This article explains how plastics processors can improve purging efficiency by combining high-quality purging compounds with well-managed processes. It highlights common mistakes—like using cheap virgin resin, choosing purging compounds only by price, and ignoring supplier instructions—that often reduce cleaning effectiveness. The article also emphasizes the importance of consistent training, process monitoring, and choosing the right supplier to reduce downtime, extend equipment life, and improve profitability in extrusion and injection molding operations.

This article explores common causes of die hole blockage in underwater pelletizing systems—especially when processing engineering polymers like PET, nylon, and polycarbonate—and outlines three key strategies to reduce cleaning frequency: automating the startup sequence to avoid premature cooling or smearing, optimizing die heating and insulation to prevent uneven temperature distribution, and maintaining stable extrusion conditions using melt pumps and continuous screen changers. These solutions help ensure consistent pellet quality, reduce downtime, and improve overall production efficiency.

This article explores the five main factors that cause wear in twin-screw extruder barrels and screws: abrasive wear from fillers, corrosive additives, high-intensity wear zones, extreme operating conditions (temperature and pressure), and internal moisture or gases. It emphasizes the importance of choosing high-performance materials—especially powder metallurgy steel—to extend component lifespan, reduce maintenance costs, and improve production efficiency in plastic compounding operations.

This article explains how to identify and resolve resin degradation in single screw extruders. Resin degradation, often caused by stagnant flow and high temperatures, leads to product contamination. The solution involves step-by-step screw removal, inspection, and design analysis—especially addressing issues like small thread radii, improper groove dimensions, and poorly designed mixing elements that cause Moffatt eddies and stagnation. Preventive measures include proper screw design, temperature control during shutdowns, and avoiding deep or narrow grooves that trap resin.

This article outlines the main types of twin-screw extruders—classified by screw rotation direction, structure, engagement, purpose, and size—and explains how to choose the right model based on material characteristics, production scale, and efficiency needs. It emphasizes that factors like screw design, speed, temperature control, and process parameters significantly affect output and performance.

This article explains the advantages of side vacuum exhaust systems in plastic extrusion. Unlike traditional top-mounted systems, side vacuum systems prevent material overflow by positioning the vacuum port laterally, improving process stability and reducing maintenance. It also clarifies that a stable negative pressure—not higher vacuum strength—is key to effective degassing. Factors such as temperature control, screw speed, and screw design also significantly impact performance. The side vacuum system is especially suitable for high-volatility materials where reliability is critical.

This article explains the principles of screw configuration in different sections of a twin-screw extruder. It outlines five key process zones—feeding, melting, mixing, venting, and metering—and describes the role of various screw elements such as conveying screws, kneading blocks, and mixing threads. It emphasizes that selecting the right screw combination based on material properties and processing needs is essential for achieving high product quality and efficient operation.

This article explores how to extend the lifespan of barrels and screws in plastic processing equipment by addressing two major threats: corrosive resins (like PVC and fluoropolymers) and high-temperature wear. It introduces effective strategies such as using corrosion-resistant materials, matching thermal expansion coefficients, and applying anti-wear coatings like tungsten alloy and Colmonoy. It also emphasizes regular maintenance, including clearance checks and timely repairs, as key to preventing damage. A case study demonstrates how these measures significantly improved equipment durability and reduced operational costs.

This article highlights the key advantages of kneading machines in processing high-loading pigments such as carbon black and high-oil-absorption colorants. Compared to twin screw extruders, kneading machines offer superior pigment wetting, better dispersion uniformity, and greater process flexibility due to their adjustable low-shear mixing capabilities. They are especially effective in applications requiring extended mixing times and can be combined with twin screw extruders for optimized results. Kneading machines are widely used in producing high-end masterbatches, conductive materials, and specialty coatings, offering enhanced product quality and energy efficiency.

This article analyzes the issue of pellet return and secondary cutting in underwater pelletizers, which affects pellet quality by increasing irregular shapes and fines. It identifies five key factors contributing to the problem: (1) excessive backflow of overflow and spray water, (2) inadequate spray flow beneath the water knife holder, (3) improper water temperature and flow rate, (4) incorrect blade back rake angle, and (5) excessive spacing between front and rear traction rollers. Solutions include optimizing backflow control, ensuring proper spray direction and pressure, adjusting water temperature seasonally, maintaining blade geometry, and setting appropriate roller gaps to improve cutting efficiency and product quality.