Inexco - Quick Die Change Systems
System Overview
Inexco quick die change systems provide fast, safe, and repeatable die changes on extrusion lines. By reducing manual handling and minimizing changeover time, they help increase equipment uptime and overall production efficiency.
Each system is engineered around the specific extrusion line, die configuration, process requirements, and utility connections. Die mounting, clamping, and utility connections are designed as an integrated system to ensure reliable and efficient die changeovers.
Originally developed for foam extrusion applications, Inexco quick die change systems can also be adapted to other extrusion processes and custom die configurations.
For Foam Profile Extrusion
Frequent die changes are common in foam profile extrusion, particularly when switching between different product geometries or dimensions. Conventional die changeovers can be time-consuming and involve several manual handling steps.
The Inexco quick die change system provides controlled die release, changeover, positioning, and hydraulic clamping. Required utility connections can also be integrated into the system.
Especially in production environments with frequent product changes, this helps reduce changeover times, simplify operator handling, and ensure repeatable die positioning.
For Other Extrusion Applications
The system is not limited to foam extrusion. Quick die change systems can also be engineered for pipe, tube, profile, and pelletizing lines, as well as for custom extrusion tooling applications.
The system layout, die mounting interface, clamping mechanism, and utility connections are tailored to the specific extrusion line and required changeover sequence. This allows the system to be incorporated into both new equipment and existing production lines as a retrofit solution.
Key Benefits
- Fast, repeatable die changeovers
- Reduced manual handling
- Safe and precise die positioning
- Hydraulic die clamping
- Integrated cooling, compressed air, vacuum, and electrical connections
- Application-specific die mounting interfaces and utility modules
- Robust design for continuous industrial operation
- Solutions for both new extrusion lines and retrofit applications
Why Use a Quick Die Change System?
CHANGEOVER TIME
Repeatable die positioning, rapid clamping, and integrated utility connections streamline the changeover process and reduce the time required to get the line back into production.
PRODUCTION UPTIME
Shorter die changeovers mean less production downtime and more available production hours.
PRODUCTION FLEXIBILITY
Frequent product changeovers and shorter production runs can be handled more efficiently, allowing the extrusion line to adapt quickly to changing production requirements.
LINE AVAILABILITY
More productive operating hours can be achieved without increasing extruder output or line speed.
OPERATING EFFICIENCY
The greater the frequency of die changes – and the longer conventional changeovers take – the greater the potential for time and cost savings. The economic benefit can be assessed individually based on the specific extrusion process and production requirements.
LESS DOWNTIME → MORE PRODUCTION TIME → GREATER OPERATING EFFICIENCY
Operating Principle
The quick die change system uses a sliding die carrier with separate production and changeover positions. While one die is running in the production position, the next die can be installed and prepared in the changeover position. This keeps the actual production interruption largely limited to moving the dies into position and completing the required process checks before restart.
- Release the Sliding Die Carrier
The die carrier is unlocked to initiate the changeover. - Change Die Positions and Lock
The active die is moved from the production position to the changeover position. At the same time, the pre-installed die moves into the production position, where it is securely locked in place. - Resume Production with the Prepared Die
Once the die has been moved into position and the required process checks have been completed, extrusion can resume with the prepared die. - Prepare the Next Die During Production
While the line is running, the next die can be installed in the available changeover position and prepared for the following die change. - Switch Utility Settings to the Active Die
The relevant utility settings and connections are switched to the die in the production position, ensuring that the required operating conditions are applied to the active die.
Change die position. Resume production. Prepare the next die in parallel.
Interfaces & Utilities
The quick die change system is engineered to match the mechanical interfaces and utility requirements of the specific extrusion line. A precision die mounting interface and dedicated clamping system ensure secure, repeatable die positioning during every changeover.
All required utility connections can be integrated directly into the die change system. Depending on the application, these may include cooling and temperature-control circuits, compressed air, vacuum, and electrical connections.
During a die change, the relevant utility connections and operating parameters can be switched over to the die in the production position. This ensures that the active die is supplied with the required process conditions, while the previous die can be removed or the next die prepared in the changeover position.
Custom-engineered adapter flanges and interfaces allow the system to be integrated into both new extrusion lines and existing equipment as a retrofit solution.
Securely clamped. Precisely positioned. Utilities connected to the active die.
Integration & Retrofit
The Inexco quick die change system can be integrated into both new and existing extrusion lines. Key design considerations include the available installation space, die dimensions, process loads, operator and maintenance access, and the required utility connections.
NEW EXTRUSION LINES
For new extrusion lines, the quick die change system can be incorporated at the initial equipment and tooling design stage. This allows the die mounting system, adapters, utility connections, and operating concept to be engineered as a fully integrated solution from the outset.
- Optimized mechanical integration
- Short, clearly defined utility routing
- Matched die and adapter interfaces
- Compact system layout
- High level of operational and process safety
RETROFIT SOLUTIONS
Existing extrusion lines can also be upgraded with an Inexco quick die change system. The existing installation is assessed in detail to develop the required adapter, mounting, and interface solutions.
- Available installation space
- Die weight and process loads
- Extruder and die interfaces
- Existing utility connections
- Operator and maintenance access
- Required adapters and connection components
Key Benefits
- Integration into existing extrusion line configurations
- Custom-engineered adapter and interface solutions
- Compact, robust system design
- Application-specific die clamping systems
- Precise and repeatable die positioning
- Controlled transfer of utilities to the active die
- Custom solutions for special extrusion applications
Applications
The quick die change system is designed for extrusion processes with frequent die changes, where changeover time has a significant impact on available production time.
The system provides the greatest time savings when the downstream equipment – such as calibration units, cooling sections, or product guides – can remain in position during the die change or requires only minimal adjustment. In these applications, the prepared die can be moved directly into the production position, clamped, connected to the required utilities, and brought back into operation with minimal interruption.
If downstream equipment must also be exchanged, extensively repositioned, or realigned for each product change, this additional setup time may limit the overall time savings provided by the quick die change system.
Key Requirement
The greatest benefit is achieved when the downstream process equipment allows the die to be changed without extensive downstream retooling or realignment.
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Ideally suited for foam extrusion lines running different product profiles, sizes, or die configurations. While one die is running in the production position, the next die can be installed, set up, and made ready for production in the changeover position. This significantly streamlines product changeovers and minimizes line downtime.
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Well suited for tube extrusion lines where the downstream sizing or calibration equipment does not prevent a rapid die change. Different tube sizes and tooling configurations can be run with reduced setup effort and shorter product changeovers.
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Pelletizing die plates require periodic changeouts due to wear, material changes, cleaning requirements, or production needs. A pre-installed die plate ready for operation helps minimize changeover time and reduces pelletizing line downtime.
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For short production runs and custom extruded products, frequent die changes can account for a significant share of non-productive line time. A quick die change system allows the next die to be installed, set up, and made ready while the current product is still running.
This reduces downtime between production runs, increases the number of productive operating hours, and makes frequent product changes and smaller batch sizes more economical to run.