Extrusion Machine

Product Overview

The Industrial Plastic Extrusion Machine series is engineered for continuous polymer processing, handling resins including HDPE, LDPE, PP, PVC, ABS, and engineering thermoplastics. Built on a heavy-gauge structural steel chassis and driven by high-torque reduction gearboxes, these systems maintain stable melt pressure and uniform output under continuous operating cycles.

Configuration options include single-screw systems for general profile and pipe extrusion, and parallel or conical twin-screw configurations for rigid PVC compounding and high-moisture recycling applications. Every line is custom-configured with gravimetric feeding, vacuum venting, and specialized tooling based on raw material rheology and end-product dimensional tolerances.

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Key Features & Benefits

High-Torque Reduction Gearbox: Features case-hardened helical gears manufactured from 20CrMnTi alloy steel, ground to DIN class 6 accuracy. Integrated forced lubrication and independent oil cooling circuits ensure a service factor (SF >= 1.6) capable of continuous operation at rated torque.

Optimized Screw & Barrel Metallurgy: Nitrided 38CrMoAlA barrels paired with bimetallic-alloy flighted screws (PTA plasma-welded with nickel-base alloy for high-wear zones) minimize abrasive and corrosive wear when processing filled polymers containing calcium carbonate or talc.

Multi-Zone PID Thermal Regulation: Cast-aluminum heater bands coupled with internal cooling channels and intelligent solid-state relay controllers maintain barrel temperature zones within +/- 1 degrees Celsius, preventing thermal degradation of shear-sensitive polymers.

Modular Vacuum Devolatilization: Multi-stage vent ports equipped with independent vacuum pumps and liquid-ring condensers continuously extract residual moisture, monomers, and low-molecular volatiles from the melt stream without material loss.

Closed-Loop Melt Pressure Control: Pressure transducers feed melt pressure data directly to the programmable logic controller, modulating screw RPM to eliminate surge and maintain wall thickness consistency within +/- 0.05 mm.

Technical Specifications

Model Series	Screw Diameter (mm)	L/D Ratio	Max. Screw Speed (rpm)	Main Motor Power (kW)	Output Capacity (kg/h)
S-65	65	30:1 / 33:1	120	45	120 - 180
S-90	90	30:1 / 33:1	100	110	300 - 450
S-120	120	32:1	85	200	600 - 850
ST-65 (Twin)	2 x 65	28:1	38 - 110	55	180 - 280
ST-92 (Twin)	2 x 92	26:1	28 - 95	132	450 - 650

Manufacturing & Quality Control

Our production facility utilizes heavy-duty floor-boring mills and CNC internal thread-grinding machines to maintain concentricity tolerances within 0.015 mm across barrels up to 4,000 mm in length.

Material Traceability: All structural steel plates, gear forgings, and alloy bars arrive with mill test certificates confirming chemical composition per international metallurgical standards.

Heat Treatment Verification: Barrel nitriding depth is verified via metallographic cross-section analysis, ensuring a diffusion layer hardness of >= 950 HV and a case depth of 0.55 to 0.70 mm.

In-House Gear Metrology: Manufactured gears undergo coordinate measuring machine inspection to verify tooth profile, lead, and helix angles before final assembly.

Factory Acceptance Testing: Every assembled extruder undergoes a 4-hour dry-run thermal cycle test at 80% maximum revolutions per minute. Vibration spectrum analysis and bearing housing temperature checks are logged and included in the machine documentation passport.

Compliance Standards: Built in accordance with rigorous industrial manufacturing standards, quality management systems, and safe electrical panel fabrication requirements.

Customization & Configuration

Because upstream raw material formulations and downstream profiles vary, our engineering team customizes extrusion configurations to match exact process parameters:

Screw Geometry Modification

Custom flight depth, compression ratio, and barrier sections designed for specific melt viscosities, ranging from high-molecular-weight polyolefins to rigid PVC powder.

Automotive Wiring Harness Extrusion Line

Drive & Transmission Selection

Integration of heavy-duty industrial gearboxes based on specific torque density requirements (N*m/cm^3).

Feeding Systems

Gravimetric loss-in-weight single or twin-screw feeders and volumetric multi-component dosing units linked directly to the main extruder line control.

Interface Integration

Standard industrial communication protocols (Modbus TCP, Profinet, or OPC UA) for integration into existing plant supervisory control and data acquisition or manufacturing execution systems.

Applications

01.

HDPE / PP Pipe Lines

High-speed continuous extrusion of pressure pipes, corrugated drainage pipes, and multi-layer conduit across various diameters.

02.

WPC & Profile Extrusion

Processing wood-plastic composite blends and rigid PVC window and door profiles with specialized conical twin-screw configurations.

03.

Sheet & Board Production

Extrusion of flat sheets including polypropylene, acrylonitrile butadiene styrene, and high-impact polystyrene for thermoforming and industrial partitioning.

04.

Polymer Compounding & Recycling

Direct pelletizing lines integrating underwater pelletizers, strand pelletizers, and melt filtration screen changers for post-industrial and post-consumer scrap.

Frequently Asked Questions

Q: How do you determine the correct length-to-diameter ratio and screw geometry for a specific polymer resin?

A: Screw selection requires a detailed rheological assessment of the raw material data sheet, including melt flow index, filler percentage, moisture content, and thermal stability. For polyolefins requiring high dispersion, we typically specify a 30:1 or 34:1 barrier screw with a mixing section. For rigid PVC powder, a twin-screw configuration with a lower length-to-diameter ratio is selected to prevent material residence time degradation.

Q: What is the lead time for standard single-screw extruders versus custom multi-component lines?

A: Standard single-screw models with standard electrical configurations typically ship within 60 to 75 days from deposit receipt and drawing sign-off. Fully customized lines requiring bespoke die heads, gravimetric batching systems, and specialized programming require 90 to 120 days, which includes full factory testing.

Q: How do you prevent premature screw and barrel wear when running heavy mineral-filled masterbatch?

A: For mineral-filled or glass-filled formulations, standard nitrided components are insufficient. We specify bimetallic barrels centrifugal-cast with high-alloy liners yielding high surface hardness, paired with plasma-welded hard-faced screw flights to significantly extend service intervals.

Q: Can the extrusion control system integrate with an existing plant data network?

A: Yes. Our automation architecture utilizes industrial programmable logic controllers capable of configuring data export via standard industrial protocols, allowing real-time monitoring of motor load, melt pressure, barrel temperatures, and specific energy consumption directly from a central control room.

Q: What quality documentation and inspection reports are provided prior to shipment?

A: Prior to crating, every machine is supplied with a comprehensive technical documentation package. This includes material test certificates for main shafts and barrels, heat-treatment hardness curves, electrical schematic diagrams, program backup files, and the factory acceptance test report containing vibration and thermal logging data.

Q: What support is available for installation, commissioning, and operator training?

A: We dispatch senior commissioning engineers to your facility to supervise mechanical alignment, electrical hookup, dry cycling, and initial wet runs with your material. On-site training covers routine maintenance protocols, temperature tuning, barrel cleaning procedures, and fault-finding to ensure operators are fully self-sufficient.

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