You say NewEX, you think New Extruder

ZAMAK MERCATOR is a brand, that for years has been associated with challenges. Interesting and complex projects, wider and wider improvement of our skills, broadening of our contact network and primarily creativity and innovation – this is what gives our Company work and intellectual commitment balance.

ZAMAK MERCATOR is proud participant of European project NewEX, which engages solely the most progressive institutions, that are not afraid of innovation and open-minded approach to technical novelties. The venture is attended by universities and companies from the Czech Republic, Slovakia, Portugal and of course Poland - apart from our Company, this prestigious event is attended only by the Lublin University of Technology.

The first, primary aim of the project is to exchange knowledge and experience in extruders design and construction between all participants of the venture. To accomplish it, mutual visits between attendees and also active participation in symposia, conferences and trainings will be necessary.

Next, more demanding, but most importantly, the most interesting goal of the project is to develop, design, build and test a single-screw extruder characterized by atypical innovations such as: grooved feeding zone with variable groove geometry, mechanically rotating cylinder part and specialized geometry of the screw.

The NewEX project will last till the end of 2020 and it brings a lot of emotions. The venture requires great commitment, creativity, timeliness and broadly understood professionalism. But this doesn’t scare us. We are convinced, that knowledge, skills and contacts we make thanks to participation in this honorable initiative of the European Union, will be the beginning of further success of our Company both in Poland and abroad.

In connection with this project we encourage especially students and graduates of Polish technical universities, but not only them, to apply for internships and internships in our Company.

General information about NEWEX:

The international project realized within Horizon 2020; Research & Innovation Framework Programme of European Union, Marie Sklodowska Curie Action, Research and Innovation Staff Exchange (RISE)

Full title:
Investigation and development of a new generation of machines for the processing of composite and nanocomposite materials

Acronim: NEWEX

Grant Agreement: GA-734205 (2016)

Duration of the project: 01. 01. 2017 – 31. 12. 2020 (48 months)

Coordinator: Lublin University of Technology (Poland) (8 participants);
Participant 2: University of Minho (Portugal) (7 participants);
Participant 3: Technical University of Košice (Slovakia) (6 participants);
Participant 4: Zamak Mercator sp. z o.o. (Poland) (5 participants);
Participant 5: SEZ Krompachy a.s. (Slovakia) (5 participants);
Participant 6: Borra s.r.o (Czech Republik) (4 participants);

Head of the project: professor Janusz W. Sikora PhD, DSc, Eng.; Lublin University of Technology


  • prof. Antonio Gaspar-Cunha; University of Minho,
  • doc. Ph.D., D.Sc. L’udmila Dulebová; Technical University of Košice,
  • mgr. Bogusław Kiszka; Zamak Mercator sp. z o.o.,
  • Betka Perháčová; SEZ Krompachy a.s.,
  • Jaroslav Hájek; Borra s.r.o.

Fund of the project: 1.305.000 Euro

Project Management Board: Janusz W. Sikora, Antonio Gaspar-Cunha, L’udmila Dulebová, Bogusław Kiszka, Betka Perháčová, Jaroslav Hájek, Elżbieta Bociąga

Project Expert Advisory Board:

  • prof. Elżbieta Bociąga; Czestochowa University of Technology,
  • doc. Jana Šugárová; Slovak University of Technology,
  • prof. Oleh Suberlyak; Lviv Polytechnic National University,
  • Aneta Bobryk-Mamczarz; Polskie Zakłady Zbożowe Lubella.


The main research goal of the NEWEX project is the construction and testing of the new innovative extruder. By the application of a new concept of vital parts od new extruder: innovative active grooved feed section (IAGFS), original rotational barrel segment (ORBS) and special screw (SS) a completely new breakthrough technology of extrusion and design of plasticizing system will be achieved. It will ensure manufacturing the products of improved properties and will enable processing materials that could not be processed so far, as well as food materials, cosmetic and pharmaceutical. In parallel to the main RTD activities the NEWEX project is aiming at industry-academia cooperation and transfer of knowledge between organizations from central-eastern and Western Europe. All the projects activities will be performed by thoroughly planned secondments and appropriate hosting institutions between industrial and academic partners.

Realization of NEWEX project will foster the real industry-academia cooperation which is of the key importance in terms of European Research Area development strategy.
The workplan consists of 7 Workpackages, out of which:
WP1-4 focus on the investigation of extruder, extrusion process and extrudate properties and tasks aiming at the selection of the best solution of new extruder vital parts, than construction and testing of new generation extruder.
WP5 concentrates on networking activities (workshops, training, knowledge exchange, etc.).
WP6 aims at knowledge dissemination (participation in conferences, fairs, publications, etc.).
WP7 is dedicated to management and administration of the whole project.


Another NewEX - Lithuania, Kaunas.


The workshop entitled: Realization in metal of extruder vital elements and auxiliary parts – results of WP3, comprised in WP5, especially in T5.1d was held in due time and in accordance with the plan.

On February 6, 2020 in Dirmeta company, representatives from various centers reported project achievements realized during the tasks T3.1, T3.3 and T3.4. Łukasz Majewski and Karolina Głogowska presented the results achieved during the implementation of task 3.1A, concerning the manufacuring of the Active Grooved Feed Section (AGFS). They presented step by step the order of the individual machining operations carried out to obtain these parts and discussed all the metalworking machines used. At the end they presented individual parts made of metal.
Doc Ludmila Dulebova from TUK presented the entire process of obtaining all the necessary parts for manufacturing the Rotational Barrel Segment (RBS). She presented the results achieved during the implementation of task 3.1B, concerning the manufacuring  of the rotational barrel segment. She step by step presented the order of the individual machining operations carried out to obtain these parts and discussed all the metalworking machines used. Finally, she presented individual parts made of metal. She also presented other parts that TUK made under the project.

Next, a representative of Dirmeta, Mr. Aurimas Valečka presented the entire process of obtaining a Special Screw (SS) and frame. He presented the results achieved during the implementation of task 3.1C, concerning the manufacuring of the special screw (SS). Step by step Mr. Aurimas Valečka presented the order of the individual machining operations performed to obtain a special screw and frame. All the machines and tools which were used in this process were discussed. Finally, he presented a special screw and frame made of metal.
Another topic presented at the workshop were the results of choosing auxiliary elements for the extruder, e.g. the main motor, the motor for rotary segment drive, temperature sensors and plastic pressure in the plasticizing system, heating elements, thermocouples for measuring barrel wall temperature. The selection process was carried out during the implementation of task T3.3. The results were presented by Marcin Buczaj from Lublin University of Technology.
Finally, the project coordinator prof. Janusz Sikora, presented the current status of task T3.4 regarding the assembly of the extruder and pointed out that everything is going according to the plan, the pace of work is good, almost half of the work is already done, and the extruder will be assembled in March.



Another NewEX - Lublin University of Technology meeting


As we are actively participating in the NewEX European project, we always eagerly take part in the meetings and conferences connected with this initiative.

For the record, NewEX engages only the most-modern institutions, which are not afraid of innovation and openness to technology novelties. The project involves universities and companies from the Czech Republic, Slovakia, Portugal and Poland. Apart from ZAMAK MERCATOR, The Lublin University of Technology is the only Polish institution participating in the project.

It was in The Lublin University of Technology where on 23rd February 2018 another meeting of all the project-team members took place. Its aim was to discuss progress on the project on which we had been working, as well as to determine and specify further activity.

At the beginning, all participants were welcomed and properly introduced. Each team is very important, as it plays a vital role in the project; without any one of the teams, the NewEX project would make no sense. One of the project objectives is to establish strong relationships among the participants, and international cooperation.

During the next stage of the conference, Prof. Sikora, the Chairman, presented his conclusions on the whole initiative process, and its influence on scientific publications. The representatives from the University in Košice, Slovakia, presented on the issue of polymer materials with fillers, while Prof. Gaspar from Portugal prepared a presentation on the process of extrusion, grooved zones and rotating sleeves, for which he made numerical calculations, and presented the structural part of the project on a new extruder.

The meeting ended with a dinner and a nice chit-chat.

We will keep you informed about the next stages of our NewEX activity.





On 10 April 2017, Technical University of Kosice hosted the team from ZAM, Poland: Agnieszka Niedziela, Bogusław Kiszka and Jakub Fic and the team from BOR, Czech Republic: Jaroslav Hájek and Tomáš Holík. Their secondments started on 10.04.2017 and are due to finish on 09.06.2017.



On 13.04.2017 L’udmila Dulebová from Technical University of Košice during the lecture Characterization of Mechanical and Thermal Properties of Polymer Composites dedicated to the members of NEWEX project presented about possibility of usage of mineral fillers to obtain new properties of polymer composites. She presented effect of mineral fillers Calcium carbonate and talc on main properties of polymer composite with PP matrix. Samples with different percentage of these fillers were prepared and basic mechanical and thermal properties were tested. She informed the members of NEWEX project with research results of testing polymer materials such as thermal conductivity, nucleation of PP and a change in modulus as a result of the change in crystallinity, impact strength, creep resistance, tensile strength, relative elongation and hardness.



On 25.04.2017 within arrival of project participants from firms Borra s.r.o. and Zamak Mercator Sp. z o.o. at TUKE was carried out a workshop on selected techniques for studying properties of composite and nanocomposite materials and their treatment.  Workshop was held at the selected laboratories of Institute of Technologies and Management, Department of Mechanical Technologies and Materials. The laboratory of mechanical and technological testing focuses on the research of mechanical and technological properties of materials. Project participants from SEZ and ZAM got to know the methodology of the research and the essence of devices operation on the example of Tiratest 2300 tensile testing machine and the one for hardness testing. In the Rapid prototyping laboratory was presented the work on a 3D device type FORTUS 400mc for rapid prototyping of Polycarbonate and Ultem prototypes, and on the 3D printer DIMENSION SST 3D Printer for the rapid production of ABS prototypes. The workshop was continued in the laboratory of CNC machine programming, where the project participants got to know and saw the work on the CNC milling machine EMCO concept Mill 155 and CNC lathe DMG CTX 310 eco. The workshop was completed in the plastic processing laboratory, which is aimed at verifying the functionality of molds, pressing and testing of plastic moldings. On the Demag injection molding machine were performed the demonstrations of injection molding process. Within the workshop the project participants explained the principle of working with equipments:  TGA /DSC thermogravimetric analyzer, Shore hardness (A, D), Charpy hammer and Raman spectrometer.



The training which took place in the Centre of Technology Transfer at Cracow University of Technology concerned the possibility of participation of enterprises in European Commission Programme: Horizon 2020. It was organized by the Team of Regional Contact Point of UE Research Projects.The training was held on 15.05.2017 and was attended by Mr Jakub Fic, D.Sc.Eng. from Zamak Mercator, who presented the aspects of participation of Zamak Mercator company in the current project and the rules of carrying out RISE projects. 


Discussion of the results of testing LDPE/HNT composites on TUKE.



At Technical University of Kosice, in accordance with WP5, a training was held on 21 July 2017 in the scope of T 5.2.1. The training was organized by LUT and had an open character. The event gathered the representatives of 5 out of 6 institutions taking part in the project.  The agenda of this event included the presentation disseminating the idea of RISE with MSCA projects, with special attention to NEWEX project. The first part of the training consisted of the lecture on the results of the studies of the extruder and extrusion process as well as the investigation of extrudate properties, conducted in particular host institutions. The activities concerning training, networking and dissemination were also characterised. In the second part of the training Mr Jakub Fic from ZAM discussed thoroughly the issues concerning practical aspects of filament extrusion for 3D printers on the example of selected plastics. Next, Mr Ján Kamenický from SEZ in an interesting lecture presented the problems of production of metal parts using CNC technology in SEZ Krompachy s.a. Then, the representative of UMI, Mr Antonio Gaspar Cunha described the rules of modelling of screw extrusion and optimization of the screw extrusion processes, pointing out important and essential elements of computer simulation.  At the end of this part of training Mrs Anna Sokół-Mazur in extensive presentation Business with passion focused on aspects that nowadays enterprises and projects face with: cooperation, international and intercultural aspects, innovations as the competitive advantage, how to build the effective team in view of personality and age aspects. Then, the constuctional solutions were presented, which were achieved during the brainstorming, discussions and conversations of team members participating in secondments in SEZ Krompachy s.a. which was  a host institution. These concepts were further discussed and developed.


Modeling of single screw extrusion

Optimization of single screw extrusion