High-speed, high-efficiency, and energy-saving technologies have consistently been the focus of continuous improvements in international plastic machinery. These advancements allow investors to achieve significant returns with relatively low capital input. However, increasing screw speed brings several complex challenges: short residence time can lead to uneven mixing and poor plasticization; excessive shear may cause sudden temperature spikes and material degradation; extrusion stability issues arise; and high-performance auxiliary equipment and precise control systems are required. Additionally, wear on the screw and barrel, as well as the design of the gear reducer, become more critical. Therefore, addressing these challenges is a key direction for technological innovation among twin-screw extruder manufacturers.
The new ZEUTX series twin-screw extruder from Berstorff, Germany, stands out due to its excellent screw diameter-to-productivity ratio. It features a maximum screw speed of 1200 rpm, high torque, and an extrusion capacity ranging from 100 to 3,500 kg/h. The machine allows simultaneous mixing, reaction, and venting of materials. Its modular barrel and screw design offer flexibility for various special processes, while the ZSEF side feeder ensures efficient solid particle conveying. The pelletizer is also adaptable to different production rates and material types.
To meet the demands of high-speed and high-output operations, the extruder has undergone numerous enhancements. It is equipped with a fast-heating barrel that can reach up to 450°C quickly. The cooling system uses reverse flow design to optimize performance. A quick-clamping device enables faster barrel replacement compared to traditional bolted systems. The barrel undergoes a patented induction hardening process, providing excellent wear resistance and eliminating the need for costly wear-resistant bushings. The machine also includes an advanced process control system for better monitoring and management.
In terms of functionality, twin-screw extruders are no longer limited to polymer processing. They are now widely used in food, feed, explosives, construction materials, packaging, pulp, and ceramics. One notable advancement is the "one-step direct extrusion" process, which integrates kneading granulation and extrusion molding into a single step, offering great efficiency.
Wood-plastic composites (WPCs) are increasingly used in outdoor applications like decking and fencing, especially in the U.S. Cincinnati’s Fiberex series has been continuously improved for WPC molding. The fourth-generation Fiberex features a wear-resistant processing unit that meets diverse customer needs and achieves high output. At last year’s NPE show, Cincinnati demonstrated a complete Fiberex pilot line using a T58 extruder with a 200 kg/h capacity, producing a 75% filled PP compound. The system manufactured a furniture profile with a 2.5 mm wall thickness at an extrusion speed of 2 m/min.
Large-scale extrusion equipment helps reduce production costs, particularly for large twin-screw granulators, blown film units, and pipe systems. China has long relied on imported equipment, but research into localizing large twin-screw granulators is ongoing. Precision in extrusion increases product value, such as in multi-layer co-extruded films. Melt gear pumps play a crucial role in achieving precision and are being actively developed.
Internationally recognized suppliers have extensive experience in developing large extruders. JSW offers a range of twin-screw extruders from TEX30 to TEX400. The largest model, TEX400, has a 443mm diameter, 35m length, and weighs 320 tons. Yanbu National Oil Company recently ordered a ZSK320 twin-screw extruder from W&P, including motors, granulators, and water-cooling systems, valued at over 20 million euros. It can produce 25–50 tons per hour depending on the polymer type. In 2006, Cincinnati shipped one of the world’s largest counter-rotating parallel twin-screw extruders to a U.S. customer, capable of producing up to 2000 kg/h for PVC sheet production.
Research institutions in China have also made progress in melt gear pump development. Beijing University of Chemical Technology has developed a range of melt gear pump products. Krauss-Maffei’s 36D series is specifically designed for PVC processing, ensuring high throughput and mechanical properties. These extruders produce consistent quality tubing ideal for PVC applications.
For high-fill formulations, Krauss-Maffei’s 36D extruders are used to process PVC sewage pipes with up to 65 parts (about 40%) of CaCO3. High-filled pipes, ranging from 50–500mm in diameter, are commonly used for sewage transportation. Special feeding, weighing, and metering systems help manage these formulations. PVC dry mix and CaCO3 are conveyed via a screw feeder into a weighing device, where a mixer and stirrer prevent bridging. All contact surfaces have special coatings to avoid blockage. The material is then transferred to the extruder’s feed port through a stirrer and a specialized twin-screw feeder.
Modern twin-screw extruders incorporate intelligent and networked features. Microcomputer control systems monitor and regulate parameters such as melt pressure, temperature, screw speed, and motor current throughout the process. This ensures stable operation and improves product accuracy. These innovations make today's extruders not only more efficient but also more reliable and easier to manage in industrial settings.
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