Custom Modular Extrusion

Apex Controls Specialists, LLC

APEX CONSTRUCTION, LLC.

APEX ENGINEERING, PLLC.

Apex Modular Extrusion™ Systems

Mobile CapacityQuick

Connect

AssetRecovery

Functionally Tested Prior to Shipping

CurrentAutomation

ExtruderData Management

17 Days from Crates to Production

Patent #8,894,398 B2

Two (2) 58mm lines – Mexico - 2000 One (1) 70mm line – Argentina – 2001 One (1) 50mm line – Brazil – 2001 One (1) 70mm line – Brazil – 2004 One (1) 70mm line – Indiana (USA) – 2006 One (1) 58mm line – Brazil – 2006

One (1) 40mm – Brazil – 2008 One (1) 50mm – Kingdom of Saudi Arabia - 2010 One (1) 58mm – Kingdom of Saudi Arabia - 2011 One (1) 50mm – Brazil – 2013 Three (3) 58mm – Western China – 2013 One (1) 50mm – Western China – 2013 One (1) 50mm – Brazil – 2014 One (1) 70mm – Brazil – 2014

The EVOLUTION of Apex Modular Extrusion™ Systems Apex Modular Extrusion™ Systems

1st Generation Modularized Sections and Modular CCC Building

2nd Generation with Completely Modularized System

Robust equipment and design Client flexibility for equipment make/model Standardization Cost advantage to traditional stick built Mobile capacity Schedule improvement vs traditional line Incorporate Lean Practices Better equipment access for operations and maintenance Easy to clean for small lot production Modules to fit in a single level warehouse (8M clear) Modules to fit in shipping containers All equipment to be pre-piped / pre-wired Latest technology for data collection and controls VPN connection for Client and for Apex

2nd Generation Design Basis - Modular Extrusion™Apex Modular Extrusion™ Systems

Shorter schedules: Standardized lines can be built in parallel with building construction.

Standardization: Engineering reduced, cost reduced, schedule reduced for additional lines.

Cost advantage: Shop construction is 20-30% lower. Less risk of scope changes.

Minimal plant site interruption: Reassembly is typically 3 wks. Welding is not required.

Client resources minimized: Single source responsibility and standardization reduce resources.

Cash flow end loaded: Production begins prior to final payment.

Advantages of Modular ExtrusionApex Modular Extrusion™ Systems


Twin Screw Extruders 40mm – 50mm – 58mm - 70mm Up to 1000 hp extruder motors Lab Line machines

Number of Feeders Eleven (11) solids feeders Three (3) liquid feeders Pigment cleaning stream

Material Handling 25kg bags Gaylord box or Octabin Bulk bag Silo or bulk transfer

Packaging 25kg bags Gaylord box or Octabin Bulk bag bulk rail or truck

Module Equipment Sizes

Apex Modular Extrusion™ SystemsPictures – Protected Tray/Conduit/Pipe

Apex Modular Extrusion™ SystemsPictures – Electrical and Plugs

Apex Modular Extrusion™ SystemsPictures – Extruder Plugs

Apex Modular Extrusion™ SystemsOn-Site Engineering

Building Mixers Silos / Day Tanks / Bulk Bag Unloaders / Box Tilters Transfer Pipe to Modules Fume Duct to Hoods Dust Collection System Dust Collection Duct to Modules Cooling Tower to Modules Air Compressor to Modules Nitrogen to Modules Utility Power to Modules and Main Drive Utility Power to Auxiliaries (Mixers / Packaging / etc.) Lighting Fire Suppression Floor Loading Adequate for Modules HEAF (if necessary) for Fume Collection Packaging Cable Tray from CCC to Modules Labor and Equipment to erect / assembly Modules VPN Communication to CCC Floor Drains Screener / Pelletizer / Waterbath / Strand Dryer

Apex Modular PlantModular Plant is the integration of all utility equipment necessary for the operation of Modular Extrusion Lines

UtilityControlCenter

Mixers

Cooling Water

Silos

Dust Collection

EDM

Centralized Skids

Apex Modular PlantDesign Basis for Modular Plant

Standardized in three systems to handle from 1-5 extruders. Each system can support production rates of 3.5 ton/7 ton/15 ton per hour).

Integrated Controls by specifying a controls platform that is identical to the “Modular Extrusion System” controls platform. Equipment would simply have a power connection and Ethernet connection for integrated control.

EDM “ Extruder Data Management” - The modular plant is provided with historian and recipe management servers. All data from each extruder line is collected and summarized in productions reports. Packaging and labeling options can also be added.

UCC (Utility Control Center) will house all control equipment, data collection / recipe servers and power distribution equipment.

Engineering to be reused to offer quicker schedules and lower costs. Equipment to have the flexibility to be placed inside or outside. Less client management required. Client needs to lease or erect a

building and provide the power/water sources.

Apex Modular Extrusion™ SystemsProject Language:

HMI - Dual Language - English / Native - Language is selected from the main HMI screen.

PLC - PLC code will be Dual Language English / Native if supported by automation platform.

Drawings will be in English / Metric units - all language will be English. Equipment manuals will be provided in native language if available.

Warranty:

All equipment will have a manufacturer’s warranty of 12 months after shipment . All programming will be tested and signed off at the time of startup. If a

programming issue should service in the first 12 months after startup, ACS will fix over the VPN connection.

Apex will provide a list of all parts manufacturers and their local contacts.

Service:

Apex will provide a list of all parts manufacturers and their local contacts for any mechanical issues.

A VPN connection will be utilized for 24/7 support of any automation issue. A local automation company will be identified to support the process if needed. Apex Engineering will supply a list of critical spare parts.

Support

Control System Design-Build CapabilitySpecialized Programming

Panel Fabrication & Testing

Apex Controls Specialists, LLC

ACS Client Valued Services

Functioning extension of clients’ Engineering and Control services

Diverse Control Panel & Control Room Design Build experience

HMI & PLC design and programming

Start-up and commissioning services

Extensive support capabilities

Training for client-specific systems and hardware


Automation Philosophy PLC is master controller. Entire system utilizes Ethernet

communications. Feeders are connected for

Ethernet communication, set points, actual values and diagnostics. Start/Stop of feeders is by I/O.

Feeder controllers are integrated into the compounding system’s main PLC over Ethernet.

All AC drives are controlled over Ethernet communications with a hardwired E-stop.

Programming software is RSLOGIX 5000 for Allen-Bradley.

A stand alone temperature controller is used for precise temperature control of extruder barrels. A Eurotherm MINI 8 is used.

All remote I/O on Ethernet connections.

Integrated Control Solutions for Extrusion


Self Contained Building – MCC – Main Drive – Heater Panel

Fire Protection – Pressurized – Heating / Air-Conditioning

Easily moved to new location fits in standard

Sea Crate

CCC (Compounding Control Center)

18

Integrated Architecture

18

Lower Operational Costs

Lower Total Cost of Ownership Easy to Maintain

Standard Open Networks

Informed decisions with Real Time Information

Scalable Flexible Systems

Ethernet/IP


High Speed Ethernet controls network

Tightly integrated drive systems, simple Ethernet connection with Estop

Real Time data for process analysis to support a quality product

Reduced wiring with Intelligent MCC and remote Ethernet

I/O

Control architecture is truly integrated - Intelligent MCC – Ethernet drive systems Ethernet remote I/O. Feeders have Ethernet interface.

Feeders are connected to the PLC over Ethernet for easy interlock and setup.

Advantages of Integrated Controls


Easy operation through one common HMI system

Process diagnostics, identify issues quickly for less downtime

On-line historical trending

On-line SPC software

Extruder setup data for each run “Lot – Grade – Color”

Dual Language

Integrated Safety features

Advantages of ACS Software


Process data historian

Recipe management systems

Material verification systems

Packaging systems – material weight and labeling

Lot tracking – Materials used – Yield calculation - Waste tracking.

IDM(Industrial Data Management)


Wireless HMI / Troubleshooting interfaces using Tablets

Modular software blocks for adding equipment

New Modular Plant interfaces

Updated Historian and Recipe management

Complete Ethernet based systems for I/O, MCC and Drives

3rd Generation Controls

ShippingApex Modular Extrusion™ Systems

Shop Assembly/TestingApex Modular Extrusion™ Systems

Apex Modular Extrusion™ SystemsFeeder Deck

Apex Modular Extrusion™ SystemsMixaco Docking Station

Apex Modular Extrusion™ SystemsCompounding Control Center

To request a modular extruder system formal quotation, please contact:Steve SpahnPH: 812-838-0148 ext. 2102E: [email protected]

To request a modular control system or a control system upgrade, please contact:Jeff WestPH: 812-838-0148 ext. 2113E: [email protected]

To request a site visit by the Apex Modular Extrusion team, please contact:Mike WalkerPH: 270-395-4121 ext. 1105E: [email protected]

Apex Modular Extrusion™ SystemsContacts/Information Request

Custom Modular Extrusion

Engineering

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