plastic extruder principles- China Manufacturers Suppliers Factory

The basic mechanism of the twin screw extrusion process is simply that a screw rotates in the barrel and pushes the plastic forward. The screw structure is a bevel or ramp wrapped around a central layer, the purpose of which is to increase the pressure to overcome the higher resistance. What do I need to pay attention to when using a twin screw extruder? The following is a detailed description.

 

Here is the content list:

l Structural principles

l Temperature principles

l Speed reduction principle

 

Structural principles

For the extruder, there are three kinds of resistance to overcome when working: one is friction, which contains the friction of the solid particles (feed) on the barrel wall and the mutual friction between them during the first few turns of the screw (feed area); the second is the adhesion of the melt on the barrel wall, and the third is the resistance of the internal logistics of the melt when it is pushed forward.

According to Newton's theorem, if an object is at rest in a certain direction, then the object is in a state of equilibrium balance of forces in this direction. For the circumferential movement of the screw, it is no axial motion, that is, the axial force on the screw is in equilibrium. So if the screw exerts a large forward thrust on the plastic melt, it also exerts a backward thrust on another object of the same magnitude but in the same direction. The thrust is exerted on the thrust bearing behind the feed opening. Most single screws have right hand threads, and if viewed from the back, they rotate backward, and they spin backward out of the barrel by rotational motion. In some twin screw extruders, however, the two screws rotate backward and cross each other in both barrels, so one must be right handed and one left handed, and in the case of an occluding twin screw, both screws rotate in the same direction and must therefore have the same orientation. However, in either case, there are thrust bearings that withstand backward forces and still comply with Newton's theorem.

 

Temperature Principle

Plastics extruded by twin screw extruders are thermoplastics, which melt when heated and solidify again when cooled. Thus, heat is needed during the extrusion process to ensure that the plastic can reach the melting temperature. So where does the heat to melt the plastic come from? First of all, the pound feed preheat and barrel/die heaters may play a role and are very important at startup. In addition, the motor feed energy, the frictional heat generated in the barrel as the motor overcomes the resistance of the viscous melt and turns the screw, is the most important heat source for all plastics, except for small systems, low speed screws, high melt temperature plastics, and extrusion coating applications. In operation, it is important to recognize that the barrel heater is not the primary heat source and that it may play a smaller role in extrusion than we might expect. The post barrel temperature is more important because it affects the rate of solids transport in the dentition or feed. In general, except for a specific purpose (such as varnishing, fluid distribution, or pressure control), the die head and die temperature should be at or near the temperature required for the melt.

 

Speed reduction principle

In most twin screw extruders, the screw speed is varied by adjusting the motor speed. The drive motor usually turns at a full speed of about 1750 rpm, which is too fast for an extruder screw. If it turns at such a fast speed, too much frictional heat is generated and a uniform, the well mixed melt cannot be prepared because the retention time of the plastic is too short. A typical speed reduction ratio should be between 10:1 and 20:1, with either a gear or pulley set for the first stage, but with a gear and a screw positioned in the center of the last large gear for the second stage. For some slow running machines (eg. twin screws for UPVC), there may be three reduction stages and the maximum speed may be as low as 30 rpm or less (ratio up to 60:1). On the other hand, some very long twin screws for mixing can run at 600 rpm or faster, thus requiring a very low reduction rate and more deep cooling. If the reduction rate is incorrectly matched to the job, too much energy will be wasted. It may be necessary to add a pulley set between the motor and the first deceleration stage where the maximum speed is changed, which either increases the screw speed even beyond the previous limit or reduces the maximum speed. This increases the available energy, reduces the current value, and avoids motor failure, in both cases, the output may increase due to the material and its cooling needs.

 

If you still have questions, you can consult our company. Nanjing JlEYA is the leading professional manufacturer of twin screw extruders in China.

The single screw extruder is mainly composed of 3 parts: extrusion system, transmission system, and heating and cooling system. The following is a detailed introduction to the basic structure of the single screw extruder.

 

Here is the content list:

• Extrusion system

• Transmission system

• Heating and cooling system

 

Extrusion system

The main role of the extrusion system of the single-screw extruder is to melt and plasticize the polymer material to form a uniform melt, to realize the transformation from the glassy state to the viscous flow state. And in this process to establish a certain pressure, by the screw continuous extrusion delivery to the head die. Thus, the extrusion system plays an important role in the molding quality and output of the extrusion process.

The extrusion system mainly includes the feeding device, screw, and barrel, which is the most critical part of the extruder, of which the screw is the heart of the extruder, the material through the rotation of the screw in order to move in the barrel and get pressurized and part of the heat.

 

Transmission system

The drive system of a single screw extruder is usually composed of a motor, reducer, and bearing, whose role is to drive the screw and supply the torque and torque required by the screw in the extrusion process. During the extrusion process, the screw speed is required to be stable and does not change with the change of screw load to ensure the uniform quality of the product. However, in different situations, the screw is required to be able to achieve variable speed in order to achieve a machine that can adapt to the requirements of extruding different materials or products of different shapes. In most extruders, the change of screw speed is achieved by adjusting the motor speed. The drive system of the single-screw extruder is also equipped with a good lubrication system and a device for rapid braking.

 

Heating and cooling system

The heating and cooling system of a single screw extruder consist of a heating device and cooling device, which are necessary for the extrusion process to be carried out smoothly. The heating and cooling devices must ensure that the polymer materials are melted and plasticized and the temperature conditions during the molding process meet the process requirements.

The cooling device is generally set up in the extruder barrel, screw and hopper bottom, and other parts. Barrel cooling can be water-cooled or air-cooled, air-cooled is generally used for small and medium-sized single-screw extruders; large single-screw extruders are mostly water-cooled or a combination of the two forms. The cooling device at the bottom of the hopper is mainly to strengthen the solid material conveying effect, to prevent the material particles from becoming sticky due to the heating, blocking the material mouth and thus affecting the feeding. Generally, for extruders with a screw diameter of 90mm or more and high-speed extruders, a cooling device must be installed at the bottom of the hopper.

 

Our company focuses on twin-screw extruders, micro twin-screw extruders, plastic extruders, parallel twin-screw extruders, and other kinds of research and development and manufacturing as the core of the isotropic rotary twin-screw compounding extruder. If you still want to know more, you can consult our company.

2022 Chinese Mid-autumn festival is coming.

Jieya team wish you happy mid-autumn festival and enjoy your holiday!!

The screw can be said to be the heart of the injection molding machine. The quality of the screw determines the quality of the product. The plasticizing screw of the engineering plastic twin screw extruder has the functions of conveying, melting, mixing, compression, metering and exhausting. It plays an important role in the quality of plasticization and is a key factor affecting the quality of plasticization.

• What is the difference between engineering plastic twin screw extruder and single screw extruder?

• What are the characteristics of engineering plastic twin screw extruder?

• What are the structural principles of engineering plastic twin screw extruder?

What is the difference between engineering plastic twin screw extruder and single screw extruder?

1. Price: single screw extruder has simple structure and low price; Engineering plastic twin screen expander is complex and expensive

2. Plasticizing capacity: single screw extruder is suitable for plasticizing and extruding polymers and granular materials. The shear degradation of polymer is small, but the residence time of material in extruder is long; The engineering plastic twin screw extruder has good mixing and plasticizing ability, and the residence time of materials in the extruder is short, which is suitable for powder processing.

3. In terms of processing capacity and energy consumption: the engineering plastic twin screw extruder has large output, fast extrusion speed and low energy consumption per unit output, while the single screw extruder is poor.

4. Operability: the single screw extruder is easy to operate and the process control is simple; The operation of engineering plastic twin screen expander is relatively complex and the process control requirements are high.

What are the characteristics of engineering plastic twin screw extruder?

1. engineering plastic twin screw extruder is divided into parallel and conical according to the relative position of the two axes;

2. engineering plastic twin screw extruder is divided into meshing type and non-meshing type according to the two screw meshing procedures;

3. engineering plastic twin screw extruder is divided into the same direction and the opposite direction according to the rotation direction of the two screws, and there are inward and outward points in the opposite direction;

4. engineering plastic twin screw extruder is divided into high speed and low speed according to the screw rotation speed;

5. engineering plastic twin screw extruder is divided into whole and combination according to the structure of screw and barrel.

What are the structural principles of engineering plastic twin screw extruder?

For the basic mechanism of the engineering plastic twin screw extruder process, in simple terms, a screw rotates in the barrel and pushes the plastic forward. The screw structure is an inclined surface or slope wound on the center layer, the purpose of which is to increase the pressure in order to overcome the greater resistance. As far as the engineering plastic twin screw extruder is concerned, there are three kinds of resistance that need to be overcome during work: one is friction, which includes the friction of solid particles (feeding) against the barrel wall and the first few revolutions of the screw (feeding zone). There are two kinds of mutual friction forces; the second is the adhesion of the melt on the cylinder wall; the third is the internal logistics resistance of the melt when it is pushed forward.

Nanjing JlEYA has focused on the development and production of engineering plastic twin screw extruders for several years. And it commits to provide perfect service for every customer from all over the world.

Nanjing Team sincerely invite you to attend The 15th China Chongqing Rubber, Plastics Industry Exhibition.

Our booth no.: S2544

Time: May 27-30, 2021

Address: Chongqing International Expo Center 

Wish to meet you at there ;)

  Nanjing Jieya Extrusion Equipment Co., Ltd. (referred to as "Jieya") was established in 2004. It has the manufacturing capacity of various types of production lines with an annual production and sales of more than 350 sets. Its comprehensive capability ranks in the forefront of the Nanjing twin screw extruders industry. The company focuses on the R&D and manufacturing of various production lines centered on co-rotating twin-screw extruders and single-screw extruders. The product applications cover compounding, modified granulation, polymerization, devolatilization, one-step molding, and recyclable resources, etc.

  Project Director Mr Chen introduced that every industry has competition, but specific to a certain market segment, the competitors involved are different. Traditional physical blending and modification is the largest market for twin-screw extruders, so the competition is the most intense. For Jieya, the bio-degradable plastic market was changed greatly in 2021, and a considerable part of Jieya’s orders in 2021 also came from this market.

  Mr Chen explained that the reason why bio-degradable plastics are singled out from the traditional blending and modification market is that there have been many entrants in this market in the past two years, which has led to the rapid expansion of the market scale. Therefore, from traditional compounding and extrusion to processing bio-degradable plastics, is it necessary to carry out certain technical reserves? Mr Chen said frankly that it depends on how much bio-degradable plastics companies want to achieve. Just like melt blown materials in 2020, some companies have astonishing shipments, and some companies choose to take the quality to a higher level. The bio-degradable material made by special equipment must be of higher quality.

  Around 2010, Jieya began to get involved in bio-degradable-related projects. During this period, we saw the ups and downs of major companies, and also witnessed the gradual growth of some companies from small to large. Most of these surviving companies are in the bio-degradable market. They started foreign trade before they became popular, and some companies even achieved a market share of about 30% in the export of Chinese vest bags.  

   He also talked about some distressing points in the biodegradable market: at present, the Chinese government has not clearly stipulated the definition and criteria of "bio-degradable". For example, some regions regard photo-degradable as a kind of bio-degradable. Many people oppose this. Mr Chen said that at present, most people in the Chinese market think that 'bio-degradable' is compostable and degradable, and garbage must be sorted and recycled before composting is possible.

  However, Mr Chen is still very optimistic about the development of bio-degradable plastics. Bio-degradable must be the general trend of future social development, but the specific direction remains to be verified. Jieya has a layout for the main bio-degradable plastic categories, such as targeting for many PBAT projects launched in China in the past two years, we are actively discussing with customers whether we can directly use the twin-screw extruder in the polymerization stage to directly make modified materials (without extruding PBAT raw materials). Jieya has also followed up on the project of carbon dioxide production of PPC bio-degradable materials and PGA synthesized with glycolide. At present, the bio-degradable plastics market is still developing and improving. What we need to do now is to develop the corresponding twin-screw technology with the industrial chain. Based on the accumulated experience of a large number of practical applications to continuously improve the stability of the equipment.

  Under the big goal of carbon neutrality, some very big changes have taken place in industries such as home appliances and automobiles. The intuitive impact is that Jieya has recently received some projects for recycling, dismantling, and regranulating waste household appliances, as well as the crushing, recycling, and regranulation of some new energy battery shells, which is also one of the important markets for Jieya in 2021. Mr Chen said that these manufacturers have multiple production lines and large projects, but they are usually new entrants, and usually require suppliers to provide them with whole-plant project planning, so they put forward higher requirements for suppliers' project experience and service capabilities.

  Fluorochemicals, another key application area for which Jieya is recognized. Fluoroplastics are also known as "plastic kings". Their corrosion resistance, solvent resistance, weather resistance and temperature resistance are relatively good, so they are often included in the field of special engineering plastics. The most well-known is the PVDF used with lithium battery binder. In 2021, Jieya also undertook some projects in this field.

   Mr Chen believes that the Chinese market is developing very fast, and twin-screw extruder enterprises must keep abreast of customer needs in order to gain a foothold in the market. Therefore, Jieya is also seeking new development in the upstream links. For example, the twin-screw devolatilization extrusion unit developed to meet the growing demand of downstream customers for products with low VOC and low residue; as well as corrosion resistance and wear resistance under high temperature conditions. The extrusion unit meets the production needs of special products under severe working conditions.

  The success of Nanjing Jieya in the market is inseparable from the technical advantages of its twin-screw extruder equipment: its core components are all self produced, including high-torque gearboxes, extruder barrels, extruder screw elements, screen changer, die, etc. The product quality is stable and controllable, which can meet the personalized customization needs of customers, and the delivery time is flexible. In addition, Jieya stable team has also played a huge advantage. It is said that its sales, technology, management, and after-sales teams have an average of more than 10 years of experience in the industry. They have rich industry experience and are relatively clear about the pain points of various market segments. Provide complete personalized solutions, and can also undertake large and complex complete system projects.

 The main system of the plastic extruder is the extrusion system, which includes screw, barrel, hopper, head, and die. The plastic is plasticized into a uniform melt by the extrusion system and is continuously extruded from the head by the screw under the pressure established in the process. The following are details about the plastic extruder extrusion system introduction.

 

Here is the content list:

• Screw

• Barrel

• Hopper

• Head and mold.

 

Screw

The screw is the most important part of the extruder, which is directly related to the application range and productivity of the extruder and is made of high-strength and corrosion-resistant alloy steel.

 

Barrel

The barrel is a metal cylinder, generally made of heat-resistant, high-pressure strength, strong wear-resistant, corrosion-resistant alloy steel or composite steel tube lined with alloy steel. The barrel and the screw cooperate to realize the crushing, softening, melting, plasticizing, exhausting, and compacting of the plastic, and to continuously and evenly deliver the rubber to the molding system. Generally, the length of the barrel is 15-30 times its diameter, so that the plastic is fully heated and fully plasticized as a principle.

 

Hopper

The bottom of the hopper is equipped with a cut-off device to adjust and cut off the material flow, and the side of the hopper is equipped with a sight hole and a calibrated measuring device.

 

Head and mold

The head is composed of alloy steel inner sleeve and carbon steel outer sleeve, the head is equipped with a molding mold, the role of the head is to transform the rotational movement of the plastic melt into a parallel linear motion, evenly and smoothly into the mold sleeve, and give the plastic to the necessary molding pressure. The plastic is plasticized and compacted in the barrel and flows through the neck of the head through a certain flow path through the porous filter plate into the forming mold of the head. The mold core and mold sleeve are properly matched to form an annular gap with decreasing cross-section so that the plastic melt forms a continuous dense tubular cladding layer around the core line. To ensure that the plastic flow channel in the head is reasonable and to eliminate the dead angle of the accumulated plastic, there is often a diversion sleeve placed, and to eliminate the pressure fluctuation of plastic extrusion, there is also a pressure equalization ring set. The head is also equipped with a die correction and adjustment device to facilitate the adjustment and correction of the concentricity of the die core and die sleeve.

 

The extruder head is divided into an angled head (120o angle) and a right angle head according to the angle between the head material flow direction and the screw centerline. The shell of the head is fixed to the body with bolts, the die inside the head has a die core sitting and is fixed to the head inlet port with a nut, the front of the die core seat is equipped with a die core, the die core and the center of the die core seat has a hole for passing the core line, the front of the head is equipped with an even pressure ring for equalizing the pressure, the extrusion package forming part is composed of die sleeve seat and die sleeve, the position of the die sleeve can be adjusted by bolts through the support to adjust the die sleeve to the die core The position of the die sleeve can be adjusted by bolts through support to adjust the relative position of the die sleeve to the die core, which is convenient to adjust the uniformity of the thickness of the extruded layer.

 

If you want to buy a plastic extruder or want to know more, you can visit our official website. Our website is https://www.njjyextrusion.com/

 

The special refining effect and excellent performance of the single screw extruder have been proved in practice. Practice has proved that the reciprocating single-screw mixing extruder is a new type of plastic extrusion equipment. The emergence of single screw extruder provides a high-performance plastic processing equipment for the majority of users. Made a huge contribution to the development of the plastics industry.

• What is the function of the single screw extruder operation screen?

• What is the significance of the emergence of a single screw extruder?

• What are the application fields of single screw extruder?

What is the function of the single screw extruder operation screen?

The operating panel is installed above the single screw extruder and can be rotated within 60 degrees for easy operation. There is a power indicator and emergency stop button on the right side of the touch screen. In an emergency, press the emergency stop button to stop immediately, which is used to protect the safety of the operator and the single screw extruder. The data recording, parameter setting, operation control and other operations of the entire instrument are all completed in this operation screen.

What is the significance of the emergence of a single screw extruder?

In the process of polymer processing, in order to give the polymer certain processing characteristics or to give the product specific use performance, it is often necessary to blend different polymers or blend the polymer with various additives and pigments. The single-screw extruder has the characteristics of uniform shearing, high dispersion, high filling, and stretching of the melt. And it combines the advantages of single and twin screw extruders. The unique working principle, coupled with a complete set of threaded components and supporting equipment, makes it more widely used. On a single screw extruder, it can achieve mixing, Mixing, plasticizing, dispersing, shearing, stretching, degassing, and granulation make the interface area of the melt flow in the machine far larger than the general shear flow.

What are the application fields of single screw extruder?

The reciprocating single-screw mixing extruder is a new type of plastic mixing processing equipment, which is widely used in the filling, blending, modification, crosslinking, grafting, color masterbatch, functional masterbatch, and resistance of various plastics. Production of fuel masterbatch, conductive material, degradable masterbatch, reinforcement, toughening and other special plastic materials.

Blending different types of polymers to obtain brand new polymer alloys with specific uses.

Various mineral fillers are added to the polymer melt to make high-filling materials with excellent performance and low price.

Production of various glass fiber reinforced and flame retardant products, with the addition of glass fiber up to 50%.

It is suitable for the production of various cable sheathing materials, insulating materials, cross-linking materials, semiconductors, shielding materials, and conductive materials.

Production of thermoplastic elastomers and hot melt adhesives.

The single screw extruder is increasingly used in industrial production.Nanjing JlEYA has committed itself to offering the best-suited single screw extruders at a reasonable price, and all that is necessary to meet the needs of the customer.

Nanjing JIEYA hereby sincerely invited you to attend 2021  China (Hainan) Degradation Exhibition.

Our booth no.: B06

Time: June 23-25

Add: Hainan International Convention and Exhibition Center

We warmly welcome your coming and look forward to cooperate with you ;)

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