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Industry processes
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IPCO’s PCCR compact chill rolls are high-performance cooling and flaking systems with a small footprint. They are designed for long life, while remaining reliable and efficient.
With a wide range offering a variety of throughput capacities – from 1-2500kg/hr of thermosetting materials – the customizable PCCR compact chill roll series provides a tailored cooling and flaking solution for every production need.
IPCO’s PCCR compact chill roll coolers offer rapid and controlled solidification of hot melts, such as extruded materials, converting materials into uniform flakes for easy downstream activities like milling.
By spreading and pressing the pooled calendered melt on to a water-chilled roller with a tensioned multipolymeric belt, the compact cooler achieves exceptional solidification in a matter of seconds. The solid materials are then delivered for uniform flaking and further processing.
Feeder matched throughput
Up to 2,500 kg/h
Designed for high-capacity cooling and flaking
Drum widths
300-1,300 mm
Adaptable to various production requirements
Thickness control
Typically 1-2 mm
Ensures consistent material solidification
The PCCR rapidly solidifies hot melted material – from over 130°C (and even exceeding 200°C) – to below 35°C in just one drum rotation, producing uniform flakes within seconds.
Melted material from the feeder (like a twin-screw extruder) is pooled, flattened and spread through a water-cooled counter-rotating calendar roller and drum (some units use two calender or nip rollers). Due to the ‘labyrinth’ design, the system extracts a high percentage of the heat right away.
The chilled roller carries the calendered layer of soft, warm material onto IPCO’s special multipolymeric belt, which acts as a tension press ensuring heat extraction during the drum rotation. The solidified material discharges from the belt to be conveyed to the flaker (or kibbler or crusher) unit.
The solidified chips are further flaked in the flaking unit. The material is broken down and smoothly consumed by a pin-breaker (kibbler or crusher) producing mill-friendly flakes.
PCCR compact chill roll coolers
Built to last – Constructed from high-quality stainless steel for long-term durability and reliability.
Efficient heat extraction – Labyrinth-style press rollers evenly spread and cool the hot melt to a consistent thickness.
Advanced composite press belt – The thick, extra-long-life multipolymeric composite belt features a smooth, heat- and chemical-resistant thermoplastic urethane contact surface, reinforced with polyester matting on the running side. Fixed guides ensure perfect alignment.
Flexible and mobile – Designed for versatility, PCCR units can operate autonomously, run on rails, or be mounted on a scissor lift for added mobility.
Simplified cleaning – Features include air wash at the drum discharge, with optional cleaning modules such as brushes and CIP (clean-in-place) systems using air or water washing.
Easy maintenance – The fully openable flaker unit allows for effortless cleaning and maintenance.
Optimized flake production – Produces flakes ideal for downstream processes like milling, with optional pin roller configurations available.
Technical
PCCR 1200x1300
Drum dia.: 1,200 mm
Belt width: 1,300 mm
Calendar roll (dia. X L): 240 x 1,300 mm
Capacity (max.): 2,000 kg/h
PCCR 1200x1100
Drum dia.: 1,200 mm
Belt width: 1,100 mm
Calendar roll (dia. X L): 240 x 1,100 mm
Capacity (max.): 1,500 kg/h
PCCR 1200x900
Drum dia.: 1,200 mm
Belt width: 900 mm
Calendar roll (dia. X L): 240 x 900 mm
Capacity (max.): 1,000 kg/h
PCCR 700x900
Drum dia.: 700 mm
Belt width: 900 mm
Calendar roll (dia. X L): 120 x 900 mm
Capacity (max.): 500 kg/h
PCCR 700x600
Drum dia.: 700 mm
Belt width: 600 mm
Calendar roll (dia. X L):120 x 600 mm
Capacity (max.): 350 kg/h
PCCR 350x300
Drum dia.: 350 mm
Belt width: 300 mm
Calendar roll (dia. X L): 80 x 300 mm
Capacity (max.): 100 kg/h
PCX extruders
Premium range of twin screw extruders offering industry-leading versatility and throughput.
SCX extruders
Ideal for repeatable small-to-medium batch operations with low energy requirements.
PCCB steel belt coolers
Low-maintenance stainless steel belt coolers for the solidification of a hot melt to a solid flake.
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