High-speed, high-efficiency, and energy-saving technologies have consistently been the core focus of innovation in global plastic machinery. These advancements allow investors to achieve substantial returns with minimal capital investment. However, increasing screw speed brings significant challenges: shorter material residence time can lead to poor mixing and insufficient plasticization; excessive shear may cause sudden temperature spikes and thermal degradation; extrusion instability becomes more common; high-performance auxiliary equipment and precise control systems are required; and there are increased wear issues for screws and barrels, along with complex gear reducer designs. Therefore, addressing these challenges is a crucial direction for technological development among twin-screw extruder manufacturers.
The ZEUTX series twin-screw extruder from Berstorff, Germany, stands out with its exceptional 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 can perform mixing, reaction, and venting simultaneously. Its modular barrel and screw design offer great flexibility for various special processes, while the ZSEF side feeder ensures efficient solid particle conveying. The pelletizer is compatible with different output levels and materials, making it highly versatile.
To meet the demands of high-speed and high-output production, the extruder has undergone multiple improvements. It includes a fast-heating barrel that can reach up to 450°C quickly. A reverse-flow cooling system optimizes temperature control, while a new tightening device allows faster barrel replacement compared to traditional bolted systems. The barrel uses a patented induction hardening process, enhancing wear resistance and eliminating the need for costly wear-resistant bushings. Additionally, it comes equipped with an advanced process control system for better performance and reliability.
Twin-screw extruders are no longer limited to polymer processing. Their applications now extend to food, feed, explosives, construction materials, packaging, pulp, and ceramics. One notable feature is the "one-step direct extrusion process," which combines kneading granulation and extrusion molding into a single step, offering efficiency and cost savings.
In the U.S., Wood Plastic Composites (WPC) have gained popularity for outdoor applications like decking and fencing. Cincinnati’s Fiberex series, especially the fourth-generation model, offers extended, wear-resistant processing units that meet diverse customer needs and enable 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% wood powder-filled PP compound profile at 2 m/min.
Large-scale extrusion equipment helps reduce production costs, particularly for large twin-screw granulators, blown film units, and pipe systems. In China, such equipment has long been imported, but local research is advancing toward localization. Precision extrusion increases product value, as seen in multi-layer co-extruded films. Melt gear pumps play a key role in achieving precision and are being actively developed.
Internationally recognized suppliers have extensive experience in large extruder technology. JSW offers a range of twin-screw extruders from TEX30 to TEX400, with the largest model, TEX400, having a 443 mm diameter, 35-meter length, and weighing 320 tons. Yanbu National Oil Company recently ordered a ZSK320 extruder from W&P, including motors, granulators, and cooling systems, valued over 20 million euros. It can produce 25–50 tons per hour depending on the polymer type.
Cincinnati Extrusion Co. 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 high-speed PVC sheet production. Beijing University of Chemical Technology has also made progress in developing melt gear pump systems.
Krauss-Maffei’s 36D series is designed specifically for PVC processing, ensuring high throughput and mechanical properties. These extruders are ideal for producing consistent-quality PVC pipes, even with high filler content, such as up to 65 parts of CaCO3. They are used for sewage pipes with diameters ranging from 50 to 500 mm.
To handle high-fill formulations, the extruder includes specialized feeding, weighing, and metering systems. PVC dry mix and CaCO3 are conveyed via a screw feeder, with a mixer and stirrer in the hopper to prevent bridging. All contact surfaces have anti-blockage coatings, and the material is transferred to the extruder via a stirrer and twin-screw feeder.
Modern twin-screw extruders incorporate microcomputer control systems, enabling real-time monitoring and control of parameters such as melt pressure, temperature, screw speed, and motor current. This enhances process stability and product accuracy, making them essential in today’s advanced manufacturing environments.
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