Brief summary
In this article, we will explore the main characteristics of this machine, how it works, and what happens in detail during the extrusion process.
What is an extruder and how does it work?
Let’s start with a clear definition: an extruder is a piece of industrial machinery used to produce plastic materials. This technology is the basis of many industries and plays a crucial role in creating the objects we use every day.
Extrusion is a process in which a material is pushed through a mold to create a continuous product with a specific shape. This material, usually in the form of granules or powder, is fed into an extrusion chamber. This chamber is fitted with at least one rotating screw, known as an extruder screw, which pushes the material through the system.
The heart of the operation is therefore the extrusion technology. During the process, the extruder’s screw heats and melts the material while pushing it through a hopper inside the extruder. This critical step makes it possible to create a continuous product that can be shaped depending on the specifics required.
The applications of this technology are surprisingly vast. In many manufacturing industries, extruders are used to produce pipes technical profiles, profiles, pellets, compounds, and even food, such as pastries and snacks. The versatility of the extruder makes it an indispensable tool in sectors that range from the plastics to the food industries.
Twin screw extruders
These extruder models are fitted with two screws that work in tandem. The two main configurations of twin screw extruders are co-rotating or counter-rotating, the main difference being the direction of the screws’ rotation.
Co-rotating twin screw extruders:
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in a co-rotating twin screw extruder, both screws rotate in the same direction, i.e., both clockwise or both counterclockwise;
Counter-rotating twin screw extruders:
In general, the choice between a co-rotating or counter-rotating twin screw extruder depends on the specific requirements of the extrusion process and the type of plastic material being produced. Both configurations have their advantages and disadvantages, and the selection will depend on factors such as the viscosity of the material, the mixing requirements, the temperature of the process, and the desired properties of the end product.
Extrusion technology: the heart of the operation
Now let’s look—in a clear and simple way—at the five steps in the process:
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Feeding in the material: the material, often in the form of granules or powder, is fed into a machine known as an extruder.
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Extrusion cylinder: the material is taken into an extrusion chamber, home to one or more rotating screws. Bausano has successfully introduced the principle of electromagnetic induction in the heating of the extrusion cylinder, an industrial innovation that differs from traditional systems based on resistance heaters. Thanks to this technology we can significantly reduce component wear and tear and energy consumption by up to 35%, contributing to optimized and sustainable production processes with the Bausano Smart Energy System.
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Heating and melting: the screw or screws in the extruder rotate while heating the material. This heating causes the material to melt, turning it into a plastic or fluid state. Heating systems are fundamental to bringing the material to the right temperature for melting. Accurate temperature control is vital for guaranteeing the quality of the end product. The right combination of these elements creates an ideal environment for the extrusion process.
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Continuous pressure and shaping: the screw or screws continue pushing the molten material through the machine. This pressure allows the material to flow through a mold or die, taking on the required shape.
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Cooling: once shaped, the products go through a cooling process that solidifies the material, fixing its shape.
The final result is a continuous product with the desired shape, which can be cut into smaller pieces or used as it is, depending on requirements.
The future of extrusion
In the current context, the overriding challenge is sustainability, a demanding and urgent issue that involves everyone, especially those who work in the plastics manufacturing sector. To tackle this challenge, it is key to focus our efforts on reducing the environmental impact, starting with limiting waste and energy consumption.
Aware of this requirement, Bausano is actively committed to developing its counter-rotating extrusion range in this direction. We have developed new cutting-edge technologies, such as the cylinder induction heating system, and innovative extruders designed to recycle polymers like PVC and polyolefins. This progress is testament to our genuine commitment to promoting sustainability.
Our mission is to help protect the environment through advanced solutions. This is why we are committed to offering more and more options to reduce energy costs and recover plastic waste material, demonstrating that it is possible to combine industrial production with environmental responsibility.
Join us in our commitment to a sustainable future. Choose Bausano for solutions that not only meet the requirements of the present but help actively preserve our planet for future generations.
