Project Details

Services Used

Mechanical Design, CAD Design & 3D Modeling, 3D Rendering & Simulation, Manufacturing Process Consulting, Product Development Consulting, Product Support & Manufacturing Documentation

Overview

This system optimizes a hot melt adhesive twin screw extrusion line by integrating a highly efficient setup that delivers product to one or both coating dies. It also provides the flexibility to purge material either before or after the storage tank, or to bypass the tank entirely when necessary. Designed specifically for a client seeking to improve operational efficiency, the system redesign led to a reduction in processing line length by more than 50 feet, which directly resulted in significant energy savings, a reduction in scrap material, and minimized maintenance intervention. The streamlined flow path, coupled with the reduction in residence time, contributed to notable improvements in process performance, ultimately lowering both degradation and product abuse during production.

Process

• Configured custom 3-way and 2-way valves with purging capability for flow optimization
• Designed custom shaft seals for melt pump gears, valve stems and filter carriers (refer to U.S. Patents US9309974B1 & US11821421B2)
• Modeled full system assembly from legacy 2D prints and client measurements
• Consulted with client for scope development and streamline design for performance
• Created 100+ production drawings and documents including:
  • Bill of Materials (BOMs) for accurate part sourcing and inventory management
  • Assembly instructions & exploded views for manuals and maintenance guides
  • Technical documentation & fabrication-ready drawings (including GD&T for precision machining) to support vendors and manufacturers

Design Tools

Autodesk Inventor, AutoCAD