Causes And Prevention Measures for Material Overflow at The Exhaust Port in Plastic Pelletizing

During the TPE pelletizing process, material overflow at the exhaust port affects production efficiency and product quality. Below are the possible causes and corresponding prevention measures:

1. Optimizing Equipment Configuration and Adjustments

1.1 Matching Feeding Speed with Main Extruder Speed

• Uneven material transport in the screw can cause material overflow.

• The feeding speed and main extruder speed should be properly set according to the plasticization and extrusion characteristics of TPE. Ensuring that the feeding speed matches the main extruder speed prevents inconsistent material transport in the screw.

1.2 Adjusting the Clearance Between the Screw and Barrel

• Check the clearance between the screw and barrel to ensure it is appropriate. Excessive clearance can reduce shear force, leading to incomplete plasticization of the material.

1.3 Installing Reverse Conveying Elements or Reverse Engaging Blocks

• Reverse conveying elements or reverse engaging blocks should be installed near the vacuum zone and exhaust port of the screw to reduce the pressure in the screw channel and minimize material overflow.

2. Precise Temperature Control

2.1 Avoiding Excessively Low or High Processing Temperatures

• If the processing temperature is too low, the material may not be fully plasticized. Conversely, if the temperature is too high, the material may become overly fluid, causing the screw to slip, both of which can lead to material overflow. The temperature from the feeding zone to the natural exhaust zone should be set based on the plasticization characteristics and extrusion requirements of TPE.

• The die head temperature is a key factor affecting TPE plasticization and extrusion. If the die head temperature is too low, the plasticized material may cool down and clog the die, ultimately leading to material overflow at the exhaust port. Appropriately increasing the die head temperature can help prevent overflow.

3. Strengthening Filter Management

3.1 Regularly Replacing or Cleaning the Filter

• The filter is a crucial component of the pelletizing machine, responsible for filtering out impurities and unplasticized particles. Over time, the filter can become clogged, leading to material overflow at the exhaust port.

• Regularly inspect the filter's condition and promptly replace or clean clogged filters.

3.2 Using Filters with Appropriate Aperture Size

• Select filters with suitable aperture sizes to improve filtration efficiency and prevent clogging, which can contribute to material overflow.

       By implementing these optimization strategies, manufacturers can effectively reduce material overflow at the exhaust port, ensuring stable production and high-quality TPE pellets.

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