LEWA ecofoam metering system for plastics extrusion

LEWA ecofoam^®Blowing Agent Metering System

LEWA ecofoam is a redundantly designed, completely leak-proof system that meters different blowing agents used for foaming in the manufacturing processes of various types of plastics, including PE or PUR foam.

The ecofoam metering system operates with a flow rate of 0.05 kg/h to 250 kg/h and a discharge pressure between 50 bar and 500 bar.

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LEWA ecofoam^®
Foam plastics with precision and safety.

When producing plastics, numerous manufacturers rely on the ecofoam system from LEWA for the precise and fast metering of blowing agents in the extruder.

The metered flow of the blowing agent is regulated according to the extruder output. The system – which features an integrated flow measurement system and a control unit – is tested and available as a turnkey system with multiple output ratings. LEWA ecofoam relies on tried-and-tested LEWA diaphragm pump technology.

This means that precise, reliable, and low-maintenance operation is guaranteed for the non-lubricating blowing agent, even at a high vapor pressure level.

Good reasons to choose a LEWA ecofoam^® metering system

The LEWA ecofoam metering system is a complete blowing agent system based on our tried-and-tested diaphragm pump technology.

Leasable pilot plant for process optimization

We are happy to provide you with a pilot plant for process optimization. The LEWA ecofoam pilot plant has been designed for all common blowing agents, including a cooling device for CO₂ and an explosion-proof design for combustible blowing agents. You will be happy with the quality of the ecofoam pilot plant and the uniformly accurate metering of various blowing agents. The plant can be leased for up to six weeks for a low flat fee, or longer following consultation.

Precise metering of the blowing agent

Precise, rapid control of the metered flow when changes are made to the extruder output or the extruder pressure ensures that the end product is always of top quality. This is achieved by a control system developed by LEWA, which continuously monitors the plausibility of set values and actual values. The control system, metering pump, and Coriolis flow meter are all adapted to the specific application.

Use of various blowing agents

LEWA ecofoam meters all known blowing agents – from halogenated hydrocarbons (Freon 11, 12, etc.), butane, pentane, and propane through to CO₂. We have also delivered pilot systems with water injection technology to customers. You can rely on our decades of experience in various blowing agents. Not only that, but we can even provide further assistance during conversion to CO₂.

Complete project management from a single source

We work with you during the project stage to clarify all the key process parameters, such as suction pressure, any cooling that may be required, pressurization, and so on. LEWA ecofoam is delivered as a turnkey system and comes completely assembled – including piping and wiring – on a base frame, ready for operation.

Special features for CO₂ applications

For CO₂ applications, we provide suction-side heat exchangers in the pipeline for cooling the CO₂ upstream of the pump inlet and a cooling jacket on each pump head. We also provide a flow cooler for cooling the cooling medium, including the cooling circuit.

Tried-and-tested LEWA diaphragm technology

It goes without saying that our ecofoam system relies on our tried-and-tested LEWA diaphragm technology that features maximum efficiency, complete sealing, integrated protection, and monitoring.

Accessories for efficient use

We supply ecofoam metering systems with a wide range of additional components: a suction-side strainer, two contact pressure gauges for monitoring pressure in the suction-side and discharge-side pipeline, and a type-tested and function-tested safety valve for protecting the metering system against overpressure.

Options

Made from special materials

Individual design: We offer piping, accessories and pump heads made from special materials for your LEWA ecofoam metering system.

Additional metering

You also want to add color or fire retardant in the low-pressure section of the extruder? No problem - you can rely on our expertise.

Special features for CO₂ applications

For CO₂ applications, we provide suction-side heat exchangers in the pipeline as well as a cooling jackets for each pump head and special run coolers.

Design according to current regulations

We design your ecofoam metering system for operation in hazardous zones, also according to BS & NEC or other regulations.

Examination by experts and authorities

We also gladly provide performance diagrams and certificates of static pressure tests also by TÜV, Germanischer Lloyd’s, Lloyd’s R. of S. or other authorities.

Pilot plant for process optimization

You can rely on over 60 years of experience in the design of equipment and systems: In cooperation with you, we develop pilot plants to optimize your processes and procedures.

Testing, acceptance and inspection

We make sure that everything works: LEWA offers numerous services, including factory acceptance test (FAT) at the manufacturing site or at your site (SAT), NDT and PMI.

Maintenance and service

No matter if maintenance, spare parts or repair - our service technicians are well trained and available worldwide. Thus, we guarantee fast response and smooth operations.

Complete documentation

Receive supporting documents and certificates, including the operating instructions, as well as design and test details in different languages.

References

CO2 Metering of liquid CO2 (blowing agent)

CO₂ Metering of liquid CO₂ (blowing agent)

The customer’s challenge: For the manufacturing of insulation materials the metering of liquid CO2 (blowing agent) is required

LEWA’s scope of delivery: System

Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDB1 / M200, cooling unit, mass flow meter, DCS with control according to set point setting

LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoam
Fluid Pressure in bar Flowrate in l/h
Carbon dioxide 300 4.2
Market Process
Synthetic Fibers -
Synthetic Materials / Plastics Blowing agents,
Expanded foam, Extrusion
Metering of butane (blowing agent)

Metering of butane (blowing agent)

The customer’s challenge: For the manufacturing of insulating material a metering system for butane (blowing agent) is needed

LEWA’s scope of delivery: System

Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm pump, type LDD3 / M910, cooling unit, mass flow meter, DCS with control according to set point setting

LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoam
Fluid Pressure in bar Flowrate in l/h
Butane 350 88
Market Process
Synthetic Fibers -
Synthetic Materials / Plastics Blowing agents,
Expanded foam, Extrusion
Metering of liquid butane (blowing agent)

Metering of liquid butane (blowing agent)

The customer’s challenge: For the manufacturing of insulation materials a metering system for liquid butane (blowing agent) is required

LEWA’s scope of delivery: System

Delivery in detail: 1 Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDE3 / M900, mass flow meter, DCS with control according to set point setting

LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoam
Fluid Pressure in bar Flowrate in l/h
Butane 350 100
Market Process
Synthetic Fibers -
Synthetic Materials / Plastics Blowing agents,
Expanded foam, Extrusion
Metering of flame retardant

Metering of flame retardant

The customer’s challenge: In the production of plastics flame retardant has to be metered

LEWA’s scope of delivery: System

Delivery in detail: Custom-designed metering system completely electrical heat traced and insulated, with 1 gear wheel pump, storage tank, strainer, valves, mass flow meter and control cabinet, for operating temperature of 80 °C

LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoam
Fluid Pressure in bar Flowrate in l/h
Flame retardant 137 14
Market Process
Synthetic Fibers - Synthetic Materials / Plastics Polyester
Metering of chlorofluorocarbon (CFC) (blowing agent)

Metering of chlorofluorocarbon (CFC) (blowing agent)

The customer’s challenge: For the manufacturing of insulating packing material the metering of chlorofluorocarbon (CFC), freon 152 a as blowing agent is required

LEWA’s scope of delivery: System

Delivery in detail: Custom-designed metering system with 1 LEWA ecoflow diaphragm metering pump, type LDC3 / M910, cooling unit, mass flow meter, DCS with control according to set point setting

LEWA main product/s:
Custom-designed metering system
LEWA ecoflow diaphragm metering pump
LEWA ecofoam
Fluid Pressure in bar Flowrate in l/h
Foaming agent 300 30
Market Process
Synthetic Fibers -
Synthetic Materials / Plastics Blowing agents,
Expanded foam, Extrusion

Fluid	Pressure in bar	Flowrate in l/h
Carbon dioxide	300	4.2

Market	Process
Synthetic Fibers - Synthetic Materials / Plastics	Blowing agents, Expanded foam, Extrusion

Fluid	Pressure in bar	Flowrate in l/h
Butane	350	88

Market	Process
Synthetic Fibers - Synthetic Materials / Plastics	Blowing agents, Expanded foam, Extrusion

Fluid	Pressure in bar	Flowrate in l/h
Butane	350	100

Market	Process
Synthetic Fibers - Synthetic Materials / Plastics	Blowing agents, Expanded foam, Extrusion

Fluid	Pressure in bar	Flowrate in l/h
Flame retardant	137	14

Market	Process
Synthetic Fibers - Synthetic Materials / Plastics	Polyester

Fluid	Pressure in bar	Flowrate in l/h
Foaming agent	300	30

Market	Process
Synthetic Fibers - Synthetic Materials / Plastics	Blowing agents, Expanded foam, Extrusion

CO2 Metering of liquid CO2 (blowing agent)
Metering of butane (blowing agent)
Metering of liquid butane (blowing agent)
Metering of flame retardant
Metering of chlorofluorocarbon (CFC) (blowing agent)

Technical data

Thanks to the tried-and-tested module system of our diaphragm metering pumps, we are able to customize the ecofoam metering system to meet your individual requirements.

Performance data

Discharge pressure, min. [bar]	Discharge pressure, max. [bar]	Flow rate, min. [kg/h]	Flow rate, max. [kg/h]	Operation, min. [°C]	Operation, max. [°C]	Viscosity [mPa∙s]
50	500	0.05	250	-40	+40	< 1 (liquid gases)

Installation dimensions*

L [mm]	W [mm]	H [mm]
2000	1000	2000

*Installation dimensions are approximate and may vary

Industries

Plastics processing

LEWA supports you in plastics processing with custom-built plants and systems. Ask our experts for more information!
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Downloads

Best partner for best solutions LEWA GmbH (DE)
Überblick über LEWA- und Partner-Produkte2.0 MB | pdf | 23.05.2019
LEWA ecofoam (FR)
LEWA ecofoam® – Le systeme de dosage des agents d’expansion dans le process d'extrusion1.2 MB | pdf | 23.08.2017
LEWA ecofoam (EN)
LEWA ecofoam metering system for blowing agents in extrusion processes522 kB | pdf | 11.03.2018
LEWA ecofoam (DE)
Übersicht LEWA ecofoam® Dosiersystem für Treibmittel in Extrusionsprozessen524 kB | pdf | 11.03.2018
LEWA ecofoam testing system (EN)
622 kB | pdf | 23.08.2017
LEWA ecofoam Testsystem (DE)
622 kB | pdf | 23.08.2017
LEWA ecofoam testing system (USA)
LEWA ecofoam testing system (USA)658 kB | pdf | 23.08.2017
LEWA metering and mixing systems (USA)
3.0 MB | pdf | 22.05.2019