE PROCESSES TO THE AUTOCLAVE

Hot plate press with vacuum chamber.Maximum temperature of plates: 300ºC.Dimensions of plates: 450 x 450 mm.Maximum clamping force: 600 kN.Programming of press cycles (clamping force and temperature of plates).

SMC PILOT PLANT

Equipped with hot plate press.Maximum temperature of plates: 500ºC.Maximum clamping force: 600 kN.Programming of press cycles (clamping force and temperature of plates).

POLYURETHANEPILOT PLANT EQUIPMENT

Manufacture of polyurethane prototypes; integral and flexible foam, elastomers and compacts. Setting up of new polyurethane formulations (two or three components).Circuit prepared for working at high temperature (up to 120ºC).Connections for vacuum and dry air or nitrogen lines.

MICROWAVE CURINGPILOT PLANT

Microwave curing of large scale parts: 6000 x 2000 x 1500 mm.Maximum power: 6000W.Irradiation by means of 6 robot arms.Power control depending on laminating temperature.Different types of antennae.Parts obtained by infusion, hand lay up or vacuum bagging.

PILOT PLANT FOR RESIN TRANSFER PROCESSES

[RTM, RTM-Light, Infusion]

Resin injection equipment with automatic catalyser feed. Maximum injection pressure: 10 bar.Vacuum equipment of 750W with accumulator and dual level.

COMPOSITES

INSTITUTO VALENCIANO DECOMPETITIVIDAD EMPRESARIAL

València Parc Tecnològic Calle Gustave Eiffel, 446980 Paterna · Valencia · SPAINTel. +34 96 136 60 40 · Fax +34 96 136 60 41info@aimplas.es | www.aimplas.net

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