ESI Extrusion Services, Inc.

The Accupunch series machines provide precision fabrication functions such as punching, notching and complex end cuts of flexible and rigid plastic, rubber or composite profiles to finished part tolerances while still in the extrusion line. High torque servomotors actuating offset cranks are used for providing high speeds to the Servo Press Accupunch. Presses can be mounted in different planes to provide multi-axis fabrication.

Accupunch precision is achieved by incorporating a servo driven, stop/go feeder with fiber optics for function triggering. Many processors have had concerns about looping the extrusion but have found that the amount of time needed to perform the desired function is measured in fractions of a second and has no adverse effect on the process. ESI has successfully utilized this unique proven process in numerous applications for over 25 years and it is the foundation of our complete "ACCU" series of fabricators, saws and flyknives.

Standard Features:

• 3“ x 18“ Servo driven smooth belt feeder
• Single Axis Fabrication assembly: Servo driven, cam actuated die-set mount
• Servo controlled feeder follows dancer and provides controlled stop prior to press cycle. Product loops during punch cycle and feeder automatically over-speeds to maintain synchronization with extrusion line.
• Takeaway conveyor is mounted at the exit of the press
• Integrated encoder or fiber optic cut activation modes 
• Machine actions and operations controlled by a programmable servo controller
• Machine capability of 90 CPM
• Cut length accuracy capability of ±0.010" in fiber optic length control mode 
• Safety enclosure surrounds the press
• Keyed interlocks are mounted on all guard doors
• Color Touch Screen operator interface 

• SERVO_PRESS_ACCUPUNCH_A.pdf

Use ESI's embossers to create patterns on your plastic or composite profiles. These machines are often utilized for embossing wood grain patterns on composite or foamed PVC decking profiles. Our heavy-duty, two-post assembly embossing stands can be custom designed to meet all your in-line or off-line processes to one, two or four surfaces of your profile. Options include driven or non-driven rolls, electrically or hot oil heated rolls, single strand or multi-strand designs, various width or diameter rolls, pre-heaters and automatic roll movement for ‘random’ patterns.

ESI offers automated, end of line stacking/palletizing equipment for wood composite decking, railing and fencing profiles, including articulating stacking tables, servo controlled pick and place systems and a variety of indexing unitizing systems.  Stacking solutions with integrated end of line cooling systems can also be supplied to provide additional cooling for difficult to cool extrusions.  ESI stacking/palletizing and packaging equipment are typically custom designed around the specific requirements of the customer and can include bundle strapping.  We invite you to look over the photos of systems ESI has supplied and contact and ESI sales engineer to discuss the possibilities of automating your end of line packaging needs.

ESI SD series pullers are a perfect choice for small profiles and tubing with lower pull force requirements as well as high-speed applications. Rubber coated timing belts are utilized providing "zero slip" with the drive pulleys. SD series offer adjustable belt height and are available with numerous belt materials, drive choices and speed ranges.

Standard Features:

• 3” wide puller belts
• 18” contact length
• “Zero Slip” timing belt
• Two post aluminum block frame with cantilevered shafts
• Local or full guarding
• 1 HP AC sensorless Vector drive with +/- .5% speed regulation
• Adjustable entrance guide rollers

ESI MD series pullers are suitable for vast array of extrusion processes. MD series pullers deliver consistent pulling speeds and reliability, critical for accurate extrusion sizing. MD series pullers are available in standard widths of 3" and 5", 6” with standard traction lengths ranging from 24" to 36".

Standard Features:

• 3", 5" or 6" wide puller belts
• 24" or 36" contact length 
• Two-post frame and outboard bearing plates
• Upper and lower belts driven via right angle gearboxes with vertical shaft
• Operator controls include: power On/Off, manual potentiometer, digital display of puller speed and ‘E' stop
• "Zero Slip" timing belt
• Local or full guarding 
• 2 HP AC sensorless Vector drive with +/- .5% speed regulation
• Adjustable entrance guide rollers

The patented Airfly cutting head was designed as a simple, efficient cutting device with very few moving parts for low maintenance. The Airfly is an 'on-demand' pneumatically powered flyknife cutter can be furnished as a 'table top' unit with basic controls. It is powered by multiple stainless steel air cylinders, and does not require the use of an electric or vacuum/clutch brake, has no linings to wear or replace, needs no electric motors or over-excitation circuits, and operates without the need for timing drums and belts.  The Airfly is available in a standard 3.5" bushing size.

ESI servo boosting (traveling) saws, for rigid extrudates, incorporate moving saw tables mounted on linear rails. ESI servo boosting saws provide superior cut length accuracy control by utilizing high resolution encoders in conjunction with a servo-motor and precision ball screw assembly. ESI servo saws have proven to produce in-line cut length accuracy of +/- .020". Models are available in either single strand or dual up configurations.  ESI also provides numerous choices in blade diameter, saw motor sizes, saw platform and control packages.

Standard Features:

• Blade diameter mounted to direct arbor motor assembly
• AC motor drive system includes an AC Inverter for the saw motor that provides dynamic braking to saw blade motor (stops motor when interlocked door is opened for added safety); also provides variable speed control of the saw motor for various cutting conditions
• Down cut saw design (where the blade “pulls” the extrudate into the back fence during the cut). Provides superior cut quality to up-cut saws because product is supported on rigid table during cut
• Moving saw carriage is mounted on heavy duty linear profiled guide rails
• Carriage actuated by servo controlled, precision ground ball screw system
• Saw carriage is triggered and cut length point is latched to line speed via encoder
• Encoder wheel rides on product and is mounted to pneumatic lever arm at saw entry
• Machine actions are controlled by a servo motion controller
• Cut length accuracy capable of +/- .020” (exclusive of product slippage)
• Color Touch Screen operator interface display panel to provide the operator with system input
• Safety enclosure surrounds the saw head and motor assembly with keyed interlocks for safety
• Saw blade is enclosed with sheet metal guard

For higher performance cutting applications, our servo driven flycutters are available with a variety of cutting torques and speeds. Brushless servomotors, directly coupled to the machined blade holder, drive these cutters. Since no friction wear surfaces such as clutch or brake assemblies are utilized, continuous adjustment or replacement to insure accuracy is a thing of the past.

The base servo control provides for 'on-demand' cutting with simple operation through the standard interface. ASC servo cutters are also available with automatic camming allowing non continuous flyknife motion up to 1000 cuts per minute and continuous cutting up to 1400 cuts per minute. Blade speed and other parameters are adjustable on the color touch screen operator interface.

Standard Features:

• 80 In-Lb brushless servo cutter motor
• Unique Self-Aligning ‘Quick change’ bushing assembly (No tools required for bushing changeover)
• One-piece 3 ½” OD cutter bushing design
• Direct coupled cutter motor & blade holder – no belts or clutches
• On-Demand mode of up to 350 cuts-per-minute
• Cutter guard electrically interlocked

ESI cooling drums are designed for efficient in-line cooling of both sides of sheet or round extrudates.  Drum systems can consist of two or more drums in either a vertical or horizontal configuration.

For sheet products the drums are typically chilled for cooling and the sheet is not exposed directly to water. For round products the extrudate makes multiple wraps around the drums. The cooling is typically achieved by submerging the bottom of the lower drum in water or by spraying the extrudate as it wraps around the drum.

Standard Features:

• Cored stainless steel faced drums mounted on stainless steel shafts with heavy duty bearings
• Sheet drums are fitted with rotary unions; each rotary union is fitted with hose that runs to a central water manifold (valved) for customer’s chilled water supply connection. These drums are typically highly polished.
• Multipass cooling drum systems have water containment reservoirs under the drum assemblies and rollers to guide the extrudate around the drums. 
• Cooling drums are chain driven by a common motor and gear reducer
• Vertical guide rollers are located between the drums to facilitate guiding product on the drums

ESI's flood tanks are designed for immersion cooling of rubber and plastic tubing and profiles and are available in a wide variety of standard cross sections and lengths.

 Standard Features:

• Manifolds are located full length along bottom of the tank to provide circulated water to the tank
• Stainless steel tank construction
• Stainless steel guide roller assemblies (vertical and horizontal); mounted at entry and exit ends
• Base tank system designed to utilize the customer’s water supply for continuous water circulation, includes supply inlets and drains
• Baffled air blow-off compartment, incorporating a flex-nozzle assembly with a fitting ready for customer connection to air supply

ESI's Accufly® in-line cutting system offers innovative technology with high accuracy cutting by incorporating a servo driven stop/go feeder with fiber optics for cut-to-length signaling.  Length is set by adjusting the fiber optic bridge assembly, or utilizing the servo feedback from the feeder motor. Just prior to the set length being reached, the feeder belts ramp down to ensure proper cut length positioning without overshoot. When the fiber optic beam is broken, the feeder belts stop and the servo driven flyknife is cycled, resulting in a square cut and high accuracy cut length.  Because the feeder is maintaining a loop ahead of the Accufly, the product is fed without tension, ensuring very accurate cut lengths, especially on highly elastic profiles such as rubber wiper blade elements. ESI has successfully utilized this unique proven process in numerous applications for over 20 years and it is the foundation of our complete "ACCU" series of fabricators, saws and flyknives.

Standard Features:

• 3“ x 18“ smooth belt feeder
• Servo controlled feeder follows dancer and provides controlled stop prior to press cycle. Product loops during punch cycle and feeder automatically over-speeds to maintain synchronization with extrusion line.
• Optional puller-cutter mode for very high cutting rates
• 80 In-Lb brushless servo cutter motor
• Unique self-aligning 'Quick change' bushing assembly
• One-piece 3 1/2" OD cutter bushing design
• Direct coupled cutter motor & blade holder - no belts or clutches
• 5' takeaway conveyor is mounted at the exit of the cutter head 
• Fiber optic length control
• Machine actions and operations controlled by a dual axis, programmable servo motion controller
• Capable of up to 120 CPM in Stop/Go operation with cut length accuracy of +/- .010" in fiber optic length control mode
• Capable of up to 1400 CPM in Continuous operation
• Cutter guard electrically interlocked
• Color touch screen operator interface
   

ESI air boosting (traveling) saws, for rigid extrudates, incorporate moving saw tables mounted on linear rails. Saw table is matched to line speed through a clamping cylinder and air cylinder assist. ESI also provides numerous choices in blade diameter, saw motor sizes, saw platform and control packages.

Standard Features:

• Blade is mounted to direct arbor motor assembly
• AC Saw motor drive system includes an AC Inverter for the saw motor that provides dynamic braking to saw blade motor (stops motor when interlocked door is opened for added safety); also provides variable speed control of the saw motor for various cutting conditions
• Down cut saw design (where the blade “pulls” the extrudate into the back fence during the cut). Provides superior cut quality to up-cut saws because product is supported on rigid table during cut 
• Air actuated boosting table on heavy duty linear profiled guide rails
• Machine actions are controlled by a solid state programmable controller
• Cut length accuracy capable of +/- 1/8” (exclusive of product slippage)
• Safety enclosure surrounds the saw head and motor assembly with keyed interlocks for safety
• Saw blade is enclosed with sheet metal guard

ESI Cleated Pullers incorporate high traction, low wear, reinforced cleats for the downstream conveying of extrudate where large pulling force is required. Cleated Pullers are provided with a unique "floating" upper carriage that allows irregular shaped extrudate to pass through without interference as well as other options.  Standard sizes include 6" to 12" wide cleats with 36" to 60" long traction lengths, but we have supplied cleated pullers in widths of up to 48” and lengths of up to 14’ with custom specifications as well.

Standard Features:

• Cleated chains are fitted with set of long wearing cleats
• Designed with heavy duty four-post frame assembly with bearing blocks and steel ‘H’ frame support plates between posts
• Pneumatic feed belt actuation of upper belt assembly; bottom belt is fixed
• Pivoting, self adjusting upper belt assembly
• Belts are driven via common variable speed, AC inverter duty motor thru a heavy duty double sprocket and chain assembly which includes a self adjusting tensioner
• Motor controller is a variable speed, sensorless AC vector drive 
• Operator controls include: power On/Off, manual potentiometer, digital display of puller speed and ‘E' stop
• Full safety cage with keyed interlocks for safety

ESI HD series pullers are designed to deliver maximum pull force and speed consistency where a cleated belt puller may not be suitable. With 6" and 12" belt width and 36", 48" and 60" contact length these chain driven pullers are suitable where large pulling force and very robust construction are required. Various belt materials are available for maximum grip on your product.

Standard Features:

• Heavy-duty gearboxes with chain drives
• Self adjusting upper pneumatic belt assembly
• Designed with two-post frame and outboard bearing plates
• Fully guarded with access doors
• Adjustable vertical and horizontal entrance guide rollers
• 3 HP AC sensorless vector drive with +/- .5% speed regulation
• Operator controls include: power On/Off, manual potentiometer, digital display of puller speed and ‘E' stop
• Upper and lower belts driven thru a double sprocket and chain assembly which includes a self adjusting tensioner

ESI's unique Accusaw series of stop/go saws have a long history of providing precision, in-line, cut-to-length results to the extruders of flexible rubber and plastic profiles and hose (both reinforced and non reinforced). The Accusaw features a servo driven smooth belt feeder and fiber optic length control that effectively eliminates slippage. The servo driven belt feeder precisely advances the extrudate through the saw until shortly before the desired cut length is reached. The feeder is then slowed until the fiber optic sensor is triggered, at which point the feeder is stopped, with no interruption to the extrusion process, and the cut is performed. The dancer controlled feeder then smoothly accelerates to catch up to the line and the process is repeated. This revolutionary technology provides unparalleled cut length accuracy and, because the extrudate is momentarily stopped during the cut, superior cut quality.

 Standard Features:

• 3" x 18" Servo driven smooth belt feeder
• Fiber Optic length control
• Integrated takeaway conveyor
• Blade lubrication system
• Drained stainless steel drip tray
• Easy to use touch screen HMI
• Encoder or fiber optic operation
• Cut length accuracy capability of +/- .010" in fiber optic length control mode
• Contact dancer speed control
• Saw head and feeder fully enclosed 
• Adjustable stroke control
• AC motor
• Adjustable blade rpm
• Dynamic saw motor brake

ESI coilers are available in single or dual station designs. When two coiling stations are provided, operator switches stations when one reel is full while other station is coiling. Coilers can be supplied with traverse mechanisms for layering extrudate side by side on a wide reel or without traverse for strip winding applications. Mechanical traverses are driven by the main coiler drive and allow the operator to mechanically adjust the ratio on the traverse mechanism. Upgraded electronic traverses are also available which incorporate a separate drive motor, which is electronically ratioed to the main coiler drive. Coilers are supplied with dancer mechanisms to control the main reel drive and adjust the rotational speed as the effective coil diameter increases. Counters and encoders are supplied which will automatically stop the reel when the desired length has been coiled on the reel.

Machines can be supplied with expandable hubs for coreless coiling or for reels not suitable for loading on a shaft. For high speed or small reel applications, or where operator is not assigned to the end of the line, machines can be supplied with automatic cut and transfer which will automatically cut the product and start the next reel when the desired length has been coiled. For some applications ESI can supply cut and transfer coilers, which can then take the completed coils, band with plastic banding and eject the completed coil from the machine.
 

ESI high efficiency spray cooling tanks are available in a wide variety of standard cross sections and lengths in either one-up or two-up designs. 

Stainless steel support rollers are mounted within the tank.  Spray manifolds surround the extrudate and stainless steel centrifugal pumps provide a highly atomized spray pattern that ensures maximum heat removal by evaporative cooling.

Standard Features:

• Non-driven support rollers
• High efficiency quad spray manifolds, full length 
• Stainless steel tank construction
• Stainless steel guide roller assemblies (vertical and horizontal); mounted at entry and exit ends
• Top mounted stainless steel lids 
• Base tank system designed to utilize the customer’s water supply for continuous water circulation, includes supply inlets and drains
• Baffled air blow-off compartment, incorporating a flex-nozzle assembly with a fitting ready for customer connection to air supply

The Accupunch series machines provide precision fabrication functions such as punching, notching and complex end cuts of flexible and rigid plastic, rubber or composite profiles to finished part tolerances while still in the extrusion line. ESI has produced Air Press Accupunches for over 25 years. Large air bladders are used for providing high punch forces to the Air Press Accupunch. Presses can be mounted in different planes to provide multi-axis fabrication.

Accupunch precision is achieved by incorporating a servo driven, stop/go feeder with fiber optics for function triggering. Many processors have had concerns about looping the extrusion but have found that the amount of time needed to perform the desired function is measured in fractions of a second and has no adverse effect on the process. ESI has successfully utilized this unique proven process in numerous applications for over 25 years and it is the foundation of our complete "ACCU" series of fabricators, saws and flyknives.

Standard Features:

• 3“ x 18“ Servo driven smooth belt feeder
• 7 Ton, 4-Post air actuated press assembly
• Servo controlled feeder follows dancer and provides controlled stop prior to press cycle. Product loops during punch cycle and feeder automatically over-speeds to maintain synchronization with extrusion line.
• Takeaway conveyor is mounted at the exit of the press
• Integrated encoder or fiber optic cut activation modes 
• Machine actions and operations controlled by a programmable servo controller
• Capable of up to 60 cycles per minute
• Cut length accuracy capability of ±0.010" in fiber optic length control mode 
• Safety enclosure surrounds the press
• Keyed interlocks are mounted on all guard doors which are not bolted shut
• Mounted on pneumatic impact absorbing bags to reduce vibration
• Shock absorber assemblies are fitted between the interior and floor base frames to reduce sway and residual vibration
• Color Touch Screen operator interface

ESI Panners are frequently utilized in the rubber industry for automatically winding product in a ‘lay flat’ condition onto a pan (e.g. uncured rubber tube or hose). Extrudate can be taken from the panner and cured in an autoclave or stored for later application of reinforcement. Panners can be single station or dual station with automatic transfer between the pans. Machines are typically servo controlled and consists of a driven lead-in conveyor, a driven support turntable and a traverse mechanism to move the turntable laterally.  Pan rotational speed and pan lateral position are automatically adjusted to lay the product in spirals with a preset gap between the extrudates. ESI also supplies hose pans in stainless steel or aluminum, pan let-offs and adjustable pan stacking carts.

ESI Cut-and-transfer coilers automatically cut the extrudate to length, index coiling stations and start the next coil without operator intervention. This can greatly reduce labor by allowing the operator to be assigned additional tasks, instead of waiting for the reel to complete. On high speed extrusion lines or lines which run short length coils it is often necessary to allocate an operator exclusively to the coiling station to change reels. The time taken to manually change reels often results in a significant length of extrudate being accumulated during the changeover causing extrudate to pile up on the floor and the operator to run the coiler at a very high speed to catch up. This can result in poor quality coils and resultant damage to the extrudate.

Depending on the application ESI cut-and-transfer coilers can include combination cut and clamp mechanisms or separate cutter and clamp mechanisms. All ESI cut-and-transfer coilers include multi-axis programmable motion controllers and brushless servomotors. For increased automation ESI can supply cut-and-transfer coilers, which can then take the completed coils, band with plastic banding and eject the completed coil from the machine. Systems can be supplied with recipe functions for storing of specific product parameters. Due too the high degree of automation on ESI cut-and-transfer systems with banding and part ejection, machine payback due to labor saving can be extremely quick.

ESI's servo puller-cutters are designed to meet a wide range of in-line flycutting of plastic and rubber tubings and profiles. Precision in-line cutting of extruded profiles and tubing requires the extrudate to be presented to the cutter at a consistent rate. ESI puller with integrated servo cutter unit offers a cut length accuracy of +/- .030" with an on-demand 350 cuts-per-minute capability.  Units are available with larger servomotors for increased cutting torque, cutter head slide adjustments, larger diameter bushings, blade lubrication and fully caged puller assemblies.

Standard Features:

• 3“ wide x 18“ belt puller; timing belts driven via right angle gearboxes with vertical shaft; shaft driven via variable speed, AC inverter duty motor
• 80 In-Lb brushless servo cutter motor
• Unique Self-Aligning ‘Quick change’ bushing assembly (No tools required for bushing changeover)
• One-piece 3 ½” OD cutter bushing design
• Direct coupled cutter motor & blade holder – no belts or clutches
• On-Demand mode of up to 350 cuts-per-minute
• +/- .030” cut length accuracy capability (exclusive of product slippage, bow, curvature and shrinkage)
• Cutter guard electrically interlocked
• Puller assembly locally guarded

ESI has developed our industry leading HAPC line of flycutting equipment which has produced in-line cut accuracy standard deviations of 0.002" at stop start cut rates of 650 cuts-per-minute. Our HAPC includes individual intelligent servomotors and drives for each belt of the puller and for the flyknife cutter.  The 3-axis, solid state servo programmable controller along with integrated touch screen operator interface display panel offers system cycle rate capability of 750 cuts-per-minute in 'On-Demand' mode, 2000 cuts-per-minute in 'Camming' mode and up to 3000 cuts-per-minute in 'Continuous' mode. These highly sophisticated machines have been used in applications automatically adjusting each individual cut length in response to feature locations sensed by a vision system at over 500 cuts per minute and locating multiple cuffs in corrugated tubing, trimming cuff length and tracking multiple different parts and separating into different bins off the packing conveyor.

Standard Features:  

• 3“ wide x 18“ belt puller; each belt driven via individual brushless servo motor with ‘zero backlash’ planetary gearbox and controlled with individual intelligent servo drive
• 130 In-Lb brushless servo cutter motor
• Unique Self-Aligning ‘Quick change’ bushing assembly (No tools required for bushing changeover)
• One-piece 3 ½” OD cutter bushing design
• Direct coupled cutter motor & blade holder – no belts or clutches
• System cycle rate is limited to 750 CPM in ‘On-Demand’ mode; 2000 CPM in ‘Camming’ mode and up to 3000 CPM in ‘Continuous’ mode
• +/- .005” cut length accuracy capability (exclusive of product slippage, bow, curvature and shrinkage)
• Cutter guard electrically interlocked
• Puller assembly is locally guarded
• Three axis solid state triple servo programmable controller

Since it’s inception in 1981, ESI has specialized in on-line fabrication. While the Accupunch series has been available since the early days, ESI is constantly evolving the capabilities of the series. ESI has supplied Accupunches with up to five fabrication presses (some equipped with programmable product features and often mounted in multiple planes), routing systems, drilling systems, sawing systems. ESI has also supplied many variations of boosting fabrication equipment, again this consists of punching, drilling, routing and sawing (including miter cuts) and often consisting of a combination of several of these fabrication methods. The return on investment on in-line fabrication is often extremely fast due to the labor reduction and elimination of work in process. In the modern manufacturing environment most of the Companies who are doing well are the Companies who can produce finished parts more efficiently than their competitors. Automation of fabrication is often the best place to look.

The machines shown on this page are only a small selection of the many different types of machines we have designed and manufactured. In many cases ESI manufactured the complete system including punch tooling in our state of the art manufacturing facility. We also often utilize our advanced motion control programming to allow synchronization of the multiple cutting mechanisms, including recipe driven automatic selection of part features from a library. Contact us today to see how we can help you with your fabrication needs.

ESI's brushing machines are designed to provide a random textured surface for plastic or composite profiles. Brushing machines can also be utilized for roughing the surface of profiles in preparation for application of adhesives. Brushes are driven by variable speed AC motors and inverter drives. Machines can be supplied with horizontal and/or vertical brush positions and brushes are easily accessible for quick replacement. Units are fully guarded and provide easy adjustment of brush depth while the machine is running. Options include: single strand or multi-strand designs, various size brushes and torques, vacuum systems to minimize dust and pinch roll pullers for isolating brushing forces or operating in a post-cut application.

For wide, flexible or rigid profiles choose ESI's Cross-Cut saw. Our cross-cut saws incorporate a moving saw carriage mounted on lineal rails.  Carriage movement can be controlled by utilizing a high resolution encoder in conjunction with a servo motor and precision ball screw assembly or using an optional pneumatic clamp and air assist for less precise applications.  The cross-cut traverse is available with either air control or motor for speed control. ESI also provides numerous choices in blade diameter, saw motor sizes, saw platform and control packages.

Standard Features:

• Blade is driven by an AC motor
• Saw motor drive system includes variable speed control of the saw motor and provides dynamic braking of the saw motor
• Cross-cut mechanism driven via a variable speed motor where speed is controlled via touch screen or by adjusting pressure and flow control for pneumatic cross-cut
• Saw table to be outfitted with adjustable fences
• Moving saw carriage is mounted on heavy duty linear profiled guide rails
• Carriage actuated by servo controlled, precision ground ball screw system
• Saw carriage is triggered and cut length point is latched to line speed via high-resolution line encoder
• Replaceable UHMW, cutting bed is fitted on top of the base plate
• Machine actions are controlled by a servo motion controller
• Safety enclosure surrounds the saw head and motor assembly with keyed interlocks for safety

ESI's ASC servo boosting saws are also available in Dual-Up configurations. The dual-up saw system consists of two (2) independently controlled servo boosting saw carriages on a common frame where the action of each saw table is controlled by a single, solid-state programmable motion controller. The controller processes the signals from the high-resolution line encoders, synchronizes the cut cycle, and controls the motion of the saw and traveling table. A color touchscreen is supplied for control inputs and status.

Standard Features:

• The saw system consists of two (2) independently controlled servo boosting saw carriages on a common frame
• Two blades located side by side at set center to center distances to accommodate the customers 2-up extrusion
• Saw blades are driven by AC motors (saw blade assemblies are 'down cut' design)
• Each saw motor drive system includes an AC Inverter that provides dynamic braking to saw blade motor (stops motor when interlocked door is opened for added safety); also provides variable speed control of the saw motor for various cutting conditions
• The blade assemblies are brought into contact with the extrudate by means of pneumatic cylinders; speed is adjustable to allow for different cutting conditions
• The moving saw tables, mounted on heavy duty linear guide rails, are driven by a servo ball screws
• Each saw carriage movement is matched to line speed by high-resolution line encoders
• The action of each saw a single, solid-state, programmable motion controller controls table. The controller synchronizes the motion of the saw carriages to the extrudate
• A color touchscreen is supplied for control inputs and status.
• An expanded metal safety cage surrounds the entire assembly with keyed interlocks for safety

ESI's conveyorized spray tanks are designed to 'carry' your product downstream, with a low tension 'pull' while providing high efficiency, spray water cooling. Smooth belts are recommended for applications where product marking may be a problem. Open mesh systems are recommended for most efficient cooling.

Standard Features:

• A continuous smooth mesh (plastic or stainless steel) conveyor runs full length of the tank on a stainless slide
• Conveyor is driven by a variable speed AC or DC motor and drive
• Conveyor speed is controlled using a potentiometer mounted on operator panel 
• Two, full length, high efficiency spray manifolds are mounted at upper corners of the tank, above the conveyor. With mesh systems spray manifolds are also mounted to spray through the belt.  
• Stainless steel tank construction
• Stainless steel guide roller assemblies (vertical and horizontal); mounted at entry and exit ends
• Top mounted stainless steel lids 
• Base tank system designed to utilize the customer’s water supply for continuous water circulation, includes supply inlets and drains
• Baffled air blow-off compartment, incorporating a flex-nozzle assembly with a fitting ready for customer connection to air supply

When you are limited on floor space for your cooling needs, just look to ESI's Multi-Pass cooling tanks to solve your problem. With our Multi-Pass cooling tank, your flexible plastic or rubber profile can be wrapped several times around our custom capstan rollers to eliminate the need for longer or multiple spray tanks. 

Standard Features:

• Capstans are mounted on each end of the tank. Depending on the application, multiple capstans can be mounted on each shaft or wide capstans can accommodate multiple wraps of the extrudate.
• Different capstan diameters and materials are available.
• With large diameter capstans, upper spray tanks can be mounted at the top of the capstan for cooling of the extrudate on the return pass. With smaller capstans the extrudate stays in the lower tank.
• Tank is constructed of stainless steel
• Two full length spray manifolds are mounted above and below the extrudate to direct the spray down on to the product
• Upper & lower spray manifolds are separately controlled with hand valves
• Capstans or an internal conveyor can be driven by a variable speed AC or DC motor/drive system
• Tanks can include pneumatically operated clear hinged lids for string-up & product access
• Central water circulation system includes stainless steel reservoir & pump
• Plumbing includes dual strainers & bypass valves
• Exit blow off section includes ring style nozzle  

ESI's accumulators are designed to provide accumulated storage of flexible material during line operation without having to shut the line down.  ESI manufactures accumulators for use ahead of the extruder on crosshead extrusion lines such as metal reinforced profiles or for use at the end of the extrusion line ahead of windups or on lines requiring additional cooling. Accumulation is typically vertical to minimize floor space and is primarily used during reel changeovers. Accumulators consist of a series of free turning upper and lower rolls.  The upper rolls are moved up and down on a linear slide and can be motor driven or pneumatic, while lower rolls are mounted in a fixed position.  Rollers are non-driven and are supplied in a variety of materials and diameters to suit the application. Accumulator is automatically synchronized to the extrusion line and is typically activated by a let-off or windup signal.

Powered Let-Offs are designed to unwind profile from coiled reels. They are typically utilized on crosshead extrusion lines and can be used for letting off metal reinforcement (e.g. automotive seal lines) or extruded tubes with or without reinforcement (e.g. hose lines). Let-offs are often supplied in conjunction with accumulators to ensure continuous supply of material to the extrusion line. Let-offs can also be used for transfer of bulk coiled extrudate to smaller consumer sized packages. Let-offs are typically dancer controlled to adjust reel speed as effective reel diameter changes and can be designed as single station or dual station.  Machines are designed for a variety of different reels sizes and weights and can lift the reel from the loading position or couple to roll around reels.

ESI offers conveyorized, cascade or submersion salt tanks for vulcanization of rubber compounds. The recommended conveyance method depends on the characteristics of the extrudate. Conveyorized tanks are recommended for delicate profiles, which will stretch if pulled from downstream, such as wiper blade elements. A stainless steel conveyor belt is mounted within the salt tank to carry the extrudate down-line, under the belt, with minimum pulling tension, driven on two large grooved steel pulley rolls (one at each end). Conveyor belt tensioning is automatically controlled within each tank by means of an air cylinder, which compensates for thermal expansion by moving the idler pulley up-line or down-line as required. Glass faced & sealed, infrared heater panels are mounted within each tank, at the entry end, above the stainless steel conveyor belt; these panel heaters are designed to provide consistent temperature to the belt (minimizing belt temperature differentials), and to assist in re-melting any salt buildup on the belt before contacting the extrudate. The bottom of the belt is submerged in the liquid salt. Submersion tanks use undriven rollers to hold the extrudate under the salt and cascade tanks allow the extrudate to float on the liquid salt while ‘raining’ liquid salt on top of the extrudate. Many tanks are supplied with cascade sections at the front of the tank to allow partial cure of the rubber before contacting it with belt or rollers. Tank lengths are dependent on the cure time of the extrudate. For tanks too long to ship in one piece ESI offers salt tanks with field welded joints. 

 
All ESI tank exteriors are constructed of carbon steel, double wall, sheet metal, fully welded to tubular steel frame. The interior salt tank is manufactured of 14 gauge stainless steel, and is "free floating" to allow for thermal expansion. Tank incorporates an integral hood with side mounted hinged doors, providing access to the tank interior. A free floating, salt service tank, fitted with a circulation pump, is located on the rear of the salt tank (for adding and pre-melting new salt); this pump is responsible for re-circulating salt to the tanks and cascade troughs. One heavy-duty immersion heater heats the Service tank. The entire tank section, hood and doors incorporate dual wall construction, with industrial grade fiber glass insulation, at top, sides, bottom and doors, providing increased energy efficiency and heat retention Tanks are heated with heavy duty immersion heaters. All heater controls are solid state and mounted in a Nema 12 enclosure.

Available options are: driven lead-in conveyors, salt removal beater bars, ring style hot air blow-off nozzles for salt removal, additional temperature control zones, heater load indicators and custom lengths and cross sections.

ESI's hot water wash tanks are used to remove excess salt from salt cured rubber profiles. Because the salt solidifies immediately when touched with cold-water, hot water sprayed with special high velocity nozzles is used. Tanks can be supplied in various lengths and with one or more zones. Multiple zone hot water washes are fitted with a cascading water system so that the cleanest water is used in the downstream section and the salt concentration increases in each zone closer to the salt tank. Special electric heaters, mounted to the exterior of the reservoir are utilized to avoid heater failure due to salt buildup. Water temperature is closely controlled and insulation is utilized to ensure tank efficiency. Tanks can also be supplied with integrated spray cooling on a common frame as the hot water wash.

ESI's IR heating channel can be used for pre-heating of rubber and plastic profiles and hoses. These ovens feature high heating efficiency, digital temperature control, clam-shell opening for easy string-up and tubular steel frames. Entry and exit guide rollers are fitted. Various lengths and heating capacities can be supplied and external IR temperature sensing and control, multi-zone temperature control and heater cutoff options to avoid fires are available.

ESI's dual servo puller-cutters are designed to meet a wide range of in-line flycutting of plastic and rubber tubings and profiles. Precision in-line cutting of extruded profiles and tubing requires the extrudate to be presented to the cutter at a consistent rate. Our dual servo puller-cutter unit includes a fully programmable motion controller, color touchscreen, servomotors for both puller & cutter. System offers a cut length accuracy of +/- .010" with electronic camming of blade motion to achieve peak blade speed at any cut rate up to 1000 cuts per minute and a continuous cut mode of up to 1400 cuts-per-minute.  Units are available with larger servomotors for increased cutting torque, cutter head slide adjustments,

Standard Features:

• 3“ wide x 18“ belt puller; timing belts driven via right angle gearboxes with vertical shaft; shaft driven via brushless servo motor
• 80 In-Lb brushless servo cutter motor
• Unique Self-Aligning ‘Quick change’ bushing assembly (No tools required for bushing changeover)
• One-piece 3 ½” OD cutter bushing design
• Direct coupled cutter motor & blade holder – no belts or clutches
• On-Demand and continuous operations of up to 1400 cuts-per-minute
• +/- .010” cut length accuracy capability (exclusive of product slippage, bow, curvature and shrinkage)
• Solid state dual servo controller
• Integrated touch screen operator interface display panel
• Cutter guard electrically interlocked
• Puller assembly fully guarded with keyed interlocks

Pinch roll pullers are used for light duty and small profiles that need very little contact length.  They are available in a variety of roll diameters and widths that best suit the specific application.

Standard Features:

• Driven bottom roll with upper idler
• Roll diameters designed to the product needs
• Rolls can be knurled or coated
• Stainless steel drip trays
• A/C or D/C drive and motor system

ESI Performer Series Puller-Saw Combinations provide an innovative, streamlined alternative to traditional extrusion line layouts. Combining two critical components of the extrusion line into a common platform and control package, enhances operator efficiency, conserves valuable floor space and insures proper machine alignment.

Performer PPS combinations are designed to provide smooth, consistent pull force while producing repeatable, finished cut-to-length parts at the end of the extrusion line. Performer PPS combinations are available with both cleated and smooth belt pullers in a variety of widths and contact lengths and with numerous drive choices. Saw table motion is synchronized using ESI's Posi-Lock speed control or via our optional ASC servo control package. Up-Cut and/or down cut saw motions are available. All ESI saws are equipped with AC inverter saw motors providing adjustable blade speed control and dynamic braking of the saw motor in power down or E-stop conditions. Full safety cages or optional sliding Lexan doors surround the puller and the saw compartments and all doors are electrically interlocked for safety.

Performer PPS combination units can also be configured with integrated embossing units or protective film applicators further streamlining the extrusion line layout. Used in combination with Performer PCT vacuum calibration tables, ESI's Performer Series provides a robust, flexible, state of the art platform in a modular extrusion line layout, designed to facilitate easier line string-up and operation, enhance operator efficiency and maximize available floor space.

Standard Features:

• Heavy duty construction
• Integrated puller and saw
• Puller Speed regulation +/- 0.5%
• Adjustable entry guide rollers
• AC inverter duty saw motor
• Adjustable blade RPM/dynamic braking
• Fully enclosed puller and saw enclosure
• Saw table mounted on heavy duty linear rails with sealed bearings
• Numerous puller and saw sizes 

• Performer_puller_saw.pdf

ESI offers pneumatically actuated dump tables in a variety of lengths and widths to match the product envelope. Dump tables can be fitted with timers to trigger actuation or can be tied into the saw or central line control system. Tilting tables are actuated using air cylinders and feature stainless steel trays and slides and are offered in single and dual strand configurations.  Various accumulation tray sizes are also available.

ESI’s ASC boosting punch is designed for fabricating profiles too rigid to stop with the Accupunch. The machine represents a combination of the press used on ESI’s top selling Accupunch and the controls utilized on ESI’s ASC boosting saw. The press is an air diaphragm type with up to 3” stroke and spring return. Standard press size is 20-1/2 x 15-1/2. A full safety cage surrounds the press and boosting mechanism. Support tables are mounted before and after press. 

Standard Features:

• 7 Ton, 4-Post air actuated press assembly
• Press is mounted on heavy duty linear profiled guide rails
• Carriage actuated by servo controlled, precision ground ball screw system
• Press is triggered and cut length point is latched to line speed via a high resolution line encoder
• Encoder wheel rides on product and is mounted to pneumatic lever arm at machine entry
• Machine actions are controlled by a servo motion controller
• Cut length accuracy capable of +/- .020” (exclusive of product slippage)
• Color Touch Screen operator interface display panel to provide the operator with system input
• Safety enclosure with front access doors surrounds the main frame with keyed interlocks

• ASC_Series_Servo_Boosting_Punch.pdf