Innovative application of high efficiency twin screw extruder in masterbatch modification

With the rapid development and innovation of polymer technology, plastic products are more and more widely used in various industries. People have higher requirements for products, so our color masterbatch needs to keep pace with The Times and constantly improve the safety, quality and performance of products.

Masterbatch is a kind of highly concentrated and efficient color composition. It is a compound of polymer prepared by evenly mixing super constant pigment and attaching it to resin through a twin-screw extruder.

In recent years, high concentration and ultra high concentration, multi - functional masterbatches of terminal products are required more and more. Through the innovative technology application of key components of twin-screw extruder, such as screw and barrel, the key technological bottlenecks such as improving the quality of color masterbatch products and reducing the waste of raw materials in the process of switching different color varieties were solved.

01 Optimization of gearbox

Haisi New gearbox of twin screw extruder has higher bearing capacity, more stable torque output and longer service life, which can escort the color masterbatch processing.

The TSE series has a higher feeding capacity of the screw, allowing more material to be added, which means that the material filling rate in the screw is significantly increased. The thicker the material, the higher the filling rate and the higher the yield. v represents the screw speed; When the screw speed is constant, the shear rate r decreases because the height h increases, which reduces the shear rate of the screw to the material. Material in the process of screw forward, the closer to the outer circle, the higher the linear velocity, the stronger the shear force, the higher the material filling rate, the closer the material will be to the small circle, the shear rate will be reduced, and because of the higher material filling rate, the probability of metal friction between the screw and the cylinder is reduced. The product has achieved lower energy consumption, higher product quality, longer equipment life and better stability.

02 Optimization of screw surface lubricity

In the process of material extrusion, if the final product has high requirements for residual impurities (such as film, XLPE cable), the screw needs to be pulled out for surface cleaning after a period of use to prevent the material carbonization and bonding on the screw surface. Especially in the process of color masterbatch operation, it is often necessary to switch different colors and quickly replace raw materials. For this kind of demand, Nanjing Haisi surface coating wear-resistant lubrication layer of threaded elements, improve the surface hardness, but also maintain good coating toughness, adhesion and lubricity.

03 Optimization design of the cylinder and the progress of the processing technology

For many years, the twin-screw extruder barrel adopts C-type bushing structure and integral bushing structure to adapt to the formulation of a variety of polymers. In the process of color master operation, because of the need to change the material often, the joint inside the cylinder will lead to the cross contamination of different colors.

C-type bushing has a joint, which leads to the residue of the material, the color switching process becomes longer; It can be seen from the whole sleeve after the cylinder is removed in the field of filling masterbatch that the inner lining sleeve and the end face of the cylinder are no longer on the same plane. The reason is that the thermal expansion coefficient of the cylinder body and the bushing is different after the cylinder is heated in the production process. Therefore, if the overall bushing structure is adopted, the presence of joints between the cylinder and the cylinder will also lead to material residue. Especially for the final product for the membrane type of work material shortcomings are particularly obvious; To solve the above problems, we developed a metal sintered wear-resistant cylinder.

The pioneering use of metal sintering technology, the alloy powder through a special process, sintered on the surface of the figure eight hole inside the cylinder, forming a uniform and dense alloy layer, the alloy layer not only solves the defects of the traditional scheme, but also better corrosion resistance and wear resistance, long service life. It effectively solves the problem of the joint of the hole in the cylinder body and greatly improves the efficiency of switching different materials.

04 Effective energy consumption reduction

Haisi have developed a new kind of cooling and heating cylinder structure, cylinder radial cooling channel design, new and used imported heating element, in improving the efficiency of temperature control as well as reduce the temperature distribution and thermal deformation of the cylinder, avoid the resulting local shear heat and wear and tear, hardware to improve the service life of equipment and parts.

The technical innovation of Haisi twin screw extruder leads the development trend of color master industry application scope, higher production capacity and lower energy consumption; The twin-screw extruder and multidisciplinary technical cooperation and application make TSE series models more suitable for the production of color masterbatch industry; The application of high torque and advanced control system makes the twin-screw extruder with high stability and easy operation, which provides reliable guarantee for the continuous and stable production of color master industry users.