Maintenance and Repair
In response to the needs of our customers, Manifold & Phalor, Inc has added the capabilities of US Die & Mold to service the needs of the blown film and extrusion industries. With seasoned professionals from industry leaders such as Sano, Cincinnati Milicron and Black Clausen, we have the expertise to support the needs of customers in these industries.
Blown Film and Pipe Die Cleaning
An important aspect of efficient blown film line operation is regular servicing of dies. Effective die reconditioning maintains high levels of line performance by reducing system backpressure, film lines and maintaining uniform film thickness. Some of the below are before and after pictures of a 3 layer film die.
Before:
After:
Blown Film and Pipe Die Repair
After a number of years of service, blown film and pipe dies need more than regular cleaning and service to continue to operate. Dies whose condition is beyond normal servicing often need to be repaired or rebuilt to continue to operate. Most often, rebuilding a die involves stripping, polishing and replating of the entire die. Depending on the condition of the die, remachining of seal and lip surfaces may be required to bring the die back to good operating condition.
Shown below are before & after pictures of a repaired top pin and bushing from a blown film die.
Before:
After:
Before:
After:
The following photos are before and after views of the internals of a corrugated pipe die.
Before:
After:
Corrugated Pipe Mold Repair
The production of corrugated plastic pipe typically uses aluminum vacuum molds to form the outer ribbing on the pipe. During normal usage, these aluminum vacuum molds require repair for wear and damage.
Reconditioning services
Another aspect of blown film line maintenance is regular reconditioning of die assemblies. Shown below are before and after pictures of a multilayer rotator before and after servicing.
Before:
After:
Our company services all brands of dies including, but not limited to, Alpine, Gloucester, Brampton, Kiefel, Reifenhauser, Milicron, W&H, Sano and Davis Standard. Service work is normally accomplished at our plant, but if necessary, can be done at the customer’s site.
Handling larger dies in house is key to servicing a full range of customer dies. Shown below is a die component from a large, 3 layer die being polished in one of our larger lathes.
And for very large dies (such as this 86” die) we provide on site servicing.
In addition to reconditioning dies, other services often required to complete servicing on a die system include manufacturing new die components, reconditioning die blocks and rebuilding rotators and oscillators.
In House Capabilities
In house capabilities to assist in reconditioning a die include turning up to 92” in diameter, boring mills, grinding, welding, cranes up to 50 tons as well as specialized polishing equipment custom tailored for dies. We also have a burn off oven for efficient cleaning of dies up to 48” wide X 72” deep X 60” high