115mm 32:1 L/D Davis Standard blown film line. New replacement v. refurbishment.

Machine 1.

Old barrel replaced with new, Bi-metallic barrel from customers existing supplier (Approx £8,400) Laser aligned. Screw refurbished to nominal size (Approx £3,500). Output up by 50%, screw speed and motor current down by approx' 50%.

Machine 2.

Barrel from machine 1 honed to 98% clean up, 1.65mm oversize by Extruder Services (Approx cost £800) fitted and laser aligned. Screw refurbished to oversize to match barrel by existing supplier (Approx £4,000). Output up by 50%, screw speed and motor current down by approx 50%.

Observations.

In both cases the customer reported almost identical increases in output and reductions in screw speed and motor current consumption. A proportion of the motor current reduction can be attributed to the correct alignment of the machines as both were approx' 3mm out of alignment. Additionally temperature override due to excessive shear heat was eliminated thus allowing the customer to regain control over their process.

Savings.

A total saving of approx £7,000.