Types and function of plastic extruders screw

• Single screw extrusion

The addition of higher-add-levels of fillers and reinforcements may be done on a single screw or a twin-screw extruder. The
choice is determined by the type of filler/reinforcement. In general, the single screw use is limited to low-aspect-ratio additives
such as Ca CO3 and talc.

The production of CaCO3 filled and talc filled materials may be accomplished using only a dry-solid mixer and a two-stage vented
extruder. An Auger-type hopper stuffer assists feeding. As the filler level increases, melt fluxing mixers, such as Farrel Continuous
Mixer (Figures 2) may be used to optimize mixing and distribution. The Farrel Continuous Mixer is a counter rotating, non-
intermeshing twin-rotor mixer. It can be divided into 3 zones: (a) Feed zone (b) Mixing zone (c) Discharge zone. The feed zone of
the mixer is designed to opimize ingestion and delivery of feed m material (s) into the mixing zone. Upon entering the mixing
zone, the feed material is melted and then continuously fluxed, pumped, backmixed and it exits through the discharge zone. The
maximum achievable loading will depend, to some extent, on the melt viscosity of the polymer, but primarily on the type of filler.
For example, specialized Ca CO3 concentrates have been produced with filler levels upto 80%, while it is difficult to reach a 50%
loading with mica.

At high filler loadings, intensive mixing may not be necessary, as long as the filler is uniformly distributed. Over-mixing can cause
separation. In general, both batch (Banbury) and continuous(FCM type) mixers are suitable.

metered feeding is necessary for all high filler-level systems. Fillers such as CaCO3 are liable to bridge in the hopper. In addition,
there is a potential for separation and build-up of the filler on vertical metal surfaces. The critical design features of the feeders
are the agitator and the feed screw and their relationship with each other. The agitator should sweep the hopper walls as closely
as possible to prevent filler build-up. The hopper should be equipped with a level control feeder.

SECTIONAL VIEW OF TYPICAL FCM IN OPERATION

The compoudning extruder should have relatively shallow flights. A compression ratio of 2.5:1 is preferred and no additional
mixing devices are generally required.

Mineral fillers tend to be hygroscopic. Therefore, a vacuum vent is utilized during the extrusion step. When a cold-cut pelletizing
system is used, the emerging strands from the die face is taken into water bath and taken out quickly, taking care to ensure
integrity of the strands. A blower assists water removal from the strands prior to chopping.
 Types and function of plastic extruders screw
Reciprocating Extruders
In these types of machines, both rotational and reciprocating action of the screw occur simultaneously and are continuous. These
machines are specifically designed to enhance mixing performance and are usually referred to as Ko-Kneaders.

A schematic sketch of a Ko-Kneader is shown in Figure (3). The Kneader is a single screw extruder with interrupted screw flights
and stationary pins or teeth in the barrel. The screw flights can be continuous in the feed section and vent section to improve
forward conveying. In this section, no pins are located in the barrel. The mixing section of the screw is typically double-fighted
with a small helix angle of 13 degree. The interruptions in the screw flights leave flight segments that look like vanes. There are
three rows of pins or teetha along the length of the barrel. The barrel has a clamshell design, which facilitates cleaning of the
barrel. Modern kneaders have a typical L/D ratio of about 11.

PP can be compounded with CaCO3, talc and glassfibres on Ko-Kneaders,

Twin screw extruders

The compounding of fillers, reinforcements, flame retardants (solids/liquids) can be achieved with a twin-screw extruder. Twin-
screw extruders are designed to allow flexibility in the method of component introduction, in addition to the ability to change
screw configuration. The extruder comes configures with multiple feed ports, allowing the polymer components to be added as
specified by the compounder. For example, the resin is generally added at the beginning of the extruder to ensure melting, mixing
and uniformity of melt temperature, while fillers/reinforcing agents or liquid additives are added further downstream.

Twin-screw extruders make use of starve feeding systems as opposed to flood feeding system utilized with single-screw
extruders. Side feeders for filler addition are also employed. Venting, pelletizing and downstream handling requirements are all
similar for systems described in section 3.2-1.

Feed alternatives (depending on formulation)

 Types and function of plastic extruders screw

Flame Retardant PP
A schematic sketch of a typical twin-screw set up for introducing liquid flame retardant into PP is shown in Figure (4). The extruder
set up requires two feeding ports, one for PP and one injection port for additive located downstream. The first section of the
extruder creates a melt pool before the liquid is injected. The viscosities of the polymer melt and liquid are matched near the
injection port and then the mass is allowed to homogenize in the latter part of the extruder. The factors which govern the quality
of the final product are the temperature profile in the extruder, screw design and extruder geometry.

Filled PP
Filled PP grades can be compounded with twin screw extruders. Dispersion requirements for talc and CaCO3 vary according to the
final product application. The primary objectives are uniform incorporation and mixing. A schematic diagram of mixing elements
which make up a configurations shown in Figure (5).

Fillers are added downstream t a melt to isolate their abrasive effects. A melt seal is formed upsteam where large pitch screws are
used. The downstream section is configured for low shear mixing for low performance applications. Applications requiring high
degree of dispersion are compounded using a high shear intensive mixing section.

Glass Fibre Filled PP

Compounding technique for incorporating glass fibre into PP requires isolation of high and low shear sections along the screw
 Types and function of plastic extruders screw
length. Chopped fibres or continuous rovings can be used. The design of the screw determines the final fiber length in PP. PP in
powder/pellet form is metered into the feed zone with stabilizers and lubricants. The additives can be preblended or metered
individually. A relatively high shear plasticizing and mixing section is used to generate a homogeneous melt. Fibres are introduced
into the melt via second feed opening located downstream (figure 6.) Metering equipment is required for chopped strands.
Continuous rovings are continuously unwound from the core, drawn in by the turning screw. One inside the barrel, the continuous
rovings are chopped to length by the kneading elements located downstream of the feed opening. A less intensive mixing section is
needed for chopped fibre, since the fibres have only to be wetted out and dispersed. Degassing and die extrusion follows the
compounding step.

Table (14) shows the effect of compounding technique on physical properties of glass fibre filled PP product. It is, therefore,
important to select the correct compounding machine to obtain reinforced products with desired mechanical properties.

Table - 14
Effects of Compounding Technique on 20% glass reinforced-PP

Property Standard Intensive twin screw Fluxed melt mixer

twin
screw

Melt flow rate, condition L.g/10 min. 4 5 9

Tensile strength (yield) MPa 79 70 49

Yield elongation, % 2.8 3.1 5.1

Flexural modulus (1% secant), MPa 4071 3726 26.22

Heat deflection temp. (264 psi), deg. C. 134 134 104

Fibre length (average), um 550 550 300

Twin screw-extruder for introducing liquid FR into PP

Twin screw Extruder

Continuous Twin Screw
 Types and function of plastic extruders screw

Typical configuration for glass fibre incorporation into PP

Schematic view of a Banbury Type Internal Mixer

 Types and function of plastic extruders screw
• Single screw extrusion
The addition of higher-add-levels of fillers and reinforcements may be done on a single screw or a twin-screw extruder. The choice is determined by
the type of filler/reinforcement. In general, the single screw use is limited to low-aspect-ratio additives such as Ca CO3 and talc.

The production of CaCO3 filled and talc filled materials may be accomplished using only a dry-solid mixer and a two-stage vented extruder. An
Auger-type hopper stuffer assists feeding. As the filler level increases, melt fluxing mixers, such as Farrel Continuous Mixer (Figures 2) may be used
to optimize mixing and distribution. The Farrel Continuous Mixer is a counter rotating, non-intermeshing twin-rotor mixer. It can be divided into 3
zones: (a) Feed zone (b) Mixing zone (c) Discharge zone. The feed zone of the mixer is designed to opimize ingestion and delivery of feed m materia
(s) into the mixing zone. Upon entering the mixing zone, the feed material is melted and then continuously fluxed, pumped, backmixed and it exits
through the discharge zone. The maximum achievable loading will depend, to some extent, on the melt viscosity of the polymer, but primarily on the
type of filler. For example, specialized Ca CO3 concentrates have been produced with filler levels upto 80%, while it is difficult to reach a 50% loading
with mica.

At high filler loadings, intensive mixing may not be necessary, as long as the filler is uniformly distributed. Over-mixing can cause separation. In
general, both batch (Banbury) and continuous(FCM type) mixers are suitable.

metered feeding is necessary for all high filler-level systems. Fillers such as CaCO3 are liable to bridge in the hopper. In addition, there is a potential
for separation and build-up of the filler on vertical metal surfaces. The critical design features of the feeders are the agitator and the feed screw and
their relationship with each other. The agitator should sweep the hopper walls as closely as possible to prevent filler build-up. The hopper should be
equipped with a level control feeder.

SECTIONAL VIEW OF TYPICAL FCM IN OPERATION

The compoudning extruder should have relatively shallow flights. A compression ratio of 2.5:1 is preferred and no additional mixing devices are
generally required.

Mineral fillers tend to be hygroscopic. Therefore, a vacuum vent is utilized during the extrusion step. When a cold-cut pelletizing system is used, the
emerging strands from the die face is taken into water bath and taken out quickly, taking care to ensure integrity of the strands. A blower assists
water removal from the strands prior to chopping.

Reciprocating Extruders
In these types of machines, both rotational and reciprocating action of the screw occur simultaneously and are continuous. These machines are
specifically designed to enhance mixing performance and are ususally referred to as Ko-Kneaders.

A schematic sketch of a Ko-Kneader is shown in Figure (3). The Kneader is a single screw extruder with interrupted screw flights and stationary pins
or teeth in the barrel. The screw flights can be continuous in the feed section and vent section to improve forward conveying. In this section, no pins
are located in the barrel. The mixing sectionof the screw is typically double-fighted with a small helix angle of 13 degree. The interruptions in the
screw flights leave flight segments that look like vanes. There are three rows of pins or teetha along the length of the barrel. The barrel has a
 Types and function of plastic extruders screw
clamshell design, which facilitates cleaning of the barrel. Modern kneaders have a typical L/D ratio of about 11.

PP can be compounded with CaCO3, talc and glassfibres on Ko-Kneaders,

Twin screw extruders

The compounding of fillers, reinforcements, flame retardants (solids/liquids) can be achieved with a twin-screw extruder. Twin-screw extruders are
designed to allow flexibility in the method of component intruduction, in addition to the ability to change screw configuration. The extruder comes
configures with multiple feed ports, allowing the polymer components to be added as specified by the compounder. For example, the resin is
generally added at the beginning of the extruder to ensure melting, mixing and uniformity of melt temperature, while fillers/reinforcing agents or liquid
additives are added further downstream.

Twin-screw extruders make use of starve feeding systems as opposed to flood feeding system utilized with single-screw extruders. Side feeders for
filler addition are also employed. Venting, pelletizing and downstream handling requirements are all similar for systems described in section 3.2-1.
Feed alternatives (depending on formulation)

Flame Retardant PP
A schematic sketch of a typical twin-screw set up for introducing liquid flame retardant into PP is shown in Figure (4). The extruder set up requires
two feeding ports, one for PP and one injection port for additive located downstream. The first section of the extruder creates a melt pool before the
liquid is injected. The viscosities of the polymer melt and liquid are matched near the injection port and then the mass is allowed to homogenize in the
latter part of the extruder. The factors which govern the quality of the final product are the temperature profile in the extruder, screw design and
extruder geometry.
 Types and function of plastic extruders screw
Filled PP
Filled PP grades can be compounded with twin screw extruders. Dispersion requirements for talc and CaCO3 vary according to the final product
application. The primary objectives are uniform incorporation and mixing. A schematic diagram of mixing elements which make up a configurations
shown in Figure (5).

Fillers are added downstream t a melt to isolate their abrasive effects. A melt seal is formed upsteam where large pitch screws are used. The
downstream section is configured for low shear mixing for low performance applications. Applications requiring high degree of dispersion are
compounded using a high shear intensive mixing section.

Glass Fibre Filled PP

Compounding technique for incorporating glass fibre into PP requires isolation of high and low shear sections along the screw length. Chopped fibres
or continuous rovings can be used. The design of the screw determines the final firbre length in PP. PP in powder/pellet form is metered into the feed
zone with stabilizers and lubricants. The additives can be preblended or metered individually. A relatively high shear plasticizing and mixing section is
used to generate a homogeneous melt. Fibres are introduced into the melt via second feed opening located downstream (figure 6.) Metering
equipment is required for chopped strands. Continuous rovings are continuously unwound from the core, drawn in by the turning screw. One inside
the barrel, the continuous rovings are chopped to length by the kneading elements located downstream of the feed opening. A less intensive mixing
section is needed for chopped fibre, since the fibres have only to be wetted out and dispersed. Degassing and die extrusion follows the compounding
step.

Table (14) shows the effect of compounding technique on physical properties of glass fibre filled PP product. It is, therefore, important to select the
correct compounding machine to obtain reinforced products with desired mechanical properties.
Table - 14
Effects of Compounding Technique on 20% glass reinforced-PP
Property Standard Intensive twin screw Fluxed melt mixer
twin screw
Melt flow rate, condition L.g/10 min. 4 5 9
Tensile strength (yield) MPa 79 70 49
Yield elongation, % 2.8 3.1 5.1
Flexural modulus (1% secant), MPa 4071 3726 26.22
Heat deflection temp. (264 psi), deg. C. 134 134 104
Fibre length (average), um 550 550 300

Twin screw-extruder for introducing liquid FR into PP

Twin screw Extruder

Continuous Twin Screw
 Types and function of plastic extruders screw

Typical configuration for glass fibre incorporation into PP

Schematic view of a Banbury Type Internal Mixer

 Types and function of plastic extruders screw
Types of the twin screw

Intermeshing and non-intermeshing twin screw

The twin screws are designed to be intermeshing or non-intermeshing.

In the case of the intermeshing twin screws, the distance between the two screw axes is
shorter than the sum of the outer radius of the two screws. Depending on the degree of
intermeshing, the intermeshing type is further divided into fully intermeshing and partially
intermeshing types. As the picture shows in the fully intermeshing type, there’s no gap
between the screw flight and the roots of the other screw while in the partially intermeshing
type, there’s the clearance between the screw flight and the roots of the other screw.

The fully intermeshing type

The partially intermeshing type

In the case of the non-intermeshing twin screws, the distance between the two screw axes is
equal to or larger than the sum of the outer radius of the two screws.

Corotating and counter-rotating twin screw

 Types and function of plastic extruders screw
According to the screw rotation direction, the twin screws can be divided into the corotating
type and the counter-rotating type.

The corotating type

The counter-rotating type

There are 2-types of counterrotating twin screw: the intermeshing type and the non-
intermeshing type.

The parallel twin screw and the conical twin screw

According to whether the screw axis is parallel or not, the twin screws can be divided into
the conical twin screw and the parallel twin screw, where the parallel twin screws are
divided into fully intermeshing type, partly intermeshing type, non-engaged type, etc. In the
case of parallel screws, the feed end and the die end have the same diameter.
 Types and function of plastic extruders screw
The diameter of the screws in the conical twin-screw extruder is larger at the feed end and
smaller at the die end.

The parallel twin-screw

The conical twin-screw

4 Types Of Twin Screw Extruders

Intermeshing corotating twin-screw extruders

Both screws and barrels are designed using the “building block” principle. The screw
configuration and barrel setup can be optimally adjusted according to different material
properties and process requirements. The “building block” design fits the extruder in various
applications. In addition, the special design allows the replacement of a single component,
extending the lifetime of the whole extruder and greatly saving the repair cost.

Due to the opposite speed of the two screws rotating in the same direction at the
intermeshing area, one screw works to pull the material into this area, while the other screw
pushes the material out of this area. The result is that the material is pushed forward in an
“∞” shape as it moves from one screw to the other.

Applications of Intermeshing co-rotating twin screw extruder

Due to the small gap in the intermeshing area, the threads and screw grooves at the
intermeshing region moves in the opposite direction, resulting in a high shear rate and a
good self-cleaning effect, i.e. it can scrape off any accumulated material adhering to the
screw, greatly reducing the residence time of the material. Therefore, the intrtmeshing
type co-rotating twin-screw extruders are mainly used for mixing and granulation. The
twin-screw extruders for polymer reaction extrusion are mostly fully intermeshing twin-
 Types and function of plastic extruders screw
screw extruders among which the intermeshing co-rotating parallel twin-screw extruders is
the most common chioce.

The intermeshing corotating twin-screw extruders has low-speed and high speed types.
The low-speed co-rotating twin-screw extruders are used for profiles while the high-speed
co-rotating twin-screw extruders are used for special compounding and reactions.

Intermeshing counterrotating extruders

In an intermeshing counterrotating extruder, the two screws are symmetrical. Due to the
different rotation direction, the path of material spiral forward on one screw is blocked by
the screw flight of the other screw. Thus intermeshing counterrotating extrudersit cannot
form “∞”-shaped material movement.

In the solids conveying section, the material is conveyed forward in the form of an
approximate closed “C” shaped chamber. However, the design leaves a certain clearance
between the outer diameter of one screw and the root diameter of the other screw so that
the material can pass through.

Intermeshing counterrotating extruders peforms welll in conveying and extruding. The

extrusion volume in the same diameter is about 1 times higher than that of the co-rotating
extruder in the same diameter. Besides, shorter residence time of the material, less heat,
fully dispersed materials and homogeneous temperature are achieved.

Applications of intermeshing counter-rotating extruders

When passing through the radial clearance of the two screws, the material is subjected to
strong shear, mixing and compact forces which increase the plasticizing rate of the material.
The desired compression ratio can be achieved by changing the gaps between the screw
flights. The intermeshing counter-rotating extruders are often used in process tasks like
extruding and granulating.

Non-intermeshing counterrotating twin screw extruder

This extruder with two parallel conveys material by friction and viscosity.

The non-intermeshing screws have a relatively large gap in between, resulting in a large
leakage flow. Hence, the non-intermeshing type has fewer applications than the
intermeshing type.
 Types and function of plastic extruders screw
Compared to single screw, the non-intermeshing screws increase material exchange
between screws but reduce positive displacement flow.They are suitable for mixing, venting,
de-volatilizing and chemical reaction.

Applications of non-intermeshing counterrotating extruders

The non-intermeshing twin-screw extruder is mainly used in the preparation of reactive

extrusion, melt or emulsion production of polymers, coloring, glass fiber reinforcement and
hot melt adhesives, and is usually used when the melt content is up to 50% and 4500-6750
kg of material needs to be dried per hour.

Conical twin-screw extruder

Conical screws decrease in size as you approach the tips. Usually, the two screws rotate in
opposite directions.

In a conical twin-screw extruder, the volume of the C-shaped channel formed by the two
screws and the barrel gradually becomes smaller from the feeding section to the discharge
section as the diameter of the screws becomes smaller. Powder materials in big bulk will be
introduced into the feeding zone and conveyed by the turning motion. As the screws
become smaller, the materials are compacted and melted. At the discharge zone, the lower
screw circumferential speed due to the smaller diameter of the screws results in a lower
shear rate which means less temp rise.

Applications of conical twin-screw extruders

Conical twin-screw extruders are suitable for processing heat-sensitive materials, so

mainly used for processing PVC powder directly into products. For lower output extrusion
production, conical twin-screw extruders with small end diameters are generally used, as
conical twin-screw extruders are considered an economical choice due to their power- and
cost-saving features.