With the wide range of plastic extruders available today, selecting the best can be a challenge. This article will walk you through what you need to consider when selecting plastic extruders to help buyers find the best models available on the market. It’ll also cover the different types of plastic extruders available so that buyers can rest assured that they’re getting the right solution for their needs.
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Table of Contents
The growth of plastic extruders market
Tips to consider when selecting a plastic extruder
Different types of plastic extruders
Target market for plastic extruders
Wrapping up
The global plastic extrusion machine market is expected to reach a value of US $7.903 billion by , registering a moderate compound annual growth rate (CAGR) of over 4.5% from to . The increasing worldwide demand for plastic extruders is being propelled by a rise in awareness about energy saving machines and rapid industrial automation. This demand is being met by an increasing supply of high-performance extrusion machines, with China dominating the supply market. To meet the needs of specific applications, the market players are manufacturing plastic extruders of various types, sizes, applications, and design complexities.
The application of the extrusion machine determines its design, and is therefore the first step for determining extruder specifications. Below is a detailed description of what you need to consider when selecting the extruder and its components.
Material selection is an essential consideration to ensure that your extrusion machine works successfully. To determine the best material, consider the following:
Once you’ve determined the suitable material properties for the part, it’s time to search the resin. It’s important to note that not all resins are fit for the extrusion process. As such, consult your supplier for recommendations based on your design and part requirements. Generally, to reduce the overall failure of the plastic extruder, it’s best to consider the design and other vital part’s requirements. You can start by considering:
Thermoplastics contract and expand whenever subjected to temperature changes. Cutting plastic profiles to their exact lengths incur higher processing requirements and attract unnecessary handling costs. The extrusions must, therefore, have a little length tolerance incorporated into the overall length.
The flow of the material determines the extrusion process. Varying thickness of the walls’ design can make the flow of plastic material difficult resulting in a distorted profile. For a balanced profile, the walls must be uniformly thick.
A good profile design should have a limited detail in hollow sections. However, if a hollow is required, the following precautionary tips can help reduce the potential risks:
While all extrusion profile corners should have a radius, sharp corners can lead to stress concentration and eventually warp and break. For a uniform wall, the inner and outer radii should be an offset of one another. The sharp-edged outer corner is 1/64 inch, thus the recommended inner radius should be the least of 1/64 inch to reduce the possibility of a breakage, especially in rigid materials.
Tapes and adhesives increase labor and material costs. Instead, an extrusion machine must have a well designed mechanical attachment. However, if tapes or adhesives must be used, the attachment or placement area should be a flat surface for proper adhesion and be over ⅛’’ wide. The thickness of the adhesive should be taken into account when ruling out the height of the profile.
The single-screw extruder is a type of plastic injection pump mostly used as a continuous extruder in the polymer extrusion operation. The primary function of a single screw extruder is to gradually input pressure in the melting of the polymer so that the polymer is extruded through the die.
These extruders are relatively cheap and have low maintenance costs. They are simple and easily provide a continuous output of materials such as HDPE, LDPE, AND PP, which is why they are popular in the plastic product recycling industry. As the design of extrusion screws has improved over the years, single screw extruders with secondary flights for faster melting are also available in the market.
Asia-Pacific is one of the leading markets for the single screw extruders, and the global market growth is expected to grow at a CAGR of 4.4% by ..
Advantages
Disadvantages
Twin screw extruders have two parallel intermeshing, co-rotating screws installed on the shafts to ensure effective transporting, compressing, mixing, cooking, shearing, and heating. Twin screw extruders are popular, with an estimated US market value of US $253.5 million and global growth value at a (CAGR) of 6.30% by .
Advantages
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Disadvantages
Blown film machines produce specialized polymer films that are widely used in packaging, such as shopping bags, barrier films, stretch, and shrink wrapping. Air pressure is used to expand the film and afterwards cooled to solidify the polymer. This extruder has multilayer film structures made through film coextrusion combining two or more molten polymer layers. The transition from using standard polymers to biodegradable polymers plus the steadily expanding pharmaceutical industry has increased the overall demand of blown film. The projected global film extrusion machinery market is valued at US $ 2,563.7 million and is expected to grow at a CAGR of 4.8% until .
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Disadvantages
Extruded plastics are commonly used across all industries and the demand is projected to grow at a CAGR of 4.5% from to . This growth is as a result of increasing demand for efficient and reliable parts that are more eco-friendly and reusable. The buying potential for the plastic extrusion machines is expected to grow across the global markets by 6.9% over the forecast period.
A rise in demand for plastic extruders in the building and construction industry is expected to boost the growth of the Asia Pacific market, which currently holds 40.2% market share, with a projected highest CAGR of 5.4%. The growth of the automotive industry in Europe will increase the current 19.80% market share. Further, the busy lifestyle of consumers worldwide has heightened the consumption of frozen foods, leading to a rise in demand for plastic extrusion machines. Northern America, Europe, and Latin America, the Middle East, and Africa (LAMEA) are potential key players in the market.
Among all kinds of plastic machinery, the core is the plastic extruder machine, which has become one of the widely used machines in the plastics processing industry. With the rapid development of the plastic extruder market, new models are constantly being introduced, which play a better role and value in different productions.
According to the number of screws, extruders can be roughly divided into single-screw extruders, twin-screw extruders, and three-screw extruders.
The twin-screw extruder machines can also be subdivided into coaxial twin screw, conical twin-screw, co-rotating twin-screw, and parallel twin screw.
Single screw extruder is the most basic extruder in production. In the multi-screw extruder, the twin-screw extruder has developed the fastest in recent years, and its application is becoming more and more extensive. Especially in the processing of PVC plastic door and window profiles, twin-screw extruder machines have become the main production equipment.
The single-screw extruder machine is suitable for pellet processing, and the raw materials used are pelletized pellets or crushed pellets. The twin-screw extruder is suitable for powder processing, and can directly use the mixed PVC material, which reduces the process of granulation but adds the process of grinding waste.
As the application fields of screw extruders continue to expand, the development and innovation of extruders have been promoted. The three screws of the three-screw extruder are arranged in a line and rotate in the same direction, which is equivalent to two pairs of twin screws. This improves the mastication effect, increases the output, and does not increase the energy consumption much. Due to the existence of the two meshing areas, the doubled increase of the rolling area can shorten the screw length and reduce the negative impact caused by the screw cantilever.
According to the design improvement on the details of the extruder and the combination of different extrusions, the types of extruders are split twin-screw extruder, two-stage extruder, vented extruder, reciprocating single-screw pin-barrel extruder, planetary roller extruder, etc.
The split twin-screw extruder machine is based on the original twin-screw extruder. Its barrel is integrated and cannot be opened. The screw and barrel of the split twin-screw extruder adopt an advanced “building block” design. The screw is sleeved on the mandrel screw block in various forms, and the barrel bushing can be adjusted according to the screw block. According to the technical requirements of material types and other technical requirements, combined with the ideal form of the screw element structure, it realizes the processes of material transportation, plasticization, refinement, shearing, exhaust, pressure making, and extrusion, so as to better solve the general difficulty in balancing the contradiction between the so-called screw versatility and specificity.
The main feature of this machine structure is that there is an exhaust port in the middle of the barrel. When using an ordinary plasticizing extruder, a small amount of gas will be discharged from the feeding port. When the residual gas has a great influence on the processing quality, the IM polymer pellets should be dried in advance. The exhaust extruder can be used to partially or completely replace the labor-consuming and time-consuming drying process. The exhaust extruder is mainly used to process polymer materials with strong hygroscopicity, such as rigid polyvinyl chloride, ABS, nylon, polyoxymethylene, and polymethyl methacrylate.
A ram extruder is an extruder without a screw. It uses the stamping principle. The material is pushed forward by the strong pushing force of the plunger. The ram plastic extruder extrudes the previously plasticized material from the die with the help of plunger pressure to achieve the molding effect. After the material in the material barrel is extruded, the plunger will return, and the operation will be repeated after a new round of plasticized material is added.
Early ram extruder machines were intermittent extrusion. At present, a continuous ram extruder has appeared, which uses double plungers to minimize the influence of the intermittent feeding on the extrusion process. Ram extruders are divided into horizontal and vertical types.
The piston of the ram extruder compresses the mixture, then uniformly heats and melts it. It is suitable for carrier materials such as drugs and has the advantages of uniform and bubble-free compaction after compression. And the remaining gap between the piston and the die of the ram extruder machine is very small, so there is almost no material loss.
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