Address
304 North Cardinal St.
Dorchester Center, MA 02124
Work Hours
Monday to Friday: 7AM - 7PM
Weekend: 10AM - 5PM
Lab-Scale Extrusion Line
Lab-scale extrusion line for polymer R&D and pilot runs—twin/single-screw, precise temperature control, in-line gauging, data logging, and fast changeovers.
Laboratory Extrusion Line for Polymer R&D & Pilot Production
Overview
The Lab-Scale Extrusion Line is a modular platform designed for formulation screening, process optimization, and scale-up from bench to pilot production. Interchangeable twin-screw/single-screw modules, multi-zone temperature control, and closed-loop speed regulation deliver tight tolerances, repeatable quality, and production-relevant data. Typical applications include compounding, film/tape, and tubing/microbore extrusion for PP, PE, TPU/TPE, PA, and specialty blends.
Key Benefits
- Fast changeovers: quick-change tooling and recipe management minimize downtime between tests.
- Precision & stability: optimized screw geometry, melt filtration, vacuum sizing, and multi-stage cooling ensure uniform OD/ID and smooth surfaces.
- Data-driven R&D: in-line laser diameter (and optional wall-thickness) gauges with SPC dashboards, batch reports, and exportable datasets.
- Scalable design: results translate to pilot and production lines via matched die designs and process windows.
- Cleanroom-ready: low-particle cabling, sealed water loops, stainless wetted parts; ISO 7/8 integration options.
- Safety & compliance: CE/UL electrical options, interlocks, emergency stops; 21 CFR Part 11–ready data management available.
Typical Applications
- Tubing & microbore for medical/lab use*
- Film/tape/monofilament trials and barrier studies
- Compounding & masterbatch development
- Profile & sheath prototypes for cable or flexible conduits
*Final device suitability depends on resin grade, biocompatibility, and regulatory pathway.
Process Flow
Feeding & (optional) drying → Extrusion & melt filtration → Die head (single/co-ex) → Vacuum sizing (for tubes/profiles) → Multi-stage water cooling → Servo haul-off → Cut-to-length or coiling → In-line metrology & SPC → Marking → Packaging
Core Modules
- Extruders: single-screw (Ø 16–35 mm) and/or co-rotating twin-screw (Ø 16–27 mm), high-torque drives, multi-zone heating.
- Feeding: volumetric/gravimetric feeders (single or multi-component), liquid dosing, strand or side feeder (twin-screw).
- Melt handling: screen changer, melt pump (gear pump) for pulsation-free output, static mixer, vacuum venting/degassing.
- Die tooling: tubing, flat film/tape, profile; co-extrusion for stripes/layers.
- Calibration & cooling: stainless vacuum tank with closed-loop control; spray/cascade cooling baths with filtration/UV (cleanroom option).
- Downstream: caterpillar/belt haul-off, flying-knife cutter or servo coiler for microbore; meter counter & encoder.
- Metrology: non-contact laser OD and optional ultrasonic wall gauge; ovality, thickness, and length SPC.
- Controls & software: PLC + HMI, recipe library, alarms, audit trail; OPC UA/MQTT/CSV data export. 21 CFR Part 11 e-records/e-signatures optional.
Technical Specifications (customizable)
| Item | Typical Value | Notes |
|---|---|---|
| Materials | PP, PE (LD/LL/HD), TPU/TPE, EVA, PA | High-temp options on request |
| OD Range (tubing) | Ø 0.6–16 mm | Down to Ø 0.4 mm with micro tooling |
| Line Speed (microbore) | Up to 120 m/min | Size/formulation dependent |
| Throughput | 0.5–25 kg/h per extruder | Screw size & resin dependent |
| Temperature Zones | 6–12+ | PID closed loop, ±1–2 °C |
| Gauging | Laser OD, ultrasonic wall (opt.) | Closed-loop control |
| Control | PLC + 7″/10″ HMI | Recipes, alarms, data export |
Options & Upgrades
- Co-extrusion for stripes/barrier layers or radiopaque fillers (grade verification required)
- Gravimetric loss-in-weight feeding; multi-component blending
- Vision inspection (scratches, gels, defects) with auto-reject
- Anti-static & ionization bars for cleanroom handling
- Cleanroom cable trays & enclosures, DI/RO water loop
- Integrated analytics: run charts, Cp/Cpk, lot genealogy
Quality, Validation & Service
- IQ/OQ/PQ support, calibration certificates, and preventive maintenance plans
- On-site installation, operator training, and ramp-up assistance
- Remote diagnostics, spare parts logistics, and application engineering support
Customer Case
FAQ
Do I need drying for PP/PE?
Normally no; blends or certain TPUs may benefit from pre-drying.
Can results scale to production?
Yes—matched die designs and screw geometries enable predictable scale-up.
Cleanroom compatibility?
ISO 7/8 options available: stainless wetted parts, sealed water circuit, low-particle routing.
How to Specify Your System
Share your target product (tube/film/profile), OD/ID or thickness, target speed or kg/h, materials, and compliance needs (CE/UL, cleanroom, 21 CFR Part 11). We’ll return a tailored configuration, layout, lead time, and quotation.
