Extruder screws Manufacturers online

Extruder screws are central components in extrusion machines, which are mainly used in the plastics, food and chemical industries.

Their main task is to convey, melt or mix and evenly shape raw materials. The extruder screw sits in a barrel and rotates to transport the material through the extruder, compacting, heating and homogenizing it at the same time.

Here is a brief overview of how extruder screws work, the materials they are made of, their uses and benefits, and considerations when using them:

How extruder screws work :

Extruder screws consist of a spiral screw located in a barrel. This unit is usually divided into different zones to correspond to the process steps of conveying, compression and dosing.
Input zone (conveying zone): This is where the raw material (e.g. granulate) is picked up and transported towards the screw tip.
Compression zone: The material is compacted by narrowing the screw chamber and, if required by the extruded material, heated by friction and an external heater.
Dosing zone: The compacted or additionally melted material is transported evenly and formed at the end of the screw by a nozzle.

Material selection:

The screw and barrel must be made of robust and wear-resistant materials, as they have to withstand high temperatures, pressures and often abrasive materials.
Commonly used materials are hardened steel or alloys that are customized for the specific application.

Use of extruder screws in various industries:

1. Plastics industry:
Plastics extrusion is the most important area of application for extruder screws. In this process, plastic pellets are fed into the machine, melted and molded through a die.
This is used for the production of:
Pipes (water or sewage pipes), films (packaging industry), profiles (e.g. window frames or seals), cable sheathing.
Twin-screw extruders are often used when particularly homogeneous mixtures are required or when several components need to be mixed (e.g. fillers, paints, additives).

2. Food industry:
In food extrusion, extruder screws are used to manufacture products such as snacks, pasta, breakfast cereals or pet food. The raw material, often flour or starch, is fed into the extruder, mixed with liquid and formed into the desired shape through the die.
The screw allows precise control of moisture, pressure and temperature, which is crucial in food production to achieve the right texture and consistency.

3. Chemical and pharmaceutical industry:
In chemical extrusion, extruder screws are used for processing chemicals, resins or even in the production of rubber or sealants.
In the pharmaceutical industry, extruder screws are used to extrude drugs or coatings into uniform shapes or formulations, e.g. in the form of tablets or capsules.

4. Recycling:
Plastic recycling uses extruder screws to melt and granulate recycled material, which is then reintegrated into the production process.
In upcycling, extruder screws can be used to shape old materials such as used plastics into new products.

Advantages of using extruder screws:

• Extruder screws enable continuous material processing and are ideal for high-volume production processes.
• Due to the pressure and uniform heating of the material, the screw can ensure an even mixture of raw materials, which is particularly important in the plastics and food industries.
• By changing the forming nozzles and adjusting the screw parameters, different materials and shapes can be processed, which enables a high degree of flexibility in the production process.
• The screw enables precise control of temperature, pressure and mixing ratio, which is essential for high-quality end products.

Considerations when using extruder screws:

• Extruder screws are subject to some wear due to constant friction and high temperatures, especially with abrasive or fibrous materials. Regular maintenance and, if necessary, replacement of the screw or barrel are therefore necessary to maintain production quality.
• Depending on the application, it may make sense to switch to twin-screw extrusion, as it enables greater homogeneity and more efficient processing. This applies in particular to complex mixtures or high production requirements.
• The screw profiling (e.g. pitch of the turns, diameter ratios) can be adapted to the specific material properties and production requirements in order to optimize the process.

Extruder screws are important components in the manufacture of products that are formed by extrusion. They play a crucial role in the plastics, food and chemical industries and enable the continuous, precise processing of raw materials into finished products. Their flexible design and customizability make them a versatile and efficient solution for manufacturing a wide range of products, from plastic tubes to snacks to recycled materials.

Here is an overview of the key points to consider when buying extruder screws:

When buying extruder screws, there are some important factors to consider to ensure they are best suited for the specific application. Extruder screws are critical to the efficiency, quality and longevity of the entire extrusion process, which is why it is important to make an informed choice.

• The extruder screw must be made of robust materials to withstand high temperatures, pressure and abrasive materials. common materials are hardened steel or alloys such as nitrided steel, bimetallic coatings or corrosion-resistant alloys**.
• Especially with abrasive or fibrous materials, such as glass fiber reinforced plastic, it is important that the screw is protected against abrasion and corrosion.
• Bimetallic screws and special coatings (e.g. tungsten carbide) can significantly extend the service life.
• The shape and design of the screw influence the conveying capacity, the melting process and the homogeneity of the end product. Different screw profiles are required depending on the material and the requirements of the extrusion process.
• Pitch: Screws with variable pitch can adjust the pressure and compression of the material.
• A higher compression ratio leads to higher pressure build-up and more efficient melting, while lower ratios are more suitable for temperature-sensitive materials.
• A screw should be divided into a conveying zone, compression zone and metering zone to ensure that the material is transported, compacted and homogenized correctly.
• Different materials, such as plastics (e.g. polyethylene, PVC), food or chemicals, require different screw designs. The screw must be compatible with the material to be processed (extrudate) to ensure optimum processing.
• Twin screw extruders are often more suitable than single screw extruders for homogeneous mixtures or the processing of mixed materials (e.g. compounds, additives).
• The throughput of the extruder screw should be matched to the production requirements. It is important to know how much material needs to be processed per hour so that the screw can efficiently convey the required amount.
• If high temperatures are required (e.g. for thermoplastics), the screw must have a high heat resistance to prevent thermal distortion and wear.
• A high-quality screw offers a longer service life and reduces maintenance costs. Screws with special wear-resistant coatings or made of wear-resistant materials generally have a longer service life.
• Easy disassembly and cleaning of the auger is an advantage in order to reduce maintenance times. Screws that are easy to replace or clean help to reduce production downtimes.
• The choice of extruder screw should be based on the relationship between initial cost and service life. More expensive screws made of resistant materials or with special coatings can justify the higher purchase costs through a longer service life and lower maintenance costs.
• It is worth investigating whether screws or parts of screws can be upgraded or replaced to reduce future costs.
• In certain industries, such as the food industry or the pharmaceutical industry, special hygiene and cleaning requirements apply. In these cases, screws made of stainless steel or with food-compliant coatings should be selected.
• If different materials are to be processed in one extruder, a flexible screw design suitable for different viscosities and processing temperatures may be required.
• Good customer support is important, especially when technical problems occur or adjustments are required. Manufacturers that offer fast spare parts supply and technical support can minimize downtime.

When purchasing extruder screws, the choice of material, screw geometry, application range and ease of maintenance are decisive factors. A high-quality screw should be durable, wear-resistant and adapted to the specific process requirements. It is important to check compatibility with the extrudate and to ensure a good balance between cost and efficiency in order to guarantee optimum performance and cost-effectiveness in the long term.

Extruder screws can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of Extruder screws from all over the world can be found on Exportpages.