Laboratory Extruder

Laboratory Extruder

Key Features of the Laboratory Extruder

Precise Process Control and Repeatability

• Servo-driven feeders and closed-loop temperature control ensure stable melt profiles and repeatable results across runs.
• High-resolution torque and pressure sensors provide real-time feedback for rheology and process window mapping.
• Modular screw and barrel design supports quick reconfiguration of conveying, mixing, kneading, and devolatilization zones.

Broad Material Compatibility and Clean Handling

• Handles commodity and engineering resins (PP, PE, PVC, ABS, PC, PA, PBT, TPU), elastomers, bio-based polymers, additives, fillers, and pigments.
• Corrosion- and wear-resistant metallurgy options (bimetallic barrels, hardened screws) for abrasive or chemically aggressive compounds.
• Enclosed feeding and venting with dust extraction interfaces for clean, safe bench-scale operation.

Smart Controls, Data Logging, and Recipe Management

• PLC + touchscreen HMI with recipe library, step-wise temperature profiles, screw speed ramps, and alarm history.
• Full data acquisition: melt temperature, melt pressure, torque, specific energy, feeder mass flow, and residence time index.
• Ethernet connectivity (OPC UA/Modbus TCP) for LIMS/MES integration, CSV/PDF batch reports, and remote monitoring.

Fast Changeovers and Low Operating Cost

• Tool-free die and screw segment change, quick-release feed hoppers, and self-cleaning purge routines minimize downtime.
• Small material inventory per run reduces waste during screening and color/changeover trials.
• Energy-efficient heaters and smart standby lower power consumption during idle periods.

Applications and Industries

Polymer R&D and Compounding

• Masterbatch development, color matching, additive screening (UV stabilizers, antioxidants, antistats, FRs).
• Filler optimization for CaCO3, talc, glass fiber, carbon black, and nanofillers with controlled dispersion.

Building and Construction

• Pilot formulations for PVC profiles, cable ducts, sealing strips, and waterproofing membranes with controlled mechanical properties.

Furniture and Interior

• Compounds for edge banding, decorative films, and laminates with stable gloss, shade, and scratch resistance.

Automotive and Electronics

• Engineering plastics for interior trims, connectors, housings; FR performance tuning and VOC/odor optimization.

Healthcare and Sustainable Materials

• Medical-grade TPU/PEBA trials (non-patient use lab evaluations), bio-based and recycled polymers, reactive extrusion pre-screening.

Technical Specifications

Performance and Capacity

• Screw diameter: 16–35 mm (lab and pilot scale); L/D configurable from 24–48.
• Throughput: approx. 0.2–25 kg/h depending on polymer, L/D, screw design, and venting.
• Process modes: single-screw and twin-screw options; co-rotating twin-screw for intensive mixing; batch or continuous feeding.

Temperature, Torque, and Pressure

• Barrel temperature zones: 4–10 zones, max setpoint 450°C (model dependent) with ±0.5°C stability.
• Torque capacity: up to 120 N·m (size dependent); melt pressure sensors up to 300 bar with auto-zero.

Feeding, Venting, and Devolatilization

• Gravimetric micro-feeders for powders, pellets, and liquids (0.05–30 kg/h).
• Atmospheric and vacuum venting ports; optional side feeder for fillers/fibers; gear pump for melt stabilization.

Construction and Configuration

• Wear packages: bimetallic barrels, HIP kneading blocks, nitrided or hardened shafts and screws.
• Dies: strand, sheet, film, ribbon, and capillary rheology die; integrated water bath, air knife, and pelletizer options.
• Safety: interlocked guards, e-stop, over-torque and over-pressure protection; ATEX options for dusty labs.

Controls, Connectivity, and Reporting

• PLC/HMI with recipe versioning, user permissions, audit trail, and KPI dashboards (OEE, SEn, yield).
• Interfaces: Ethernet, OPC UA, Modbus TCP; batch report export (CSV/PDF) and label printing.

Energy and Utilities

• Power: 3–12 kW depending on size, heaters, and auxiliaries.
• Compressed air: 0.4–0.6 MPa for strand cutting, valve actuation, and purge.
• Smart standby and zone-by-zone heat scheduling reduce idle energy up to 20–30%.

Note: Specifications vary by screw diameter, L/D, and selected options. Custom lab-to-pilot configurations are available for seamless scale-up.

Customer Case

User Recognition and Market Performance

Customer Feedback

• R&D teams report 30–60% faster formulation cycles due to rapid screw reconfiguration and accurate micro-feeding.
• Operators commend intuitive HMI, stable temperature control, and low material consumption per trial.
• Quality and lab managers value complete data logging for reproducibility and faster tech transfer to production lines.

Representative Case Studies

• Masterbatch lab: reduced off-spec color trials by 25% and cut start-up scrap on production twin-screw by 15% through data-driven scale-up.
• Automotive supplier: achieved consistent UL94 FR results across shifts using co-rotating twin-screw with precise venting control.
• Building materials pilot line: improved impact/tensile balance in PVC formulations and shortened approval lead time by 30%.

Market Competitiveness

• Differentiated by modular screw/barrel system, data-rich controls, and MES-ready connectivity for Industry 4.0 labs.
• Strong ROI through reduced trial material, faster approvals, and predictable scale-up to production extruders.