From 3 to 5th February 2016 MORETTO held a 1600 m2 exhibit in Pordenone Italy as part of an in-house tech expo and international sales meeting. Customers, visitors and operators from the plastics sector enjoyed an overview over 40 applications of MORETTO technology.
This ranged from a full multi-storey film line with closed circuit gauge control called Contrex to the feeding of PET flake, PVC powder, Calcium carbonate and other difficult to feed materials.
Visitors were taken on a journey through two great innovations: Eureka Plus, completion of the Eureka project, whose perfect drying process definitively comes full circle, and ONE WIRE 6, the only auto-adaptive conveying system in the market.
The result of 13 years of passionate research and driven design, developed at the company’s premises by a team of specialists, Eureka is formed by four core elements:
- first OTX, the Original Thermal Exchanger, the exclusive exchanger where energy meets moisture,
- X MAX modular dryer with constant performance,
- Flowmatik, the auto-adaptive air manager for process air distribution,
- and finally Moisture Meter, a system to measure and control moisture in-line allowing closed-loop corrective measures by the dryer to ensure properly dried material.
Such an engineered drying system ensures an unequaled energy efficiency since the synergy of the components is unique and results in benefits for the whole moulding process: a better cycle time, higher performance, a lower waiting time and higher efficiency and profit.
OTX (Original Thermal Exchanger)
The hopper, known as OTX (ORIGINAL THERMAL EXCHANGER), is the innovative exchanger where energy meets moisture and air is the transport medium. The OTX particular geometry and fluid dynamics guarantee a homogeneous material and air flow, an excellent process to reduce the treatment time by 40% with any material. Flowmatik intervenes in the interaction between X MAX and OTX to distribute the correct air amount generated by X MAX on all active hoppers. This task is entrusted to a device based on a technology which is widely used on airliners: a perfect close loop. Air is the transport medium for energy: a correct air utilization results in a correct energy utilization. Flowmatik permits to employ the exact air amount required and to set only two parameters: material type and throughput. All the rest is AUTOMATIC!
Each of these four elements contributes to avoid energy wastage and to obtain a perfectly controlled process. The result of the Eureka process is now tangible in the product quality and, in particular, Moisture Meter can finally certify the production.
X MAX intelligent modular dryer
X MAX is an intelligent modular dryer based on zeolite technology, enabling to realize drying systems up to 20.000 m3. The uniqueness of this system is its constant performance which has the capability to keep the dew point steady during the process, at around –65° C, keeping unimaginable efficiency levels.
X MAX, designed in cooperation with the University of Padua, carries an absolute novelty: a turbocharger integrated in the machine, a solution dedicated to drying systems even with very heavy duties, such as the applications which require PET dehumidification on a large scale.
The Moretto Moisture Meter
Moisture Meter is the absolute renovation in the drying system market. MORETTO is the only company supplying an effective device to measure the residual moisture in the plastic granule during the process.
The constant communication between the moisture meter and the dryer enables one to set the process by the input of numbers as required by the material’s technical sheet. The opportunity to manage the drying system according to a number provides an incomparable efficiency in treatment, which positively affects the quality of the moulded products and reduces waste and energy consumption.
Moisture Meter enables to certify the production and, through the continuous measurement of the final moisture value, clears all doubts about the drying level of the polymers to be processed. CERTIFIED QUALITY WITH MOISTURE METER.
No other systems can be compared in terms of energy efficiency. Moisture Meter exploits an extremely advanced technology and, once it is adjusted at the plant’s premises, it does not need to be set each time the material lot changes. Certified quality over time.
The real novelty in this new invention allows one to know minute by minute what the exact water quantity to be extracted is, controlling the initial and obviously the final moisture. “With these data we can manage the dryer by using the strictly required energy for a tailor-made treatment.” Says Renato Moretto, CEO of the company.
The Moisture Meter is available in two versions: one that is integrated into the MORETTO Drying system to provide closed loop control and the other version as a “Bolt-on” unit that can be fitted to any existing drying hopper or just as a lab unit to show moisture content (ppm) of material. No calibration or special set-up is required.
ONE WIRE 6: the transport system that sets itself
ONE WIRE 6 is the only conveying system on the market which can automatically adapt to the plant status, recognizing every change. In a conventional transport system, the operator is required to set the parameters related to the suction and pipe cleaning time. OW6 is a revolution in terms of system management: its automation optimizes the performance to the maximum. Each time a material or a feeding segment changes, OW6 automatically recognizes the new situation and adapts the suction and pipe cleaning time instantaneously: the machines recognize the new conditions, automatically adapting and re-calculating the transport time.
The OW6 server can manage up to 80 users such as receivers, suction units, manual and automatic manifold units. A touch view colour screen composes the interface and an optional 7” WIRELESS palmtop with touch view colour technology is available as system supervisor. ONE WIRE 6 can be connected to MOWIS, Moretto integrated supervising system, and equipped with an ETHERNET connection dedicated to remote support.
The conveying system is equipped with a ONE WIRE 6 management system and KASKO receivers which stand out in particular for their renewed design, a clean style, and a full stainless steel construction suitable also for the medical, pharmaceutical and food sector. Together with OW6, KASKO receiver performs its best feature: the KASKO series requires no setting. The KRONO sensor makes them adaptive. The KASKO receivers connected to the new ONE WIRE server for an auto-adaptive system; this new goal releases precious time that the process department manager can dedicate to quality.
Kruise Kontrol – manage granule speeds
The exhibition space also demonstrated Kruise Kontrol, the only system which can manage the granule speed in conveying systems automatically by setting only two parameters and which creates the most suitable working set for each material regardless of the distance or height of the conveying pipes.
By setting the material type and the number of the machine to be fed, KruiseKontrol guarantees a gentle granule transport with a total absence of dust and a lower pipe wear, all in addition to the complete elimination of the “angel hair” phenomenon.
Moretto Gravimix blenders
Another Highlight was the Moretto Gravimix blenders which range from small machine mounted units right up to a 12 tons/ hr unit.
Moretto DGM gravimix blenders can be configured from 2-12 materials types, have fixed or remote touch screen for easy navigation and setting, have the Moretto patented eyelet gates and algorithmic control providing up to 0.001% accuracy.