In the actual production process, the actual production capacity is often lower than the designed production capacity. If the barrel and temperature control system are fixed (our temperature control is adjustable), then the only thing that can be changed is the screw.
To increase the output of plastic recycling and achieve twice the result with half the effort by designing the extruder screw, the following aspects can be optimized:
Increase the effective area: Reasonably increase the effective area of the feed port, which can increase the free fall of the raw materials and thus increase the feed volume. This helps to ensure that more raw materials can smoothly enter the screw area for processing.
Optimize the shape of the feed port: By adjusting the shape of the feed port, such as using a conical or gradually expanding design, the raw materials can be more effectively guided into the screw, reducing the accumulation and blockage of raw materials at the feed port.
- Optimization of conveying screw elements
Select a suitable lead: According to the required capacity and the ability of the screw to withstand torque, select a suitable lead of the conveying screw element. A larger lead can increase the conveying capacity. But it will also increase the torque that the screw needs to withstand. Therefore, it is necessary to ensure the strength and stability of the screw while ensuring the capacity.
Optimize the thread structure: By adjusting the parameters such as the pitch and depth of the thread. The conveying performance of the screw can be further improved. For example, the variable pitch design can achieve different conveying speeds in different areas. so as to better adapt to the processing requirements of raw materials.
Reasonable control of the length of each section: According to the characteristics and processing requirements of plastic recycling, the length of the feeding section, the melting dispersion zone and the distribution zone should be reasonably controlled. The length of the feeding section should not be too long or too short to ensure that the raw materials can be fully compacted and smoothly enter the melting dispersion zone; the length of the melting dispersion zone should be moderate to achieve full melting and dispersion of the raw materials; the length of the distribution zone should be long enough to ensure that the molten plastic can be evenly distributed and meet the required quality requirements.
Use special screw design: For specific plastic recycling raw materials and processing requirements, specially designed screws can be used, such as barrier screws, mixed screws, etc. These specially designed screws can better adapt to the processing characteristics of raw materials and improve recycling output and product quality.
- Collaborative optimization of temperature control system
Accurately control temperature: Although the temperature control system is fixed, the working state of the screw can be optimized by accurately controlling the temperature of each zone. For example, lowering the temperature appropriately in the feeding section can reduce the adhesion of the raw materials and improve the conveying efficiency. Raising the temperature appropriately in the melting dispersion zone can accelerate the melting process of the raw materials.
Optimize the temperature gradient: By setting the temperature gradient reasonably, it can be ensured that the raw materials gradually heat up on the screw and reach a molten state. This helps to reduce energy consumption, improve production efficiency and product quality.
- Other considerations
Regular maintenance and care: Regular maintenance and care of the extruder, such as cleaning the screw and replacing worn parts, can ensure the stable operation and long-term performance of the equipment.
Optimize the operating process: By optimizing the operating process and improving the operating skills level, the plastic recycling output and product quality can be further improved.
In summary, by optimizing the design of the feed port, the conveying screw element, the overall screw design, and the coordinated optimization of the temperature control system, the plastic recycling output can be greatly increased and the product quality can be guaranteed. At the same time, it is also necessary to pay attention to the regular maintenance and care of the equipment and the optimization of the operating process.
