Twin-screw extruder RES-2BP 2x12 mm L/D=40 equipped with a gravimetric feeder for powders.
Laboratory extruder RES-2PN 2x12mm
Laboratory twin-screw extruders RES-2PN 2x12 mm enable testing of materials before production and conducting research on new polymeric materials. The plastics market always wants more new technologies. The plastics market is now demanding more and more complex, faster, smarter and better quality solutions in extrusion plants. This involves optimizing equipment, materials, processes and technologies. Innovation is key in plastic extrusion technology. The evolution of basic materials, composites and polymer blends and reactive extrusion is becoming a challenge in the field of plastic extrusion research. For this reason, manufacturers of laboratory extruders and associated equipment adapt to new and diverse materials and polymer composites. Customers are looking for ease of use and flexibility in polymer processing. Government safety and environmental regulations are a constant challenge for the plastics and polymers industry. Customers are looking for laboratory extruders that can effectively and reliably simulate production equipment in the process of testing plastics and polymers. Laboratories use extruders to develop new compounds, composites or to ensure the quality of their own extrusion systems. Zamak Mercator laboratory extruders for plastics provide scientists with a high ability to reproduce and design industrial processes in the conditions of a research laboratory. Due to the high complexity of the extrusion process, the research extruder should have all the capabilities of industrial extruders and even surpass them in terms of technical parameters and functionality.
Technical data of the device
|Extruder Extruder Screw Diameter:||2 x 12 mm||Replaceable cylinder working surfaces:||Yes |
|Extruder screws length:||40 - 48 L/D||Horizontally split cylinder:||Yes |
|Segmented construction of extruder screws:||Yes ||Top dosing and measuring ports [every 4D, side ports every 8D]:||Yes |
|Co-rotating operation of the extruder screws:||Yes ||Volumetric and gravimetric dosing systems:||Yes |
|Counter-rotating operation of the extruder screws:||Yes ||Zonal cylinder cooling system:||Yes |
|Maximum torque per extruder screw:||9 Nm||Water-cooled charging zone with its own closed-circuit cooler:||Yes |
|Maximum rotation of the extruder screws:||600 - 1200 obr/min||Automatic configuration change from concurrent to counter-rotating:||Yes |
|Drive unit power available:||2.2 kW||Co-rotating extruder screws:||Yes |
|Maximum power density:||10.92 Nm/cm3||Counter-rotating screws of the extruder:||[option] |
|Maximum working temperature of the plasticizing system - nitrided steel:||400/450 ℃||Real-time PLC and Ethernet controller:||Yes |
|Maximum operating temperature of the plasticizing system - acid-resistant steel:||270 ℃||Cylinder inserts and screws nitrided extruder:||[option] |
|Cylinder cooling system - air independent for each zone every 4D:||Yes ||Cylinder inserts and hardened acid-proof screws:||[option] |
|Feeding zone cooling system - pressurized water with its own cooler and pump:||Yes ||Cylinder inserts made in HIPP technology:||[option] |
|Temperature measurement and control for each cylinder zone and head:||Yes ||Side feeders:||[option] |
|Measurement of the torque of the extruder screws:||Yes ||Degassing system:||[option] |
|Measurement of the axial force acting on the extruder screws:||Yes ||Dosing of liquids to be filled with a peristaltic pump:||[option] |
|Material pressure and temperature measurement:||Yes ||High-pressure dosing of fluids into the cylinder by a gear pump:||[option] |
|Measurement of the drive load:||Yes ||Dosing gases into the cylinder under pressure:||[option] |
|Recording and archiving of measurement data and recipes:||Yes ||Wifi and tablet control:||[option] |
|Measurement of consumed electricity:||Option ||Remote supervision and service diagnosis:||[option] |
Important performance characteristics
Precise measurement of the axial force acting on the screws
No need to disassemble the dispensers to open the cylinder and see the process progress
Modular construction models Series -RES-2P Vertex 2x16 / 2x20 / 2x24 mm
Non-modular models Series -RES-2P Vertex2x12 / 2x16 / 2x20 / 2x24 mm
Many models and equipment options available
Replaceable inserts forming the working surface of the cylinder
Wireless remote control
Replaceable cylinder liners
Integration of gravimetric and volumetric dispensers for granules of powders, liquids and gases
The possibility of thermal calibration of the cylinder
Digital control and communication system
High speed heating and cooling of the cylinder for all zones
Possibility to measure temperatures and melt pressure in each zone
Freely configurable cylinder ports
The possibility of using concurrent and counter-rotating worms with a segmented structure
The cylinder heating and cooling system ensures accurate and reliable temperature control of each zone
Modular side conveyor system
Laboratory twin screw extruders easy and convenient access of horizontally split cylinder 2 x 12mm lab extruder
Possibility to personalize the plasticizing system
Gravimetric and volumetric dispenser systems for granules, powders, liquids and gases
Personalized dispenser mounting systems
Personalized application programs
Side systems in combination with gravimetric and volumetric dispensers
RES-2PN 2x12 mm Zamak Mercator research extruders provide scientists with a high ability to reproduce and design industrial processes in a research laboratory. Due to the high complexity of the extrusion process, a research extruder should have all the capabilities of industrial extruders and even exceed them in terms of equipment and functionality with versatile adaptability to almost any processing task and easy system operation, they distinguish laboratory extruders as an excellent research instrument.
The construction of modular and non-modular extruders is based on innovative design assumptions, modern components and is based on many years of experience gained in the plastics processing industry.
Zamak Mercator is a manufacturer of laboratory twin-screw extruders with screw diameters: 2 x 12 mm and 2 x 16 mm.
Twin-screw research extruders designed for larger tasks [applications] with screw diameters: 2 x 20 mm and 2 x 24 mm.
The extruders can work as co-rotating and, after changing the operating mode, as counter-rotating with the L/D range up to 48, with a modular and non-modular structure.
The counter-rotating extruder shows a narrower melt residence time distribution in the plasticizing system and better dispersion mixing ability.
The co-rotating extruder showed improved separation mixing capability. The co-extruder is best suited for melt blending operations.
The key factor determining the quality and credibility of research on the extrusion process is the control and reliable measurement of the melt temperature in each zone of the extruder.
The extruder cylinder is divided along the longitudinal axis in order to obtain the possibility of optical control of the process of plasticizing and mixing the melt.
The extruder barrel is equipped with ports for side feeders and ports on the top of the barrel for dispensing liquids or gases. The heaters are arranged so that the heat is evenly distributed in each heating and cooling zone of the extruder barrel.
The temperature measuring sensors are arranged in such a way as to ensure reliable temperature measurement and limit measurement interference from heaters operating at a higher temperature than the plasticizing system.
In order to avoid uncontrolled temperature rises, each zone of the cylinder is equipped with an efficient and fast cooling system that cooperates with the heating system of the plastic extruder cylinder.
Precise temperature control of the plasticizing system of the extruder is provided by a multi-zone temperature controller designed by our company.
The temperature control system has the ability to calibrate and shape the heating and cooling characteristics of the plasticizing system by the researcher.
We have designed cylinders with exchangeable inserts constituting the working surface of the extruder cylinder. In practice, this means that we can adapt the extruder to work with other materials in a short time by replacing the cylinder inserts. Interchangeable inserts allow for quick and relatively cheap regeneration of the plasticizing system. In principle, inserts can be made of any material and technology that is suitable for this purpose. A set of augers is easy to replace with another one.Virtually all materials can be researched including the plastics, medical, pharmaceutical and ceramics industries.
Vertex II gear extruders replace two extruders, extending the research possibilities.
Zamak Mercator research extruders can be equipped with a precise tensometric measurement of the force acting on the screws lengthwise, this mechanism additionally extends the possibilities of conducting research.
Vertex II gear extruders replace two extruders, extending the research possibilities.
Our research extruders are reliable and repeatableThe preparation time for subsequent tests is shortIn the practice of a research laboratory, meeting such an assumption means that in a short time the extruder must reach and stabilize the working parameters set by the scientist Changes of the set parameters must be reliable, repeatable and fast All measurement data must be reliable.
You can get reliable scale-up, reduced time-to-market.
Our laboratory twin-screw extruders offer flexible configurations from small batches to pilot scale or low-volume production and are ideal for research and development in the polymer, pharmaceutical, biology and nanotechnology sectors. Our laboratory extruders meet a wide range of process requirements, even for the most difficult formulations.
The purpose of applying the described solutions used in twin-screw extruders is to obtain the possibility of conducting research on any thermoplastics, polymers and other materials in a large range of temperatures and screw torques. extruder for a specific task in a short time The extruder quickly responds to temperature changes by the operator.Rich additional equipment and the ability to change the configuration further expand the possibilities of conducting research.
Important functional features of laboratory twin-screw extruders.
A wide range of possibilities for conducting laboratory tests.
High torque extruder screws.
High speed range of the extruder screws.
Measurement of the axial force acting on the screws
Extruder cylinder divided along the horizontal axis.
Replaceable cylinder liners constituting the working surface of the cylinder.
The ability to change the position of the side feeders (a unique feature, requires a service kit).
High allowable pressure inside the extruder barrel.
Dedicated side feeders controlled by the PLC computer of the extruder.
Efficient and economical zonal heating and cooling system for the extruder cylinder.
Low energy consumption during extruder operation.
Ergonomic operation, extensive accessories.
Dimensions of the device adapted to the conditions of the laboratory.
Advanced research software.
Digital PLC control system with HMI touch panel.
Remote wireless control from a tablet
Remote service and extruder software update.
Modular design of the laboratory extruder.
We have made every effort to ensure that the information about our products is factually correct. Please treat the technical data of the devices as indicative, because we constantly improve our products, adapting them to changing technologies.
The presented offer is informative and does not constitute an offer within the meaning of the Civil Code