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A Company of the
TROESTER Group
Since founding, X-Compound manufactured and continuously Due to a high expertise X-Compound advanced to a market leader.
developed suitable compounding plants for the processing of X-Compound supplied complete compounding plants to important
any kind of wire & cable materials. cable manufacturers.
The major demands are The design and versatility of the process relevant parts allows a
smooth and intensive kneading and mixing as well as the accurate
> Accurate dosing control of the required process temperature profiles.
> Perfect dispersion and homogeneity
> Energy-saving process
> Versatility
HFFR halogen-free cable compounds are the optimum solution Advantages of the X-Compound Kneader Technology
for a broad range of cables meeting IEC fire test standards. Used
for both insulation and jacketing, HFFR halogen-free cable com- > Work in of high filler content up to 80% by a
pounds maximize value by providing superior process efficiency. split feed system
Its innovative low-density formulation increases yield, lends to > Special degassing system related to the kneader and
minimizing waste and processes under lower extruder motor load. the product inlet zones to allow optimal filler-intake
> Injection of coupling agent liquids into the melt
Applications > Accurate process temperature control to prevent
degradation of the fillers. (e.g. ATH < 185°C)
> Low price cables for buildings, ultrathin wires for > High flexibility for the processing of a large variety of
automobile up to military/aerospace cables compounds with a unique screw profile
A D D IT IV E S
A T H A T H
E V A E V A P E
F IL L E R S P O L Y M E R
v a c u u m p u m p
s c re e n c h a n g e r
v a c u u m
6 .3
6 .5
d is c h a r g e
6 .4
X -C O M P O U N D K N E A D E R
C K C H D 1 5 0 -2 0 0 (1 8 L /D )
L IQ U ID S
c u s to m e rs
B ig b a g / O c ta b in
w e ig h in g
O il O il O il O il O il w a te r w a te r u n d e r w a te r
p e lle t iz e r
HFFR 3
A significant role in the cable industry is the use of PVC PVC cable compounds are divided into the categories
insulation material. The market share is worldwide more than
70% of the cable sector. > Insulation
> Sheathing
PVC cables are mainly used in the low voltage segment > Bedding
in applications as:
For PVC compounding combined with the pelletizing system
> Telecommunications X-Compound use the established cascade kneader design.
> Installations
> Machinery and equipment homogeneous gelification by controlling of
Requirements, such as homogeneou
> Automotive industry H O T dispersive distribution of the
product temperature and/as well as d
> Household T U R B O - superbly in the X-Compound
fillers and additives will implement su
M IX E R
> Communication- and operation window can be covered
Kneader. Furthermore a large operat
control cables which is decisive for frequently
with a single screw configuration, wh
> Semi conductive PVC cables MA C
formulation changeovers.
M
C O O L IN G A C X-Compound offers
M IX E R
IN T E R M E D IA T E
S IL O 1 ,5 m ³
D R Y B L E N D
X -C O M P O U N D K N E A D E R v a c u u m
C K IC D 1 5 0 -2 0 0
s c re e n c h a n g e r
v a c u u m p u m p
w a te r w a te r O il O il O il
p e lle t tr a n s p o r t,
c o o lin g , d r y e r M
F IN A L P R O D U C T
4 PVC
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Cross-linkable PE Compounds
(XLPE)
Peroxide cross-linkable XLPE (PEX-A) The X-Compound inline process is designed as follows:
Silane grafted (Sioplas) cross-linkable Polyethylene (XLPE) The X-Compound kneader technology is perfectly capable to
compounds are suitable for the use in the manufacture of low process any kind of grafted polymer compounds. The crosslinking
voltage as well as medium voltage cables up to 33 kV. process is worldwide established.
Both compounds are produced on the X-Compound Kneader. Advantages of the X-Compound Kneader
Due to economic reasons it is recommendable to buy the catalyst
masterbatch from specialised manufacturing companies. > Direct injection of silane into the polymer melt
> Minimum material deposits inside the process area due to
the self cleaning kneader principle
> Perfect mixing behavior allows reduction of silane quantity
A P O L Y M E R > Reproducible grafting reaction
Silane
A D D IT IV E S
XLPE Line 0 ,4 m ³
LV, MV
m e ta l
d e te c to r
A A
A v a c u u m u n d e r w a te r
m e lt p e lle tiz e r
p u m p
X -C O M P O U N D K N E A D E R s c re e n c h a n g e r
C K M P D 1 5 0 -1 1 0
S IL A N E
IN J E C T IO N
H e a tin g c o o lin g u n its v a c u u m p u m p
6 XLPE Insulation
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Semi Conductive Compounds
The main task on the manufacturing of semi conductive com- Advantages of the X-Compound Kneader Technology
pounds is the perfect incorporation of high structure carbon
black into the polymer matrix. In order to keep the required > Uniform mixing and distribution of high structure carbon
conductivity it is of importance to prevent any damage of the black
carbon black structure. > Split feeding of conductive carbon black which permits
high level of filler loading and minimize the critical formation
The X-Compound Kneader is well adapted to requirements of agglomerates
as homogenizing and dispersing (break up of agglomerates), > Precise temperature control to prevent degradation of the
wetting and distributing of pigments, additives and fillers into heat sensitive polymers
the polymer matrix. > Smooth mixing process to avoid damage of the filler
chain structure
Semicon a s p ir a tio n s y s te m
Line
A D D IT IV E S
c a r b o n c a r b o n
b l a c k b l a c k E V A E V A P E
F IL L E R S P O L Y M E R
v a c u u m p u m p
v a c u u m
u n d e r w a te r
m e lt
p e lle t iz e r
p u m p
X -C O M P O U N D K N E A D E R s c re e n c h a n g e r
C K M P D 1 5 0 -1 1 0 (2 0 L /D )
L IQ U ID S
c u s to m e rs
B ig b a g / O c ta b in
w e ig h in g
O il O il O il O il O il w a te r w a te r
XLPE Semicon 7
FURTHER
8 APPLICATIONS
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Control Systems & Service
X-Compound designs and builds complete control systems with X-Compound is your reliable partner for the supply of spare
visual displays for Turn key plants as well as for replacements or parts covering oscillating single screw compounders of nominal
supplements to existing plants. On request we also manufacture size up to 600 mm.
less sophisticated control systems.
X-Compound offers
The application of existing peripheral plant components as well as
their incorporation via Profibus network is also part of our standard > High quality, durable, and corrosion resistant
programme. - kneading elements
- barrel liners
Basically our control systems are designed as follows: A PC based - kneading teeth
Windows system which performs plant monitoring and controlling > All spare parts, e.g.
together with a programmable logic controller (PLC). The process - screw shafts
and the plant are visualised using a series of on-screen pages and - worm shafts
allowing interactive display and modification of current setpoint - lubrication pumps
values and alarms. - process chamber sealing systems
- die plates
- pelletizing knife arms
> Interchangeable kneader barrels completely refurbished
and guaranteed
> Any individual part for gear boxes or complete
interchangeable gear boxes, all guaranteed
CONTROL SYSTEMS
& SERVICE 9
Technical Data Screw Process Speed Max. drive Screw Process Max. drive
diameter length max. power diameter length power
Type mm L/D rpm kW mm L/D kW
CK 45 45 8 - 24 500 30 55 6 15
PVC
HFFR Semicon XLPE XLPE Black Insulation/
Process Data Silane peroxide Jacketing sheathing/
bedding
Spec. energy [kWh/kg] 0,07 - 0,12 0,15 - 0,25 0,2 - 0,3 0,12 - 0,16 0,15 - 0,25 0,06 - 0,08
CK 45 20 - 40 40 - 70 40 - 80 40 - 60 40 - 80 70 - 110
CK 90 300 - 600 350 - 700 500 - 800 500 - 800 500 - 800 700 - 1400
CK 120 450 - 800 500 - 900 600 - 1000 800 - 1200 600 - 1000 1000 - 1800
CK 150 800 - 1500 900 - 1600 1000 - 1500 1400 - 1900 900 - 1600 2500 - 3500
CK 200 1500 - 2800 1800 - 3000 1700 - 2200 2000 - 2800 1800 - 3000 3500 - 5500
10 Technical Data
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11
X-COMPOUND 2013/03 · 250 · E © TROESTER GmbH & Co. KG 2012. Only the contract between the customer and X-COMPOUND is binding for any guarantees and commitments. The particulars
given herein do not represent promises of any special characteristics. They serve purely for general information purposes and may differ in individual cases. No claims of any nature may be derived
herefrom. The observation of commercial trade marks or patents shall in every instance be the responsibility of the customer.