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Twin Screw Extruder System

For Plastic Compounding

For a modified polymer compounding granulation line, there are three major machines:feeders ,twin screw extruder, pelletizer. An effective compounding production line means a proper combination of these three equipment.
The twin screw extruder is a key component in this process as it plays a crucial role in determining the final product quality and efficiency. This article aims to provide an insight into the science behind twin screw compounding production line and to show some projects in various applications.

Configuration Of A Twin Screw Extruder System

Drive train

In the compounding process, the shear and energy for transferring, melting, mixing, are imparted via rotating screws.
Gearbox powered by motor provide equal speed and torque to the two screws at a suitable screw speed.
The relation between Power, Rpm and Torque could be describe in formula:
Power=r*torque/9550
In general, the greater torque means greater loading capacity of the screws,then the greater output.

Feeding system
The “system” concept is critical, since processors need both good individual feeders and a good overall feeding system, from the refill mechanism to the extruder, if the compounding line is to operate efficiently.When choosing feeders for a compounding extrusion line,you shoulud know：
Materials’ particle sizes and shapes
Bulk densities
Flow characteristics (free-flowing or not)
Throughput and accuracy requirements for each feeder

Compounding system
Twin screw extruder is core part of compounding process to achieve a high-quality，homogeneous melt by modular designed screws and barrels.
Reconfiguration of the segmented barrels and screws provides the extruder flexibility not seen in other technology, such as single screw extrusion. It saves cost for customers who want to use one equipment to accomplish several production tasks.
Usually, we divided the barrel /screws into individual zones according to process tasks, such like intake zone, melting zone, vacuum zone and meter zone. Each barrel section is independently heated and cooled for precise barrel-temperature
control.

Pelletizing system
Granulation is an important part in the total production process.In order to cut material efficiently, you’ll need a granulator configured specifically for your application.There are two categories of pelletizing system: Strand pelletizing VS Die-face Pelletizing. The main difference is the timing of cut,after cooling or before.
Before choosing the granulator appropriately,you should need information:
•Application : blow molding, injection molding, extrusion, recycling—imposes different demands on a granulator.
•Material: Different materials can react very differently in a granulator.
•Part dimensions: Try to capture the range of potential part sizes include largest and smallest, thickest and thinnest.
•Capacity: What lb/hr or kg/hr is expected

How To Evaluate

A Twin Screw Extruder System

For twin-screw compounding extrusion processes, an effective production line means effective combination of each machine and extrusion conditions（temperature, residence time ,pressure).However, challenges can exist anywhere: from the feeding system through the compounding section to pelletizing machine.For example:
In the feed section, Low-bulk density polymer powder, difficult-to-handle materials may stick or flow poorly through feeding equipment, limiting the feeding rate, ultimately limiting the output.
In the compounding section, an improperly designed melting section may not be able to fully melt the polymer above a certain throughput rate. Improper residence time will result in polymer melting too early, that may reduce the mixing efficiency.
In granulation process,lack of maintenance alone can lead to poor quality granulate with excessive fines and high dust content in the material and in the plant environment.

An effective compounding system should be meet several requirements:

1.quantity
output, energy consumption
2.quality
heat homogenization ,degree of mixing, quality of dispersion, stability of extruder throughput, structural changes – degradation, quality of the extrudate – appearance, physical properties
3.customer experience
length of service life, production versatility, automation of extrusion process

Factors Affecting

Twin Screw Extruder Price

The price of a twin-screw extruder can be influenced by various factors, and it's important to consider these elements when assessing the overall cost.Some of the key factors affecting the price of a twin-screw extruder include:

Capacity and Size:

Larger extruders with higher production capacities generally come with higher price tags. The size of the extruder, often measured in terms of the diameter of the screws, affects the overall cost.

Material of Construction:
The choice of materials used in the construction of the extruder can impact its price. Extruders made from high-quality and durable materials may cost more upfront but could provide better long-term performance and reliability.For example,when processing biopolymers, as materials such as PLA may contain free lactic acid,we may select corrosion-resistant materials to build the screw elements ,barrels and die plate,which would result in a higher cost.When adding reinforced filler into the polymer,we would apply more wear-resistant material.

Screw Design and Configuration:
The design and configuration of the screws play a crucial role in the performance of the extruder. More complex or specialized screw designs, such as co-rotating or counter-rotating twin-screw configurations, can contribute to higher costs.

Control System and Automation:
The level of automation and sophistication in the control system can affect the price. Extruders with advanced control systems, touchscreen interfaces, and automation features may be priced higher than basic models.If necessary, it can be equipped with communication interface to realize data teletransmission with customer’s DCS system. DCS system can remotely monitor the operating parameters of the equipment.These customerized models will bring in more cost.

Brand and Manufacturer:
Well-established brands with a reputation for producing reliable and high-quality extruders may command higher prices. The reputation of the manufacturer and the level of customer support they provide can influence the overall cost.

Auxiliary equipment and Optional Features:
Additional features, such as cooling systems, feeding systems, die heads, and other upstream or downstream equipment, can impact the overall price. The inclusion of optional features or customization to meet specific processing requirements may add to the cost.

Energy Efficiency:
Extruders designed with energy-efficient features, such as improved heat management or more efficient motor systems, may have a higher upfront cost but could result in long-term savings in operating costs.

Delivery and Installation:
Shipping, delivery, and installation costs can vary depending on the location and complexity of the installation. These factors may contribute to the overall cost of acquiring and setting up the extruder.

Market Conditions:
Economic factors, market demand, and competition can influence the pricing of twin-screw extruders. During periods of high demand or when specific industries are thriving, prices may be higher.

After-Sales Service and Support:
The availability and quality of after-sales service and support from the manufacturer can affect the overall cost. Manufacturers that provide comprehensive support services may price their extruders accordingly.

When considering the purchase of a twin-screw extruder, it's essential to evaluate these factors in relation to your specific processing needs and budget constraints. Additionally, obtaining quotes from multiple suppliers and comparing specifications and features can help in making an informed decision.

Benefit From Jieya Compounding Extruder

In-house Manufacturing Capability

Modular Design

Easy Operation

Reliable service

Equipped with CNC machining centers,we have in house manufacturing capability of screws , barrels and auxiliary machines,enabling a tight control of quality and cost.
Segmented screw element and barrel are designed for different tasks in every operating units. In this way, the whole process are accurate controled,which ensure reliable performance of extrusion.
What we provide is not only a twin screw extruder,but a systematic solution from the very beginning preparation of material to final masterbatch.