Energy efficiency remains the main issue for injection moulders when drying polymer. However, production flexibility, speed, reliability and precision control are other important factors. Manufacturers of drying equipment are developing a range of ways to meet these demands.
Piovan has widened the Genesys system, launched in 2009 for PET preform and bottle production only, and is now offered in a new range of systems for a much wider range of applications. Genesys is a single-hopper, individual or central, fully automatic drying system. The company says that it can adapt and automatically control operating parameters based on ambient temperature, initial moisture level, type and quantity of polymer, the final moisture content of the polymer, and granule size. In conventional applications a drying unit is commonly used to generate dry air, which is then circulated in drying hoppers. Different polymers require specific individual conditions for optimum operation (air flow, temperature and pressure) depending on the different process variables. A safety condition is systematically adopted and the drying system is sized based on the most critical processing parameters – maximum material consumption and temperature, with the highest airflow. However, this goes against any principle of energy efficiency and raises running costs, as these extreme conditions rarely occur.
Instead, Genesys adjusts and controls optimal operating settings for the material to be dried, using only the overall amount of energy strictly required. The settings are constantly compared with the data collected by the sensors installed on the system.
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