Twin screw compounding

We have extensive experience in twin screw compounding. Some of the specific areas in which we can help improve and optimize your process include but are not limited to the following:

• Screw configuration design
• Barrel layout design
• Downstream addition of solid additives
• Liquid injection into the polymer melt
• Scale-up and translation

We can provide assistance with the entire twin screw compounding process and have close to 20 years of twin screw experience.

Single screw compounding

Single screw extruders provide a lower cost simple process for compounding of many polymeric systems including 

• Polymer blends
• Addition of pre-dispersed pigments into polymers
• Post consumer plastics recycling
• Film, tubing, profile and pipe extrusion

We can help with troubleshooting processing issues, setting up new blends and formulations.

Batch polymer processing

Polymers and rubber products can be compounded in a batch process using an Internal Mixer such as a Banbury (by Farrel) or similar unit by Stewart Bolling and others. Internal mixers are especially good for compounds with high filler loadings where high dispersion is required. These include carbon black loadings as high as 40+% in PE, TiO2 and other pigments in PE and PP at loadings as high as 50% or more, rubber compounds including pelletized NBR, EPDM and other rubbers.

To successfully compound a product in an internal mixer, some key process variables must be accurately controlled including:

• Total batch size
• Accurate melt temperature measurement of the batch to control the drop temperature
• Proper addition of additives before and after flux
• Feeding of the batch into the extruder

We can assist with optimization of these parameters and troubleshooting of the compounding process.