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In July 2020, Dieffenbacher GmbH (Eppingen, Germany) received an order from a U.S. customer to manufacture a direct-long-fiber thermoplastic molding (D-LFT; see “Continuous tapes, D-LFT meet up in new compression molding process”) line that includes a hydraulic press from the company’s Fiberpress series. The modified extrusion technology upstream of the press will enable the line to produce high volumes of thermoplastic components larger than previously possible.

According to Dieffenbacher, the new line will be the highest-capacity line of its type. It will also produce D-LFT extrudates with only one machine. For example, typical D-LFT plants typically consist of a two-stage extrusion process (melting up of the polymer, and incorporation and cutting of the fiber and mixing with the melted polymer), therefore requiring two extruders. However, this specific project, a second extruder is no longer required. Dieffenbacher contends that melting, fiber-incorporation and cutting/mixing can be done within one machine. 

Further, low-cost recycled polymers from post-consumer and post-industrial plastics will be used as the raw material. Adjustments of the dosing equipment and an adapted length of the extruder barrel will enable the plant to efficiently and economically produce thermoplastic components from 100% recycled material.

The plant concept was developed collaboratively by Dieffenbacher’s Composites and Recycling business units. “This project is an excellent example of the possibilities that Dieffenbacher can offer its customers thanks to the collaboration of its various business units,” says Marco Hahn, Sales director for the Composites Business Unit. "Our combination of a unique technological concept and the use of recycled raw materials convinced the customer to select our company.”

The new D-LFT line will be installed in mid-2021. Production is scheduled to start by October 2021. The company adds that this plant concept is available to Dieffenbacher customers worldwide.