Innovative concepts for the manufacture

of plastic and rubber products

Systems – Service – Solutions

 Contents

Integrated systems 4
Compounding facilities 6
Compact skid systems 9
Film and sheet extrusion lines 10
Foam extrusion lines 12
TPE systems 14
Rubber processing systems 15
Profile production lines 17
Flooring product systems 18
Performance 20
Customer service 21
Product portfolio 22

2
Systems – Service – Solutions

... providing the key to your success

By the end of this decade, world demand for plastic An additional factor contributing to business success
products will have almost doubled and the range of derives from the security of knowing that we at
rubber products will also have increased considerably. Berstorff can provide help promptly if a rubber or plas-
As a result it is more important than ever that produc- tics machine should break down. We perform the reg-
tion machines are not simply inter-combined on an ad ular maintenance of complete systems in order to min-
hoc basis. Technical efficiency, productivity and profit- imise the downtime necessary to carry out repairs. If we
ability can only be maximised with machinery, plant ascertain that a machine component needs to be
and systems comprising modules that are ideally replaced, we will ensure that only original replacement
matched to one another. parts are installed.

The progress we have made in process engineering and

design, augmented by advancements achieved in close
collaboration with the chemical and plastics industries
provide the sound foundation on which our technolog-
ically proven machines and systems are based.

Berstorff is available to its customers around the clock,

providing extensive expertise, specialised personnel
and testing facilities in our well-equipped technical
centres.

Modular concept

1
3
2 1 Polymer 9 Vacuum air knife 17 Heat exchanger
2 Filling or reinforcing 10 Strand pelletiser 18 Pellet drying
C
A B
A Recycling materials 11 Classifier screen 19 Bow screen
3 Additives 12 Silo 20 Agglomerate
B Rework
D
3 4 Twinscrew 13 Silo loading separator
C Resign blend side-feeder 14 Weighing and 21 Diverter valve
E
D Premix 5 Twinscrew extruder bagging
E Big bag 6 Vacuum degassing 15 Under-water
7 Strand die head pelletiser 12

8 Water bath 16 Heat exchanger 11

10
4
9
5 6 6 8

7 14

18

11
21
20

12
15 16
19 13
17 16

14

3
Integrated systems

From the single extruder to the turnkey production plant

Our range of services includes everything from the For every new extrusion plant, a qualified project team
design and manufacture of individual extruders to coordinates all the work of the different departments
planning and constructing integrated facilities and and suppliers in order to achieve an intelligent system
turnkey plants for the manufacture of plastic and rub- layout combined with maximum engineering cost-effi-
ber products. ciency. The team also exercises strict control over the
project and keeps a close eye on deadlines and cost at
Our complete solutions bring you not only economic all times. Our project people stay with every stage of
advantages but also the guarantee of the best possible system implementation right up to final acceptance,
technical coordination of all the individual compo- providing advice and inputting know-how wherever
nents. Right from the design stage we ensure that required.
interface problems will not arise at a later date. Intensive training during the commissioning phase also
ensures that your personnel are well prepared to oper-
ate the plant.

Roller head system

4
Co-extrusion line for the
manufacture of films 5
Compounding facilities

... giving you the edge

Taking the desired product as our basis, we as your And there’s more: our compounding facilities offer the
general contractor will provide all the services required decisive advantage of being constructed from individu-
for construction of a high-performance compounding al, self-supporting components that offer all the bene-
plant – with system concepting, plant logistics, basic fits derived from stand-alone modules.
and detail design, interface coordination with the In addition, activities such as
building supplier, test laboratory and workshop design,
construction of the plant, training of the operating  preassembly,
personnel and commissioning.
 interface testing and

 inspection under production conditions

are all performed in our factory. The modules are sub-

sequently dismantled at precisely defined interfaces for
easy transportation to your site. Once there, they need
only to be erected and/or reassembled with one
another using the plug-in and flanged connections pro-
vided.

The Berstorff
modular concept

6
 Performance features

 Exceptionally short project planning times

 Self-supporting steel construction enables reliable

transportation of modular plant components

 Lower project costs due to minimised on-site

installation times

 Lower construction costs, because the customer

only has to provide a simply walled-in space
instead of an entire steel construction

 Higher operational reliability with in-factory test-

ing of the equipment under production condi-
tions, enabling interface problems to be identi-
fied at an early stage and thus quickly and cost-
effectively rectified

 Early training of operating and maintenance per-

sonnel as part of our in-factory commissioning
programme

 Easy, rapid plant relocation if required

7
In-factory test set-up 8
Compact skid systems

... consistently superior Performance features

Berstorff sets the current standard for compounding  Ideally graduated sizes of plant and different
systems and process technology, whether it be in the machine series
design and construction of new plant, or in the mod-  Thoroughly proven method of construction
ernisation of existing facilities. Based on our tried and  Almost unlimited range of applications
tested twin screw extruders, our compact skids are  Outstanding productivity
designed in strict accordance with modular construc-  Excellent cost-efficiency
tion principles.  Exceptional availability
 Assured product quality
With this plant design, all essential components such as
the control system, the side feeder, vacuum generating
units and filter units are installed ready piped and
wired on the baseframe, and then delivered having
already been shop-tested and inspected. The metering
system is installed on a further unit and can be easily
connected with the extruder via a plug-in and flange
connection system. This substantially reduces commis-
sioning time, allowing you to begin production with-
out delay.

Compact skid
ZE 90A x 32D UT

9
Film and sheet extrusion lines

... future perfect

Offering the very latest in advanced technology and film products such as roofing membranes, swimming
designed according to the modular construction princi- pool linings, seals and liners for rainwater retention
ple, our extrusion systems can be ideally tailored to basins, linings for landfill sites, foundation membranes
your requirements, but without the usual expense of and floor coverings. New areas of activity include the
customisation. Constantly redefining the market stand- manufacture of thermal and sound insulating materials
ards, they can be made to satisfy any set of demands and instrument panels from thermoplastic olefin (TPO)
and are fully upgradeable for ongoing future viability. sheet and film. It is also possible to integrate our
systems directly with facilities manufacturing products
Our in-line compounding systems are primarily used in from films (laminates) and sheets, such as automatic
the automobile components industry and by manufac- thermoforming machines.
turers of civil and construction engineering sheet and

Co-extrusion system

10
 Performance features

 Increased product quality

 Greater flexibility and faster production

re-rigging – even for special formulations

 Reduced capital outlay costs

 Lower energy, equipment and maintenance

requirements for reduced operating cost

 Use of low-cost raw materials instead of manu-

factured compounds

 Less capital tie-up in the warehouse

 Lower waste disposal costs

11
Foam extrusion lines

... more advantages than ever

For decades we have been designing and building tech- Aside from their low weight per unit area, the products
nologically sophisticated systems, from foam extruders manufactured in our foam extrusion lines are charac-
to entire foam production plants. We are able to offer terised by their excellent thermal insulation, good
a wide range of experience and know-how in the field shock absorbency and high rigidity. These properties
of single screw and twin screw extruders, plus the pro- enable the manufacture of tailor-made products for
totyping and testing facilities of our technical centres widely varying applications, from waterproofing
for the planning and engineering of advanced foam through soundproofing to packaging. And the asso-
extrusion lines. ciated products, whether films, tubes, beads or boards,
Berstorff Schaumex® and Schaumtandex systems are can also yield unmatched solutions, guaranteeing more
specially designed and constructed to meet the most advantages than ever.
varied requirements of physical foaming.

12
Schaumtandex ZE/KE
 Performance features

 PS, PE and PP can be processed without modify-

ing the screw and/or barrel configurations

 Use of environmentally friendly propellants

 Starting materials, edge trimmings and web

scraps etc. can be recycled without difficulty

 High productivity

 Exemplary operational reliability

 Assured product quality

13
TPE systems

... outstanding evolutionary advancement Performance features

As a major player right from the start in the processing  Production of outstanding foam profiles
of thermoplastic elastomers (TPEs), Berstorff has devel-
oped and successfully implemented a considerable  Reliable implementation of innovative solutions
number of systems in this field. Through the achieve-
ment of ever more significant advantages such as  Exceptional productivity
weight reduction, pigmentation options, weldability
and improved recycling properties, the TPE foam pro-  Unsurpassed product quality
files manufactured by our systems are successfully used
in the automobile, building and construction, and  Excellent cost-efficiency
furniture industries.
 Good environmental compatibility
Through our R&D effort, we are able to offer TPE
systems with a wide range of highly advanced features.
These units are capable of combining the functional
properties of rubber with the processing possibilities of
thermoplastics. So the dichotomy between the
advanced properties of elastomers and the advantages
of thermoplastics has been narrowed, making way for
an almost unlimited range of sophisticated hybrids.

14 TPE co-extrusion plant

Rubber processing systems

... a unique portfolio Performance features

A whole series of new and further developments has  Advanced, patent-protected technological
considerably extended and improved our range of features
systems for manufacturing and processing rubber. We
are renowned for the unique portfolio of services that  High output
we offer. These encompass plant planning and system
engineering, the manufacture of systematically con-  High availability
structed and individually designed extruders, calen-
ders, double belt presses (AUMA® rotary presses), micro-  Low energy consumption
wave lines, equipment for testing laboratories and waste
processing plants, plus training for your operating per-  Low operating costs
sonnel and a full range of commissioning services.

Aside from our advanced multiplex extrusion systems

for the manufacture of tyre components, this wide-
ranging capability has enabled us to develop integrat-
ed systems for the production of V-belts, V-rib belts
(open-flanked and fully sheathed), lightweight con-
veyor belts with textile tensile members, rubber floor
coverings and mats, as well as seal profiles for doors,
windows and automotive applications.

Multiplex unit

15
16
Profile production lines

... meeting your requirements to a “T” Performance features

Our rubber profile production lines enable the most  Reliable processing of a wide range of rubber
widely varying products to be manufactured to the compounds
highest standards imposed by the construction and
automotive industries. The profile and extrusion  Unlimited configuration options
options available include: hollow or solid; smooth fin-
ish or individually contoured; with or without steel  Outstanding productivity
reinforcement; high quality or extra-high quality.
 Tailored product quality
Our rubber profile production lines are equipped to
your requirements with different but nevertheless opti-  Excellent cost-efficiency
mally matched extruders, vulcanising screws, cutting
and winding machines as well as the necessary meas-  Good environmental compatibility
urement and control devices. We supply cold-fed
extruders, cold-fed devolatilising extruders or devola-
tilising extruder lines featuring pin-lined barrel technol-
ogy – all to suit your specific requirements. And we can
offer an equally wide range of options for your vulcan-
ising process needs – with shock module, microwave,
hot air and salt bath lines all available.

Rubber profile production

17 facilities
Flooring product systems

... comprehensive single-source supply

We have a huge amount of expertise both in process Located at the heart of our flooring product systems
technology and on the machinery and systems side. are components of both our plastics and our rubber
Our flooring product systems are a classic example. As processing systems. Using our single-source supply
a general contractor, we can engineer solutions for capability we combine these in accordance with your
every stage of the process chain – from raw material specific requirements, incorporating processing units
input to end product winding. A characteristic feature for preparing, feeding, metering, mixing and distribut-
of our systems is that both colour changes and cleaning ing the raw materials, single screw extruders, two-roll
operations can be performed with the utmost ease and calenders and double belt presses (AUMA® rotary
expediency so that even small batch sizes can be man- presses), as well as reclaim extruders/pelletisers and
ufactured with minimum disruption and maximum emerising, embossing and winding devices.
cost-effectiveness.

Berstorff AUMA® rotary press

18
 Performance features

 Customised concepts

 Full integration

 High flexibility

 Excellent cost-efficiency

 Assured product quality

AUMA® for the manufacture

of floor coverings

19
Performance

Comprehensive competence
– in production and development

As one of the world’s leading extruder manufacturers,

we have set ourselves the target of providing you with
technically feasible and economically viable extrusion
technology capable of meeting the ever increasing
demands that characterise today’s markets. Thanks to
our wide range of extruders – covering almost every
conceivable material and offering the full range of pro-
cess steps – we are able to offer precisely the process
configuration to suit your particular requirements.
Latest machinery technology
in the Test and Let’s work together
Development Center
Our Test and Development Centres in Germany and
USA, equipped with the latest machines, are available
virtually any time for trials. Together with a team of
qualified technicians you can test and optimise every
process step, every screw configuration, and every barrel
arrangement under operating conditions, using your
own materials.

A range of measuring and inspection instruments are

available for collecting and recording the trials data, as
is an inspection laboratory to conduct initial tests on the
manufactured products.

Twin screw extruder

ZE 60A UTX

20
Customer service

A name you can rely on

Whatever your problem, our Customer Service Centre

is there to help you – right around the clock.

Our well-managed spares warehouse guarantees

prompt supply of any replacement parts you may
need. Spares are normally shipped on the same day as
you place your order.

Our experienced service crew of technicians and engi-

neers can be at your door within hours to perform any
maintenance or repair job that may be required. And
you can call our Service Hotline to talk to our qualified
experts about problems affecting your equipment – at
any time, day or night.

To ensure your equipment continues to operate with

maximum reliability, we also offer extensive mainte-
nance and service contracts. And if your machines are
PLC-controlled, we can check your system, localise
faults, and make the necessary adjustments by Standards to match your own
modem.
State-of-the-art methods and equipment for planning,
design and production, and the in-depth expertise of
our application specialists, combine to ensure the high-
est possible standards. Naturally, we operate a compre-
hensive quality management system and are certified as
per DIN ISO 9000.

With the aid of sophisticated computing procedures, we

simulate the processes that take place in our extruders
and use finite element analysis to optimise the strength
of our components, screw shafts and extrusion dies.

CNC machine tools and machining centres ensure maxi-

mum precision. Materials specially selected for your pro-
cess secure the highest possible operational reliability of
your equipment over a long service life.

21
Product portfolio

Striving for our mutual success

Founded over a century ago, Berstorff today ranks

among the world’s leading manufacturers of machinery
and systems for the production and processing of plas-
tics and rubber. In close cooperation with raw material
producers, processors and research institutions, we
develop and engineer pioneering solutions, time and
time again, making it possible to manufacture innova-
tive products and help improve production processes for
existing products.

22
 Supply programme

Berstorff GmbH supplies machinery, systems and pro-

duction lines for plastic and rubber products. We also
handle complete plant projects, from concept to com-
missioning.

Plastics technology

Twin screw extruders

Single screw extruders
Foam extrusion systems
Film and sheet extrusion lines
Plastics calenders
Pelletisers

Rubber technology

Extruders and extrusion lines

Rubber calenders
Microwave, hot air and salt bath vulcanising lines
AUMA® rotary presses
V-belt production equipment
Roll covering equipment

We develop designs precisely matched to your individual

requirements, from individual machines to turnkey facto-
ries.
Why not give us a call?
Our experts will be delighted to discuss any questions you
may have.
Berstorff GmbH
Postfach 61 03 60, D-30603 Hannover
An der Breiten Wiese 3-5
D-30603 Hannover
Phone (+49/5 11) 57 02 - 0
Fax (+49/5 11) 56 19 16
Hotline Rubber Technology (+49/1 72) 5 11 96 20
Hotline Plastics Technology (+49/1 72) 5 11 96 21
Service Hotline (+49/1 72) 5 11 96 23
Internet: www.Berstorff.de
E-mail: [email protected]

Berstorff USA Berstorff Southeast Asia

7095 Industrial Road 23 Tagore Lane # 04-15
P.O. Box 6270 Singapore 787601
Florence, KY 41002- 6270 Republic of Singapore
USA Phone: (+656) 5 53 58 33
Phone: (+1/8 59) 2 83 02 00 Fax: (+656) 4 55 04 19
Fax: (+1/8 59) 2 83 18 60 E-mail: [email protected]
E-mail: [email protected]
Berstorff Russia
Berstorff China Makarenko 5-5
Beijing office 105062 Moskau
1501 China World Tower 1 Russia
No. 1 Jianguomenwai Avenue Phone: (+7/0 95) 9 70 17 30
Beijing 10004 Fax: (+7/0 95) 9 70 17 31
China E-mail: [email protected]
Phone: (+86/10) 65 05 05 16
Fax: (+86/10) 65 05 41 61 Berstorff France
E-mail: [email protected] 5 Allée des Barbanniers
F-92632 Gennevilliers
Shanghai office Cedex
Ground Floor, Part D1, Bldg. No. 44 France
Plot D12 No. 207, Tai Gu Road Phone: (+33/1) 46 85 25 37
Wai Gao Qiao Free Trade Zone Fax: (+33/1) 46 85 25 16
Pudong New Area Shanghai 200131 E-mail: [email protected]
China
Phone: (+86/21) 58 68 07 97
Fax: (+86/21) 58 68 11 73
E-mail: [email protected]
SSS-engl.-1000/05

A company of the
Mannesmann Plastics Machinery Group