Ingtec Technik AG

Company Presentation EnMat EN Feb 2016

Ingtec Technik AG

Date: 03.08.2016 Page: 2

Ingtec Technik in a nutshell Ingtec Technik AG is an innovative Swiss engineering company, operating globally in the field of specialised construction, covering a wide scope. Our main focus is on batch and continuous mixing and compounding technology for ambitious tasks like high viscosity products or energetic materials. We are a powerful team of experienced engineers, which excels in inventing genius and construction of heavy machinery. New technologies, applications and solutions are driving us forward – Every day.

Ingtec Technik AG

Date: 03.08.2016 Page: 3

Ingtec Technik Project Network

• Excellence in Manufacturing • State of the art Production Facilities

& Technologies

Ingtec Technik AG • Plant Layout • Engineering • Software Design • Project Management • Sourcing • Quality Control • After Sales Service

Mechanical Manufacturing

Partners

• One shop stop solution for our clients • Total Customer Orientation • Maximum Flexibility • Small, High-Performance Organisation

Long-Term Partnerships

Client

Ingtec Technik AG

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Ingtec Technik in a nutshell

Starting out with more than 30 years of experience in mixing and agitation technology, Ingtec Technik developed into its present focus application: Compounding of high viscosity products. Our top quality machines and plants are employed in sensitive industries like the automotive and aerospace industry. Also the defence industry relies on our products in the manufacturing of state of the art systems. Ingtec Technik AG is proud to be among the chosen few world-class suppliers in energetic materials. We also offer our services as general contractor in planning, design and assembly of entire plants. Our services include the construction of the machines, process automation, raw material handling and post processing steps. We can cover greenfield development and we can implement our equipment solutions into existing infrastructure. With our swiss-made technology you achieve superior quality for your pro-ducts. Do not hesitate to challenge our performance and contact us with your special construction application.

Date: 03.08.2016

One of our recent projects: 1000 L Vertical kneader including solid and liquid dosage systems plus discharge press.

Fields of Activity

Fluid Handling

● Mixing and Dispersion Technology

● Mixing and Storage Vessels

● Filling and Dosage Technology

● Turn-Key Plants

Bulk Material Handling Control Systems

● Storage Silos

● Pneumatic Conveyor Systems

● Mechanic Conveyor Systems

● Weighing and Dosage Systems

● Dust containment & Removal

● Programmable Logic Controller

● Parameter Trending and Recording

● Process Visualisation

● Formulation Management

● Integration into superior Control

Systems (SCADA, MES, ERP)

● Process Control Systems (PCS)

● Instrumentation and control

engineering We are active in several industries:

● Construction Materials ● Mineral Products

● Paints & Coatings ● Chemical Industrie

● Food & Feed ● Adhesives & Sealants

and more

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Batch-wise or continuous Processing?

Mixing and compounding are among the most widespread technological processes. Whenever planning equipment for a mixing process, the first decision for the user to take is which processing principle should apply: Batch-wise or continuous processing.

Traditionally, the starting point is batch processing. But especially mixing tasks are often designed as continuous processes. Ingtec Technik offers solutions for both categories, also for special applications like energetic materials.

Some basic criteria, which may help to decide which technology is suited best for a given task:

Process Technology

Date: 03.08.2016

PROCESS Batch-wise Continuous Process Flexibility ++ Excellent – Multi-Purpose Plant - Dedicated Equipment

Product Quality - Fluctuating + More Constant

Raw Material Supply + Simple - Complex

Large Scale Production - More difficult with scale ++ Excellent

Slow Processes + Suitable - Difficult (short residence time)

Set-up Time - For each batch + Only once per run

Processed Volume - = Batch Size + Small

Application of Energy - Low + High

Investment + Low - High

Manpower - High + Low

Process Automation + Low Level feasible - High Level mandatory

Start-Up/Shut-Down Procedure + Short - Complex

Maintenance + Relatively simple - Complex

Process Safety - More difficult with scale + Excellent

Mixing & Compounding – The basic Process

Low and Middle Viscosity

Agitators and Mixing Vessels

Slow moving

Past mix (semi-continuous)

Fast moving

High Viscosity

Vertical Planetary Kneader PKV (batch)

Atextruder (open, continuous)

Twin Screw Extruder (closed, continuous)

Fluid Handling

Process Technology

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Typical coaxial combination of fast and slow moving agitators

Fluid Handling

5000 L Mixing Vessel for the Production of Emulsion Paint & Plaster Production, Bosshard AG, Switzerland

Mixing & Compounding – The basic Process

Low and Middle Viscosity

Agitators and Mixing Vessels

Slow moving

Fast moving

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Slow Fast

3500 L Mixing Vessel for the Production of Emulsion Plaster Production, Austria

Fluid Handling

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Production Plant for Emulsion Plasters, incl. Bulk Material Handling, Saint-Gobain AG, Switzerland

Fluid Handling

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3500 L Mixing Vessels on previous slide are part of:

3000 L Conical Shaped Co-axial Mixer KDA for Emulsion Paints and Plasters, Greutol AG, Switzerland

Fluid Handling

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Slow Fast

Production Plant for Emulsion Paints and Plasters, Switzerland

Fluid Handling

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6 x 7000 L Agitated Maturing & Storage Tanks for Emulsion Paints, Switzerland

Fluid Handling

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PAST mix 1000L for RTV Sealant Manufacturing, Sika AG, Germany

Fluid Handling

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Mixing & Compounding – The basic Process

Low and Middle Viscosity

Agitators and Mixing Vessels

Slow moving

Past mix (semi-continuous)

Fast moving

High Viscosity

Vertical Planetary Kneader PKV (batch)

Atextruder (open, continuous)

Extruder (closed, continuous)

Special Equipment for RTV Sealants

Vertical Planetary Mixer 1000 L for Automotive Adhesives, Dow, Germany

Fluid Handling

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Discharge Press for Automotive Sealants, Dow, Germany

Fluid Handling

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PKV 1000 Plant, Energetic Materials, incl. Bulk Material Handling and Discharge Press

Typical PI Diagram of Mixing Plants (red: solids, black: liquid raw materials)

Fluid Handling

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Complex mixing and compounding equipment requires sophisticated control systems:

• Managing of Process Procedures: Weighing, Dosage, Mixing, Thermostatting, Vacuum, Manual Process Steps, etc.

• Optimising of Plant and Equipment Utilisation – Administration of multiple batches in a production line -> Campaign Management

• User Interface: Process Visualisation, Setting of Parameters, Formula Administration

• Consistent Data Recording of all Process Parameters

• Statistical Analysis

• Production Planning and Monitoring

• Interface to superior control systems

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Control Systems

Human Interface of PKV 1000 Plant, Process Visualisation

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Control Systems

Fluid Handling

Process Technology

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Mixing & Compounding – The basic Process

Low and Middle Viscosity

Agitators and Mixing Vessels

Slow moving

Past mix (semi-continuous)

Fast moving

High Viscosity

Vertical Planetary Kneader PKV (batch)

Atextruder (open, continuous)

Twin Screw Extruder (closed, continuous)

Process Technology

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When processing energetic materials, there is also demand for continuous equipment. Ingtec Technik provides two major technologies for continuous processing of energetics: • Atextruder and • Twin Screw Extrusion

The outstanding advantage of continuous processing is the comparatively low amount of material inside the equipment at a particular time, dramatically reducing the risk potential. The residence time of the product on the machine is very short.

Energetic Materials

When processing energetic materials, the mechanical sensivity of the material against impact and friction is a critical factor in process design.

Typically, compounding of PBX materials is performed batch-wise on vertical kneading machines of the PKV type.

Advantages of the PKV: • Small but well defined distances of the mixing blades, hard contact of mixing tools or vessel is impossible • Product does not get in contact with shaft sealings of the kneader • No dead zones – The entire useful volume is worked by the mixing blades • Amount of shear is well controlled by the torque, applied • Vacuum degassing • Ingtec Technik exclusively uses hydraulic drives in environments, where explosive atmospheres may occur.

Nevertheless, with increasing batch size, perspective may change: • The increasing potential risk of large batches needs to be taken into consideration • Heat exchange is getting slower with increasing kneading vessel size

Vertical Planetary Kneader PKV

PKV 1000 PKV 50 PKV 5

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PKV 2000 for Automotive Adhesives PKV 5 for Energetic Materials

Vertical Planetary Kneader PKV

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PKV: Movement of kneading blades

Vertical Planetary Kneader PKV

For simplicity of illustration, the central blade is shown stationary.

Intensive shear is created when the blades intermesh with each other and the wall of the mixing vessel

PKV 1000: Gap of kneading blades 4.0 – 6.0 mm

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Atextruder ATE

Rotation of grooved Rollers (red) and Material Flow (green)

Atextruder ATE

Roller Gap adjustable between 500 - 5000 m on both ends individually

Constant Shear Decreasing Shear Increasing Shear

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Atextruder ATE

• Very low hazard potential, owing to the open construction (no confinement) and Small amounts of energetic material present on the

device during processing • Continuous operation, suitable for remote control • Flexible process design, not limited by the rigid position of

ports, arranged on a fixed barrel • Homogenisation of the processed material by shear in the

gap of the roller, the rollers never touching • Variable but very precise adjustment of the distance of

the rollers (roller gap), gradients possible • Shear applied to product by rollers, gap small but well

defined, hard contact of rollers is impossible • Reproducible, constant product quality

The Atextruder has many special advantages:

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Atextruder ATE

Type ATE 150 approx. Capacity: 3 to 30 L/h Roller Length: 1345 mm Length/Diameter (L/D): 9 Diameter of Rollers: 150 mm Type ATE 250 approx. Capacity: 15 to 150 L/h Type ATE 350 approx. Capacity: 75 to 500 L/h Performance of drives: 11 - 40 kW. For maximum process safety, for processing energetic materials, we recommend hydraulic drives

Material Feeders: No spatial restrictions in positioning

Product felt on one of the two rollers

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Atextruder ATE

Temperature Gradient: Hot to Cool

Flow

Temperature Gradient: Cool to HOT

Up to 4 temperature zones: Flexibility in temperature control

Feed stream

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Twin Screw Extruder

In some applications not only the continuous compounding is required, but also a subsequent forming of the product is desired. In this case, conventional extrusion is the method of choice, because it can provide the necessary pressure on the product for forming. Ingtec Technik offers also Twin Screw Extrusion Technology, especially adapted to the requirements of energetic materials. • Co-rotating screws to limit shear and friction on the products • Folding half barrel design to enable emergency pressure relief • The extruder is operated below the maximum technically feasible feed rate of starting materials to reduce the degree of

filling and hence mechanical stress on the product. Pressure is only generated towards the output zone of the extruder. • If no pressure for forming is required in the process (only compounding), we can offer bearings of the screws on both ends.

In this case the product is exposed only to very gentle pressure during processing.

Co-Rotating For compounding and forming processes

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Twin Screw Extruder

Drive Safety Clutch Gearbox Shaft Coupling Processing barrel with screws Output Material Feeders omitted, Degassing, Thermostatting

Modular Structure of the Process Barrel: Barrel Segments (closed version is illustrated), Serrated Shafts with modular Screw Elements (not in operating set-up)

Co-Rotating For compounding and forming processes

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Typical Extrusion Process

Material Input Atmospheric Degassing

Vacuum Degassing

Solid Feeder

Material Input

Mixing Zone

Plasticisation Zone

Twin Screw Extruder

Homo- genisation

Feeding Zone

Degassing Zone

Degassing Zone

Product Output

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Zweiwellenextruder

Twin Screw Extruder suitable for Energetic Materials with folding half barrel design

Flow Pattern of the material inside the co-rotating Twin Screw Extruder

Twin Screw Extruder

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Thank You!