CHINA

WAT C H O U T !
I n t h e n e x t i s s u e o f E x t r u d e r Ti m e s
the main review article would be on
“The Art of Extruder Maintenance”

Ÿ To share breakthroughs and happenings in the

Polymer & Extruder Industry.
Ÿ To serve as an information sharing platform for
STUDENTS, ENGINEERS and COMPOUNDERS.
Ÿ To encourage contributions from scientists,
technocrats and the teaching community and to
generate triggers for new innovations.
Modern high performance extruders are distinguished by their
specialized features. Although, performance measurements are
common to the industry, new developments have resulted in a large
pool of useful information that needs to be disseminated. New
material grades with specific process requirements are being
developed and extruder manufacturers need to accept fresh
Within the span of several decades, necessary improvements were
challenges to provide solutions that give processors improved
made to the twin-screw extruder gearbox and thrust bearing design
process capability to achieve the desired quality at economically
which resulted in increased throughput and greatly extended the
viable throughput rate. Yet, most twin-screw extruder suppliers rely
service life. The twin-screw extruder design evolved to include a
on traditional design that can limit the machine’s range of
modular barrel and segmented screw which enabled a high level of
performance.
flexibility for quickly adapting to various processing requirements.

What is a TSE? Several notable companies (Werner Pfleiderer, Leistritz, Berstorff,

JSW, Toshiba and others) have made significant contributions to the
The basis for a twin-screw extruder (TSE) is in essence two advancement of the co-rotating twin-screw extruder design. In more
Archimedean screws positioned in a parallel configuration. The use recent years, STEER has introduced innovative technologies which
of dual screws as opposed to a single screw enables a degree of have further advanced twin-screw extruder performance. STEER has
positive conveying as a means for material transport in contrast to a created a paradigm shift that has “Game Changing” consequences to
single screw’s drag flow mode of conveyance. Twin-screw extruders the customer by giving the ability to treat the extruder as a mixing
were first applied to plastics processing in the first half of the 20th vessel. STEER’s “Generation Next” slogan embodies its corporate
century. Two distinct design approaches were successfully philosophy to advance twin-screw extruder performance to the
implemented and characterized by the direction of rotation of the highest degree.
screws in relation to one another, namely counter-rotating and co-
rotating screws. Another aspect in twin-screw design is the degree
of intermesh between the two screws which ranges from zero or non- Why a TSE and how TSEs over the years have become a
intermeshing to fully intermeshing. The focus of this article will be on necessity?
the closely intermeshing, co-rotating twin-screw extruder.
Twin-screw extruders have become the preferred choice for
compounding and continuous reactive and devolatilization processes.
In fact, most plastic in use today has undergone a compounding step
prior to becoming an end-use product. While single screw extruders
still have a major stake in extrusion, twin-screw extruders offer a
number of advantages over single screw extruders:

1. Stable intake of a wide range of materials due

to higher conveying efficiency
2. Ability to perform multiple process operations
in one machine
3. Flexibility to change formulations
The invention of the intermeshing, co-rotating, twin-screw extruder
4. Capable of feeding multiple components
is attributed to Roberto Colombo of Italy with early application in the
5. Adjustment of mixing intensity or residence
processing of cellulose acetate and PVC.
time by screw rpm
A major adaptation of the co-rotating twin-screw extruder came by 6. Self cleaning aspect of the screws
the way of Rudolf Erdmenger, a German engineer employed by Bayer 7. Shorter length required to melt
AG in Germany. Erdmenger’s keen insight into the science of 8. Flow patterns in the twin-screw extruder offer
kinematics introduced a “self-wiping”, closely intermeshing profile to much improved mixing over the single screw
the design of extruder screws. This resulted in self-cleaning of the extruder
screws as the flight of one screw wiped the root of the adjacent 9. Shorter residence time
screw. This invention also provided for a degree of positive 10. Rate independent of discharge pressure
conveying of the material which reduced average residence time of
the material in the extruder.
What are the opportunities - existing and new?

The twin-screw extruders have made it possible to produce high

quality, specialty plastic compounds used in the most common
products as well as highly engineered products. These products
ultimately provide humans with a higher quality of life and enable us
to reach a higher level of technology. New opportunities for using
twin-screw extruders are constantly being developed. Some of the
latest materials are high performance elastomers, nano composites,
biopolymers / natural fiber composites that utilize renewable The equation for calculating the theoretical centerline distance with
resources, and biodegradable compounds. Due to its high flexibility known values for outer diameter and inner diameter:
to adapt, the twin-screw extruder remains a viable machine for future
processing requirements. Cd= Ro + Ri or 0.5 (Do + Di)

Channel depth can be calculated as follows:

h = Ro – Ri or 0.5 (Do – Di)

c. Diameter Ratio ( Do / Di or D / d )

The ratio between the outer diameter of the screw (Do) and the inner
diameter (Di) of the screw. Larger diameter ratios have more screw
Performance measures for twin-screw extruders.
volume. The centerline distance and diameter ratio set a limit on the
maximum volume of the screw. As the outer diameter (Do or D) of the
There are essentially three performance indicators used to quickly
screw increases, the inner diameter (Di or d) must decrease in order
gauge an extruder’s overall performance capability for a given
process or range of applications: to maintain the fully intermeshing, self-wiping attributes of the
1. VOLUME Erdmenger design. It is important to note that the inner diameter
2. TORQUE determines the maximum diameter of the screw shaft which has a
3. SPEED limiting effect on maximum allowable shaft torque.

d. Number of Flights
1. VOLUME
The channel volume is also dependent upon the number of
Theoretically, higher free volume of the screws results in a higher
intermeshing flights. The Erdmenger geometry requires a tip angle
melt conveying capacity, yielding a higher throughput rate. Free
greater than zero to maintain the closely intermeshing relationship.
volume of the screws can be calculated as follows:
Flight tip angles are also equal regardless of the number of flights.
The free volume of a twin-screw extruder is dependent upon the
mechanical design parameters of the screw geometry.

a. Screw Diameter

Screw diameter typically refers to the Outer diameter (Do) expressed

in millimeters. Screw elements have both an outer diameter and Number of Ratio of
inner diameter (Di). Flights diameters (Rd)
1 1< Do / Di< ∞
b. Centerline Distance (CD)
2 1< Do / Di< 2.41
EQUAL TIP ANGLES
The measured distance between the center of the two output shafts 3 1< Do / Di< 1.37
of the gearbox. The centerline distance affects the maximum
4 1< Do / Di< 1.18
channel depth.

-3- THE EXTRUDER TIMES / ISSUE 09 / APRIL–AUGUST 2009

 1000

800
Breaking Torque (Nm)

600

Breaking Torque
400

200

0
Involute Continua
Spline Type (-)
STEER has also introduced elements with enhanced conveying
efficiencies for use in the intake zones of the extruder. The elements
are characterized by the number of flights and share the negative
angle undercutting of the pushing flight.

SFV elements are based on a uni-lobe profile with a pushing flight

machined at a negative angle producing a concave form. The 7. SIDE FEEDER AND VACUUM SIDE STUFFER
element profile has shown a significant increase (in some cases
a. Side Feeder
greater than 200% improvement) in conveying efficiency for low bulk
density and powder feedstock when used in the feed zone. Side feeders are often employed on twin-screw extruders to laterally
feed dry materials into the extruder’s process section. Side feeders
typically have two self-wiping, closely intermeshing screws providing
positive conveying of materials. There are multiple advantages
associated with the use of side feeders.

i. Improved feeding of difficult powders and fibers

ii. Reduced screw and barrel wear
iii. Higher quality and/or production rate

b. Vacuum Vent Stuffer

Vacuum vent stuffers are used to apply vacuum to the process section
to remove gas entrainment in the melt while simultaneously
preventing the melt from blocking the vent opening. Advantages
associated with the use of vent stuffers are:

i. Improved volatile removal

ii. Decreased downtime due to vent blockage
iii. Higher quality and / or production rate
S C R E W S P E E D ( r p m )

STEER side feeders and vacuum vent stuffers are both designed for
RFV elements are based on a bi-lobe profile with a negative angle mounting laterally to the extruder barrels. Side feeders and vent
undercut pushing flight. The element offers enhanced intake and stuffers are usually mounted on the downturn side of the extruder
conveying efficiency in side feed zones. screws for optimum performance, however it is possible to locate the
equipment on the opposite side if required. The STEER side feeder is
available with optional quick disconnect Jiffy Clamps to facilitate
cleaning and maintenance. STEER side feeders and side vacuum
vent stuffers share a common design for gearbox and screws. The
gearboxes are designed for extreme service and have special features
allowing a high degree of flexibility.

The screws of the STEER side feeder and vacuum vent side stuffer
TFV elements are based on a tri-lobe profile using fractional lobe borrow from the extruder’s segmented element and shaft design.
technology. The pushing flight also features a negative angle The screws are decoupled from the gearbox output shafts via a
undercut. The TFV element can be effectively utilized for force fed connecting zone in the same manner as the extruder. This approach
zones such as vertical densifier feeders and side feeders. provides the ultimate degree of process flexibility, allowing for
specialized configuration of the screw elements. The STEER side
feeder and side vacuum vent stuffer are fitted with high performance
Screw element types can be separated into three categories:
gearboxes with thrust bearing assemblies which provides the highest
1. Intake; 2. Melting; 3. Mixing. Some elements are multi- level of reliability and service life expectancy. The devices are
functional in design and can share more than one category. available in two mounting configurations: extruder frame mounted
[ Refer the table in Page No. 12 &13. ] support or a separate mobile support stand.

-8-
-10-
 STEER’s GENERATION NEXT TWIN-SCREW EXTRUDERS

Choose H Class Extruders.

Available in 30, 40 & 50 mm sizes with Enhanced Melting & Mixing Capabilities
 Special Tooth
Mixing Elements

FME - Fractional
Mixing Elements

PRODUCTS
CHINA
 QUESTION YOU

Q 1. What are the key benefits of a lab extruder?

To understand the key benefits of a lab extruder we must understand what a Lab Extruder is
first.

A Lab extruder is a scaled down version of an actual extruder whose bulk performance is
almost identical to the scaled up extruder.

A Lab Extruder has the following features: powerful functions, easy operation, simple
parameter adjusting and precise data.

Lab Extruders offer numerous process technical advantages;

v A Lab extruder offers realistic extrusion on a

laboratory scale.
v Helps in optimizing the process parameters.
v A lab extruder is highly modular in nature & hence
eases of change of application.
v It helps in studying the rheological properties of
the material.
v Helps in material development.
v It offers flexibility in operating conditions.
v It accommodates instrumentation of an extruder.

Q 2. Why are lab extruders increasingly becoming a necessity in industries

and universities?

Nowadays, industries are more focused towards materials development and R&D. A lab
extruder is highly efficient in providing real-time extrusion in a laboratory. This helps in
innovation of newer materials at a lesser price. Plus, polymer compounding industries use it
for trial production before extrapolating to a bigger scale. This leads to minimum wastage
and is cost-effective.

Lab extruder is gaining popularity in Universities and Polymer colleges as it offers real-time
extrusion and helps in academic research. It offers a combination of theory, practice in
teaching & science study. STEER offers OMICRON 12, ALPHA 18 and OMEGA 20 for R & D
labs, industries and universities.

Answer provided by: Mr. Karan Chandan, Mumbai

SCS STEER CONSULTANCY SERVICES