AF-Color, a branch of Akro-Plastic GmbH specialising in masterbatches, and the mechanical engineering company Feddem, both part of the Feddersen Group, have implemented a joint development project for the FED 26 MTS extruder. The project has concluded with the handover and commissioning of a modified line, in which key solutions from the laboratory extruder FED 18 MTS have been transferred to the FED 26 MTS model. The investment enables AF-Color to expand its capabilities for developing additive concentrates from the AF-Complex product family and colour masterbatches from the AF-Color range, while at the same time increasing flexibility and capacity for small-scale production campaigns. The project covered both the adaptation of the new line and the upgrading of the existing FED 43 MTS production line to ensure process comparability and straightforward transfer of formulations.
Expansion of AF-Color's development capacities
The new FED 26 MTS configuration is aimed at supporting research and development activities for AF-Complex additive concentrates and AF-Color colour masterbatches, while simplifying the transition from laboratory to production scale. According to AF-Color, the project was designed both to accelerate development work and to facilitate the transfer of developed solutions into industrial conditions.
"It was important for us to implement a solution that not only accelerates our development work but also facilitates transfer into production. This is precisely where the close coordination within the project team proved particularly valuable. The entire workflow was analysed, enabling many potential challenges to be identified and resolved at the concept stage" explains Kathrin Portugall, deputy production manager at AF-Color.
Technical modifications and application-specific solutions
As part of the project, a series of functional changes were implemented in the extrusion system. According to the companies, an important improvement was the conversion of the FSB side feeders from a swivel arm design to a movable slide mechanism. This results in significantly simplified handling and reduced effort for changeovers. The use of quick-release fasteners and handles, combined with improved mobility on guide rails, enables all work involving the FSB side feeders and the FSV side vacuum degassing unit to be carried out from the operator side of the extruder.
At AF-Color's request, the FSB side feeder in the smaller model 26 was equipped with a cooling function for the first time. This solution ensures reliable feeding of low-melting materials without agglomeration or blockage at the feed inlet, which is particularly important when processing sensitive additive systems.
In addition, the height of the extruder was adjusted so that it fits optimally beneath the new working platform installed at AF-Color's plant. This bespoke adaptation allows efficient utilisation of the available production space.
The FED 26 MTS extruder was height-adjusted to the new working platform at the AF-Color plant, enabling optimal use of space.
The new line is characterised by extensive process flexibility, which corresponds to AF-Color's broad product portfolio. Simple conversion operations allow rapid switching of the processing length between 32 L/D and 42 L/D configurations, as well as changing the pelletising method between strand pelletising and underwater pelletising. This facilitates process optimisation depending on the type of masterbatch being processed and the requirements for pellet shape and quality.
Upgrade of the existing FED 43 MTS line
In parallel with the delivery of the FED 26 MTS, the existing production line from the FED 43 MTS series was upgraded. This line was equipped with technical solutions similar to those implemented on the new FED 26 MTS, including FSB side feeders, an FSV side vacuum degassing unit, variable process length and the option to choose between strand pelletising and underwater pelletising.
The identical functional features on both systems enable process comparability and the transfer of parameters and formulations from the development line to the FED 43 MTS production line. In future, the modernised line is to be used for the commercial production of sophisticated additive masterbatches from the AF-Complex portfolio.
Exploiting synergies within the group
During the project, regular coordination meetings were held between the AF-Color project team and the Feddem team. The cooperation was described as based on open communication, technical exchange and a shared understanding of requirements and proposed solutions.
"The project clearly demonstrates what can be achieved when development, engineering and practical application are closely aligned. The collaborative partnership with AF-Color was the key success factor" adds Heiko Hornberger, operations manager at Feddem.
During the handover ceremony, the managing directors of the companies, Dieter Groß (Feddem) and Dirk Steinbrück (AF-Color, branch of Akro-Plastic GmbH), expressed their thanks to all employees whose commitment and expertise contributed to the successful completion of this synergy project. Looking ahead to future day-to-day operation, AF-Color expects efficient utilisation of the new and modernised lines and highlights the importance of Feddem's technical know-how as reliable support for future process challenges.
Project participants from AF-Color and Feddem during the inauguration of the modified FED 26 MTS line.
