Maximizing Extruder Performance: How to Prevent Screw and Barrel Wear

As a manufacturer of plastic products, you know the importance of having efficient and reliable extruder equipment. One of the biggest challenges faced by plastic product manufacturers is screw and barrel wear, which can significantly reduce the output and quality of their products. In this blog, we’ll discuss how to prevent screw and barrel wear and maximize the performance of your extruder.

Screws and barrels work together in a plastic extruder. The combined work of the two parts has an impact on the plasticization of plastic materials, the quality of products, and the efficiency of production. As a result, the quality of the work depends on the manufacturing precision and the gap between the screw and barrel. During periods of severe wear and tear, you should replace the screw or barrel or arrange for their repair.

01 Understanding the cause of extruder screw and barrel wear, breaking, or getting damaged:

1. the extruder screw is rotated in the barrel.

Eventually, the extruder screw and the barrel’s working surface wear due to a combination of plastic material and friction. Gradually, the extruder screw diameter reduced and the barrel bore diameter increased. As a result, the screw and barrel of the extruder gradually wear away the gap diameter, with gradual wear of one and a small increase in the other. While the barrel in front of the head and the resistance of the manifold remain unchanged, the extruded material is more likely to leak forward. It increases the flow of material from the diameter gap to the direction of feed. This reduces the extruder’s production volume. As a result, the material in the barrel spends more time there, causing material decomposition. If the material is PE, polyethylene, hydrogen chloride is produced from its decomposition to reinforce corrosion of the extruder screw and barrel.

2. Wear and tear from the material being processed.

Materials such as calcium carbonate (CaCO₃), wood powder, stone powder, and other fillers can accelerate the wear of the extruder screw and barrel.

3. The plasticisation of the material is not ideal.

Incorrect plasticisation or the presence of metal foreign bodies. As a result, the extruder screw rotation becomes more intense suddenly. The extruder screw becomes twisted off when the torque exceeds its strength limit. This is screw barrel unconventional accident damage.

Proper screw and barrel maintenance: Regular maintenance, such as cleaning and lubrication, can significantly reduce the risk of screw and barrel wear. Regular inspections can also help detect and repair any potential issues before they become more serious.

02 Proper processing conditions:

Proper processing conditions, such as controlling the temperature and pressure, can also help prevent screw and barrel wear. It’s also important to monitor and adjust the processing conditions to ensure that they are within the recommended range for the specific material being extruded.
Consider upgrading to a high-performance screw design: If you are experiencing frequent screw and barrel wear, consider upgrading to a high-performance screw design. These screws are designed to optimize the extrusion process and reduce the risk of wear.

Conclusion:

Preventing extruder screw and barrel wear is crucial for maximizing the performance of your extruder and ensuring the quality of your products. By understanding the cause of wear, using high-grade materials, maintaining your equipment, controlling processing conditions, and considering a high-performance screw design, you can significantly reduce the risk of extruder screw and barrel wear.

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