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1 Batch – Type
1.1 Ram Extruders
1.2 Reciprocating screw extruders
2 Continuous –Type
2.1 Screwless Extruders
2.1.1 Disk Extruders
2.1.2 Drum Extruders
2.1.3 Other Extruders
2.2 Screw Extruders
2.2.1 Single-Screw Extruders (SSE)
2.2.2 Twin-Srew Extruders (TSE)
2.2.3 Multi-Screw Extruders
Feed hopper
Extruder Screw and Barrel
Drive system (motor, gear box, transmission)
Thrust Bearing
Heating and Cooling Elements
Screen Pack and Breaker plate
Die
Temperature and pressure controls.
Important Specification
Nominal dia of screw
Output(kgs/hr)
PVC screw
CORPORATE TRAINING AND
PLANNING
Nylon screw
P A SCREW
Electric Heating
1. Induction Heaters
2. Cast-in Heaters
3. Band Heaters
i. Mica Insulated
ii. Ceramic Insulated
The electric heating is most commonly used due to :
1. Accuracy
2. Reliability
3. Easy to hook up.
CORPORATE TRAINING AND
PLANNING
INDUCTION HEATERS
AC Current passes through coil thus setting up a magnetic flux. Heat is
generated from the resistance offered to the eddy current set up by the flux.
The barrel is heated directly by its resistance to the induced current
The insulated heating elements are cast into semi-circular or flat aluminium
blocks, which are machined to match the surface to be heated
Cast-In
Resistance Heaters
STEAM HEATING
The high specific heat and latent heat of vapourisation of water makes steam
an excellent heat transfer medium. However, this system is not frequently used
because of low maximum temperature that can be achieved, a need of working
with high pressure piping, frequent leaks of steam that require shutting down
of heating for repairs, and corrosion effects.
CORPORATE TRAINING AND
PLANNING
COOLING SYSTEMS
For small extruders fans that blow air over or around the barrel are used
SCREW COOLING
The cooling may freeze a layer of plastic on the screw root, reducing the
channel depth thus producing more shear at a cost of throughput.
This may also reverse the required relationship between the friction coefficient
(low friction coefficient on the screw, high on the barrel), further reducing the
drag flow.
Furthermore, there is a danger that the material staying a long time near the
screw root will degrade, contaminating the product.
It is important to remember that the conveying ability of the screw is
controlled by the friction coefficient ratio : f(barrel) / f(screw) ó it is important
to maximize this ratio.
Under normal circumstances the minimum value of the ratio that guarantees
conveying is 1.4. CORPORATE TRAINING AND
PLANNING
SCREW COOLING
However, it should be carried out using the cooling fluid at the temperature
above the softening point of the principal polymeric component.
Functions
- Support for Screen pack
- Converts the Spiral flow of melt in to stream lined laminar flow
- Holds back contamination and unmelted particles.
Fig.3.7
CORPORATE TRAINING AND
PLANNING
SCREEN PACK
The die is a channel, whose profile changes from that of the extruder bore to
an orifice, which produces the required form.
The dies can be classified using different criteria. For example, considering cross
section of the extrudate one may recognize dies to produce:
Solid Cross-Sections
Another classifications scheme is based on the die attachment to the extruder barrel:
Offset dies
CORPORATE TRAINING AND
PLANNING
SOLID CROSS - SECTIONS
A Typical Die Design for extruding a solid rod is shown in fig.
In the figure, DD is the diameter of die orifice, DB is the diameter of bore of
extruder barrel, is the lead-in angle, and P is the die land.
Because of the screen pack and breaker plate assembly, the pressure in the
extruder (PE) is reduced by the pressure loss across the assembly (PL).
Since the die outlet is at atmospheric pressure, the working pressure is the die
pressure (PD) given by the difference: PD = PE – PL.
CROSSHEAD DIES
Arranged with their axes at an angle of 908 (458 and 308 are also used) to
the melt feed.
No need for spider assembly.
Used for the production of insulated wires, cables
• OFFSET DIES
Combination of both straight – through die and off-set die.
Used for the production of pipe.
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PLANNING
EXTRUDATE SWELL
Numerically, the extrudate swell is defined as the ratio of the outer extrudate
diameter (DE) to the other diameter of the die exit (DD), i.e., B = DE / DD
When the melt emerges out of the die lips, there will be expansion in the
direction perpendicular to flow and contraction in the direction parallel to
flow.
Constrained molecules tends to relax at the die outlet. This leads to die swell.
MELT FRACTURE
If die entrance is tapered
Dead spots are eliminated
Minimise development of tensile stresses and hence minimise distortion of
stream lines.
CORPORATE TRAINING AND
PLANNING
SHARK SKIN & BAMBOOING EFFECT
Shark Skin
Roughening of the surface of the extrudate
The melt as it proceeds along the die channel, has a velocity profile with
maximum at the centre and zero at the wall.
As it leaves the die lips, the material at the wall has to accelerate to the
velocity at which the extrudate is leaving the die.
This generates tensile stress and if the stress exceeds Tensile strength, the
surface ruptures causing the visual defect - “shark skin”.
If the conditions causing shark skin becomes more intensive, eg. Pressure at
the extruder becomes excessive or die temperature drops, the extrudate
“snaps back” -- “Bambooing effect”.
The extruder throuhtput (Q) is given by the sum of the drag flow, the
pressure flow, and the leak flow, i.e., Q = QD - QP - QL Since both QP (the
pressure flow) and QL (the leak flow) will have opposite signs to QD (the
CORPORATE TRAINING AND
drag flow) PLANNING
Drag Flow
Drag Flow takes place by virtue of adhesion of the melt to the slab (barrel
wall).
As shown in fig., the maximum melt velocity is at the barrel wall (the
same velocity as that of the wall), linearly decreasing to zero (screw is
stationery) across the screw channel depth.
Imagine again the straight channel width a metal slab above the screw
flights at the over flight gap distance.
If pressure is generated near the channel end, the material will not only be
pushed along the channel (as discussed above), but also across the over
flight gap ò this is known as the leak glow.
The over flight (a radial clearance between the lands and the barrel) is
normally small, of the order of 0.13mm, thus the flow velocity is much
smaller than for the pressure flow.
1 MATERIAL
2 FEED
3 SCREW
4.1 Grooved Increases Increases Grooved barrel in the feed section ensures higher
compression
5 SCREEN PACK
6 DIE
Co - Rotating
Counter - Rotating
Both screws either turn clock-wise One screw turns clockwise and other
1
or counter clock-wise. counter clockwise.
In Blown Film Extrusion a tube of plastic material is extruded out of the die,
while hot it is blown into a bubble, then cooled.
The bubble is inflated by air pressure contained in between the die and the
seating provided by the nip rolls.
Disadvantages:
4. Cannot be rotated
2.Can be rotated
Disadvantages:
3. Easy to clean
4. Can be rotated
Disadvantages:
BR = DBMmax / DD
Lay Flat Width is the width of the flattened lay flat tubing :
LFW = ( DD / 2 ) BR
Higher melt strength – Stiffer film allows more air to be blown against the
bubble without causing bubble instability. Hence higher output.
Recycled materials – low melt strength. Hence low speed of operation and
low output.
LDPE/LLDPE blends – highest rates can occur when BUR is about 2.2 to
2.8. Low BUR – not much surface area to cool hence low output rate.
The Melt emerging out of the die lips strikes the chrome plated
chill roll where it solidifies.
Subsequently the film is pulled through nip rolls .
Trimming blades trims-off the thicker edges. Then the film is wound
on the winder. CORPORATE TRAINING AND
PLANNING
FLAT FILM DIES
BLOWN FILM
CAST FILM
1. Tougher than Cast Film
1. Less Toughness
2. More Stiffer
2. Less Stiffer
3. Cheaper
3. More Costlier Process
4. A High output Tubular
4. Requires less space.
film requires high tower &
Bigger building to
accommodate
5. Not so easy
5. Easily changeable film
width by changing air
pressure 6. Excellent gloss & clarity
6. Less gloss & clarity
CORPORATE TRAINING AND
PLANNING
TUBULAR-QUENCH
It involves the downward extrusion of a tubular extrudate from
an Annular die
Followed by Quenching on water–covered converging boards
Which causes rapid crystallization which enhances the optical
property.
The tube is inflated with air to give a film of required lay-flat
width and thickness.
It is widely recommended for PP film.
Cooling water
Collapsing
Board
Water level
Basic PS film in its non-oriented form is brittle and has only a limited use
as a dielectric in capacitors. When biaxially oriented, the film is tough and
can be thermoformed into crystal clear tubs, trays and larger items such as
cake covers.
The principle of the linear type can be illustrated by considering the two-
stage process shown in fig 3.27 (a) and (b).
FILM BLOWING
There are two techniques of
making film. One is the cast film
process. The other is the blown film
process. The difference in qualities is
that the blown film is more christalline
than the cast film
AXON manufacture CORPORATE
machinery for AND
TRAINING
both processes PLANNING
Blown Film Co-Extrusion
Barrier properties is the main reason to go for multi layer film
Multimanifold three-
layer flat-film die
Feed Block
Material used :
HIPS is the most important sheet material. HDPE, PVC, ABS are also used.
Sheet grades usually have high melt viscosity.
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Sketch TRAINING
of PLANNING
Paper ANDfor Extrusion Process
Coating
Dies
Coat hanger die
‘T’ type die
Coat-Hanger Die : (a) Die Body, (b) Manifold, (c) Fixed Jaw,
(d) Movable Jaw, (e) Choker Bar, (f) TRAINING
CORPORATE Clamping Screw and (g)
AND
Jaw AdjustingPLANNING
Screw
Wire Coating/Cable Covering
Unit comprises of
Cooling Trough
Un wind unit (For conductor) Take off/ wind up.
Pre treatment unit
Wire coating unit
Steps Involved
Wire/conductor is unwound & straightened by Tension
Control Unit.
Pre treated to promote adhesion of molten plastic
Then passed through the Cross head die of the coating unit
Coated wire is then cooled by passing through cooling trough
Wound on the winder CORPORATE TRAINING AND
PLANNING
Wire Coating Extrusion Line
Diagram of a production line for the coating of wire or cable with plastic. The conductor
to be covered unwinds at the left, is preheated, passes into the crosshead die (center). The
extruder is behind the die, and feeds it with molten plastic, which coats the conductor. The
finished product is cooled, tested and wound up at the right.
Pressure die
T-TYPE
DIE
COAT
HANGER
TYPE DIE
( Widely Used)
STRAIGHT THROUGH
Sizing plate
Method involves pulling the pipe through a series of brass plates
Mainly for small dia pipes/tubes.
A C
The cylindrical part of the pipe die head extends into the closed area
of a revolving mould block chain. The plastic tube is pressed against
the profiled, revolving mould block halves by internal air pressure or
by vacuum calibration.
Poor gauge uniformity Melt flow is not stable Use gear pump to stabilise flow
Clean hopper
Streaks Contaminated System Check screw and die;
Clean if necessary