Blender Selection: A Case In Point.

At Deerfield Urethane, an international leader in the production of thermoplastic polyurethane film, blending is a crucial process step before resin, colorants and lubricants can be fed into an extruder. Consistency and throughput are critical, since demand for polyurethane film is soaring. A hot product in the plastics industry, polyurethane film is fast replacing other materials in manufacturing such products as greenhouse glazing, rain coats and sporting gear, seals and gaskets, and fuel cell linings - where higher performance and special properties are in demand.

Thanks to its reputation for quality, custom formulating and fast delivery, Deerfield Urethane is growing rapidly. Following a recent plant expansion, the company now runs ten process lines - including the only line in the world that produces up to 120” ultra-wide TPU film. A ribbon blender on each line feeds a high speed extruder, and together they produce hundreds of unique formulations for customers worldwide.

“We change products constantly, so we have to clean each blender three or four times a day,” say Bill Tippins, manufacturing manager. “We needed to switch to a ribbon blender design that would allow us to discharge fast and clean easily. With our older blenders, we were literally chipping material from crevices in the trough with a screwdriver. The cost in lost production was terrible.”

During preparations for the recent expansion, the company consulted Charles Ross & Son Company of Hauppauge, NY, and selected the Ross Ribbon Blender to become the new standard in the plant.

“To select a ribbon blender, you have to look closely at the small details in design and construction. In these blenders, the internal finish is excellent,” says Mr. Tippins. “No rough welds. No crevices. They discharge nearly completely.”

With a short blending cycle and a product that is not particularly shear-sensitive and does not require vacuum, there was no need to consider a switch to a cone screw blender. But floor space in the plant was still an important consideration.

“Naturally, we were concerned about the space that would be required by the horizontal blenders. But we found that the Ross ribbon blender is actually more compact than the blenders we are replacing,” says Mr. Tippins. 𠇊 right-angle gear drive gives it a small footprint. And since the drive is not a separate standalone unit, it is easy to move and maintain. We also have the option of easily mounting the unit on load cells. With pneumatic conveyors and a programmable control system, this is one way to further automate our process lines.”