Plastics
Division

Twin-screw laboratory extruders

Zamak Mercator polymer extruders designed for conducting testing in laboratory and industrial conditions

The design of ZAMAK MERCATOR innovative laboratory extruders is based on many years of experience gained in various industries. The main features of our extruders is high ability to map the industrial processes in terms of testing laboratory conditions. Equally important is the functionality and simple operation.

 

Important functional characteristics

• Wide range of testing opportunities
• High torques
• High permissible pressure inside the cylinder
• Efficient and economical heating - cooling zone system
• Low power consumption
• Simple and ergonomic operation
• High durability of components
• Space saving
• Customizable design to customer requirements
• Advanced testing software
• Digital control system
• Possibility of use in industry

 

Extruder Blue Integra - laboratory extruders for plastic, including materials difficult to extrude because of the need for application of high torques, the content of additives in the form of glass fibres, carbon, organic, powders or nanoparticles. Extruders may be equipped with volumetric feeders, gravimetric feeders, side feeders, pumps for plastic material, other.
• Parallel extruder 2x12 mm - synchronous, asynchronous, switchable
• Parallel extruder 2x16 mm - synchronous, asynchronous, switchable
• Parallel extruder 2x20 mm - synchronous, asynchronous, switchable
• Parallel extruder 2x24 mm - synchronous, asynchronous, switchable
• Conical extruder 5-10-15 ml - synchronous, asynchronous, switchable
• Conical extruder versatile 5-20 ml - synchronous, asynchronous, switchable

Extruder Blue Modular- this solution is more versatile and composed of two elements:

• drive module (Extruder Blue Power) which contains the main drive of the extruder with a maximum power of 26.4 kW, the hopper cooling system and a complete digital control and measurements system. It is equipped with an accurate torque converter.
• Extrusion modules (Extruder Blue Modular) all parallel, conical extruders and grinder mills manufactured by Zamak Mercator can be connected to the drive module.

Blue Modular Modules:

• Parallel extruder 2x16 mm - synchronous, asynchronous, switchable
• Parallel extruder 2x20 mm - synchronous, asynchronous, switchable
• Parallel extruder 2x24 mm - synchronous, asynchronous, switchable
• Conical twin-screw extruder 5-10-15 ml - synchronous, asynchronous, switchable
• Conical twin-screw extruder versatile 5-20 ml - synchronous, asynchronous switchable

Zamak Mercator testing extruders are distinguished by high capacity, durable and ergonomic design, low power consumption, and save valuable space.

The main drive of extruders

Testing extruders are driven by modern AC motors in the 120 Hz technology, power range up to 22 kW, and 87Hz in the range of higher powers. These engines have increased range of rotational speed control, especially at low rotational speeds and provide a constant maximum torque in all speed range. Furthermore, these engines are practically maintenance-free, and the costs of their operation are low. An important element of the drive is a frequency converter (inverter). The inverter allows for controlling rotational speed and torque. We use inverters produced by renowned manufacturers. Optional measurement module of energy consumed and the control of its quality allows controlling the costs and quality of energy used, which increases testing capabilities.
The drive module is additionally equipped with an accurate torque converter.

Torque splitting transmission to two screws and thrust bearings

Torque splitting transmission to two screws is the key element in the construction of testing extruders, it determines the maximum torque and the reliability and durability of the device. The gears for our extruders were developed after many years of experience and R&D works. The structure of transmission allows for the transfer of maximum torque on two screws of the extruder and axial forces caused by the pressure in the cylinder through special thrust bearings. Our gears depending on configuration can work, as synchronous or asynchronous or switchable, which is their unique feature. All cooperating gear components are lubricated with oil through dedicated pump equipped with filter driven by an independent motor, which makes lubrication system independent of rotational speed and provides good lubrication of highly stressed parts in the entire range of rotational speeds, especially very low.

Hopper module

An important component of testing extruder, which has an impact on capacity, product quality, reliability and ergonomics of operation. The hopper module developed and designed by Zamak Mercator does not require disassembly while opening the cylinder of the plasticizing system. This is a unique feature as the extruder operator does not need to dismantle the dispenser unit, which is time consuming and requires physical effort. In order to maintain a sufficiently low temperature of the hopper, it is cooled by means of liquid in a closed system, which is an environmentally friendly solution.

Cylinder and screw module

The extruder cylinders are designed to operate at a pressure of 200 bar. Testing extruder cylinders are divided horizontally, both parts can be opened and the lower one can be tilted downward. Such a solution provides easy and convenient access to the interior of the cylinder and screws and facilitates operation - furthermore, raising and lowering the cylinder parts is supported with gas actuators. During these operations the hopper can remain closed. The cylinder is divided into heating - cooling zones, arranged every 4d. Each zone can have a top and side port, but the side ports can be arranged at every second zone due to the size of side dispensers. The configuration of the cylinder is adapted to customer expectations. The upper and lower part of the cylinder is composed of two parts: a housing containing heaters and measuring sensors and inserts, which is the operational part of the cylinder. The insert can be made of different materials and have different wear-resistant coatings. In addition, by replacing inserts you can change the configuration of the plasticizing system without dismantling the cylinder, e.g. you can change its length. The cylinder is equipped with a wedge closure allowing for easy attachment of the head or pump of plastic material. The cylinder is always equipped with a cover made of stainless steel which limits the possibility of touching the heated cylinder by the operator.

Screws

have a segmented structure, which allows for customization of configuration to specific testing works and the configuration of the cylinder. The structure of the screw is adapted to transfer adequately high torques and axial forces acting on thrust bearings and a mechanism for measuring the value of this force.

Force measurement

the cylinders of our testing extruders are equipped with a mechanism for measuring axial force exerted on screws by the melted polymer under pressure. This solution allows expanding the scope of testing potential and provides additional protection against excessive pressure and mechanical stress.

Cylinder zones thermoregulation

The ecological thermoregulators we use in our extruders have excellent technical parameters and, at the same time, are easy to use. Each cylinder zone (4d) is equipped with a digital temperature adjustment system at range up to 450° C. Each zone has heaters, which allow obtaining preset temperature in a short time and radiator with ventilator, which allows quick temperature reduction. 

Heaters and cooling system are simultaneously controlled by a digital PID controller. This solution allows maintaining the desired temperature with high accuracy of about 1°C (0.1°C temperature measurement accuracy) and avoid the so-called, overdrives, meaning uncontrolled increases or drops in temperature This solution allows maintaining the desired temperature with high accuracy of about 1°C (0.1°C temperature measurement accuracy) and avoid the so-called, overdrives, meaning uncontrolled increases or drops in temperature. Each cylinder has its own thermal characteristics stored in the controller's memory. An efficient cooling system allows adjustment and stabilizing temperatures in the case of processes that create large amounts of heat.

 

Pressure adjustment


The processor and the extruder program may perform pressure measurements of plastic material by means of appropriate transducers. You can apply up to 4 pressure transducers of plastic material. This allows to adjust the pressure and supply of plastic material using just the extruder. After attachment of pump for plastic material, the extruder program takes control over pressure transducers on the inlet and outlet of the pump and its capacity - it gives the possibility of very precise pressure regulation and supply.

Torque adjustment

All testing extruders are equipped with the capability to measure torque. In case of modular construction a drive module is additionally equipped with an accurate torque converter. Measurement of torque allows its adjustment by the user, which increases testing potential. Extruder can be operated automatically in different modes:

• Stability of rotation and temperature
• Stability of pressure, also with polymer and temperature pump
• Stability of axial force and temperature
• Stability of torque and temperature

We can stabilize the selected parameter and on others impose limits of obtained values.

Vacuum degassing system

Our extruders may be equipped with a degassing system, one or two vacuum pumps may be used. Degassing is carried out through the ports in the top of the cylinder.

Pumps for plastic material

Testing extruders for plastic material may be equipped with pumps that provide precise pressure control and supply of the melted polymer. The pumps are properly selected to the model of the extruder. They have precise temperature control and supply of the plastic material, which is managed by a control computer of the extruder. The extruder can operate with the pump, using its own pressure control program, which allows obtaining for unique precision dosing of plastic material to the head. Thanks to this, we can extrude, e.g. accurate filament for 3D printers or polymeric optical fibers.
 

Digital control system

As we cannot imagine testing processes and production without their automatics, our automation department, based on many years of experience, developed software allowing management of extruders and entire testing lines. Our software allows for controlling, monitoring and managing the extrusion. Continuous monitoring of extrusion parameters such as pressure, temperature, rotation, torque, force acting on the screw and cylinder, energy consumption, allow for controlling the process and the device. Additionally, saving parameters in the database for further analysis and archiving, displaying graphs on-line and work in the plant network or even global is also possible. The software designed by Zamak Mercator can carry out the production while the process, and a video image transmit via Ethernet to any place on computers, tablets, etc. 
We can adapt our software to the expectations of our customers. The process can be controlled from the touch screen on the device console or Ethernet. We use our own programs as well as Bernecker + Rainer Industrie Elektronik GmbH and Lenze Drives GmbH equipment to implement our solutions in the scope of automation and drives. We also cooperate with many other renowned companies. Our equipment can be integrated with device control systems produced by other manufacturers.

We manufacture efficient and durable extruders. The appearance and convenience of operation has meaning to us - extruders in accordance with the needs of our customers.