Thermoplastic elastomers (TPEs) are naturally colorless and can be colored using pigments or dyes through pre-coloring or in-process coloring methods. In-process coloring, often performed with twin-screw extruders, allows pigments to disperse evenly during melting without adding extra thermal stress. The most common approach is using color masterbatch, which combines pigments with compatible carrier resins such as PP, PE, PS, or EVA to ensure uniform color and good material performance. Proper carrier selection, dilution ratio, and process optimization help achieve consistent, high-quality colored TPE pellets for various molding and extrusion applications.

This article compares extrusion and pelletizing equipment used for TPE, TPR, TPU, TPV, and silicone rubber materials. While all elastomer pelletizing lines share core components—such as twin-screw or single-screw extruders, cooling systems, and pelletizers—each material has specific equipment needs. TPU requires precise temperature and moisture control, TPV demands high-torque twin-screw extruders for dynamic vulcanization, and silicone uses specialized extruders with vacuum degassing and curing systems. Overall, process optimization and tailored screw configurations are key to achieving high-quality pellets and efficient production.

This article discusses how to increase the output of a twin-screw extruder by optimizing the screw configuration. It explains how improvements in feeding efficiency, melting performance, side feeding design, mixing quality, and pressure build-up can enhance extrusion productivity. By adjusting the screw elements, such as conveying and kneading blocks, manufacturers can achieve higher throughput, better material dispersion, and more stable processing without changing the extruder size.

Breathable film masterbatch, produced mainly with polyethylene and additives through extrusion processes, is widely used in medical, packaging, and construction fields. With excellent breathability, stable quality, and bright colors, it plays a key role in manufacturing breathable films. Its production involves raw material mixing, melt blending, hot-melt extrusion, and cooling. As demand grows, factories are focusing on technological innovation, eco-friendly materials, and market expansion to enhance competitiveness.

This article introduces four main methods of physical blending for polymer modification: dry powder blending, melt blending, solution blending, and emulsion blending. Among them, melt blending using extrusion equipment, such as single-screw and twin-screw extruders, is the most widely applied in industry due to its efficiency and ability to achieve fine dispersion. Each method has its own advantages, limitations, and application scenarios in research, testing, and industrial production.

Laboratory extruders are compact, high-precision extrusion machines designed for material research, small-batch production, and educational use. Compared to industrial extruders, they feature flexible modular design, precise control systems, and lower throughput, making them ideal for polymer modification, masterbatch development, reactive extrusion, and pilot-scale testing. With screw diameters typically ranging from 12 to 45 mm and output capacities of 0.25–150 kg/h, lab extruders provide critical data for process optimization, scale-up validation, and innovative material development across plastics, pharmaceuticals, and food industries.

This article explains why a universal screw design for plastic extrusion does not exist. Different polymers, such as HDPE and HIPS, have unique thermal, viscoelastic, density, and friction properties that directly affect melting, conveying, and throughput. These variations make it impossible for one screw geometry to efficiently process all materials, highlighting the need for polymer-specific screw designs to ensure optimal extrusion performance.

This article discusses how different TPE pelletizing methods, such as cold cutting and hot cutting, influence product quality. It highlights key extrusion parameters including melt temperature, pressure, and conveying speed, which directly affect pellet consistency and final product performance. Common pellet quality issues—such as black spots, discoloration, poor plasticization, or excess moisture—are analyzed with corresponding solutions to ensure stable extrusion, improved material properties, and higher product reliability.

Seaweed–polymer extrusion is an innovative and sustainable method of processing seaweed directly into polymer materials such as pellets, films, filaments, and 3D-molded parts. Unlike conventional fossil-based polymer production, this process minimizes CO₂ emissions while utilizing all natural seaweed components. The resulting seaweed-based polymers, known as Carraphane, offer biodegradable and eco-friendly packaging solutions with potential applications in films, small parts, and recyclable products. Continuous research aims to enhance water resistance and expand their role in the circular economy.

This article analyzes the challenges of carbon black dispersion in black masterbatch production using twin screw extruders. Issues such as brittle or broken strands, hopper bridging, and uneven feeding are discussed. Key factors include dispersant ratio, temperature control, screw speed, and hopper design. Practical solutions—such as adjusting EVA wax content, optimizing temperature and screw configuration, adding vibration devices, and improving pre-dispersion of pigments—are proposed to enhance extrusion efficiency and ensure uniform masterbatch quality.