Extruders, devices and laboratory lines for plastics > Laboratory stands for granulation

Granulator with water cooling and twin screw extruder

Laboratory granulation line with water cooling

Laboratory granulation line with air cooling

Laboratory granulation line with water and air cooling

Granulator, twin-screw extruder RES-2PN 2x20mm or RES-2PN 2x20mm and a cooling bath is a technically advanced tool for creating new plastic granules.

Twin-screw extruders RES-2PN 2x20mm or RES-2PN 2x20mm have excellent performance parameters and high functionality. They can be equipped with side dosing systems and Movacolor's advanced gravimetric or volumetric dosing systems. The dispensers can dispense powders, granules, liquids. Zamak Mercator additionally offers high-pressure liquid dispensers based on gear pumps. The stand is designed to test materials that can be cut without the use of cooling water directly at the extruder head.

The key device that has a decisive influence on the possibilities of conducting research is a laboratory twin-engine extruder. In the basic version, the stand is offered with a twin-screw extruder from the Vertex II series, model RES-2PM 2x24mm, and optionally with an extruder from the Vertex II series, model RES-2PM 2x20mm. These extruders have unparalleled possibilities in terms of offered parameters, equipment and configuration possibilities. The offered extruders can be made in versions for processing plastics, food and in an acid-resistant version applicable in pharmacy or for testing ceramic materials. The modular design of the devices included in the test stand allows you to change the configuration of the devices during use. The extruders can be equipped with dosing systems for powders, granules, liquids and other devices from the Zamak Mercator offer. The software of the extruders and the granulator can be adapted to the customer's expectations.

To sum up, the Zamak Mercator laboratory twin-screw extruders in combination with a granulator and a cooling bath for the extruded filament together form a perfect tool for creating new plastic mixtures, conducting reactive extrusion, creating dye carriers, filling plastics with mineral or metallic powders.
The laboratory granulator is designed for cutting plastic strands with a diameter of 2-4 mm, previously extruded on any laboratory extruder, into equal granules. The range of cutting lengths is wide, allowing to obtain granules and even flakes. It is an indispensable peripheral device in research lines. Its mobility and versatility allow it to work with various extruders.

The granulating system consists of a replaceable cutting knife driven by a 2.2 kW motor, feeding rolls and string guides. The rotational speed of the rotary knife can be fully adjusted. The line insertion system into the cutting zone is led outside the housing, which protects the operator from access to rotating parts. The feeding of the cutting lines is carried out by a separate drive with a power of 0.55 kW, which ensures the transport of the lines in a large range of linear speeds.

The control system allows you to adjust the linear speed of the cut lines and adjust the rotational speed of the knife. Thanks to the independent regulation of the rotational speed of the knife and the speed of feeding the lines, it is possible to obtain the required length of granules in a large range of the linear speed of the fed lines. The processor controlling the granulator enables independent control of the rotational speed of the blade and the linear speed of the cut filament, or it is possible to set the length of the cut granules for a fixed linear speed and the processor will select the rotational speed of the cutting knife itself. Changing the linear velocity will not affect the length of the pellets.

The granulator can work as an independent device or it can be connected to a unified control system in the entire laboratory line and thus setting and reading of operating parameters can be done from the extruder panel.

Related products:

Universal free-standing granulator

Laboratory extruder RES-2PN 2x24 mm

Laboratory extruder RES-2PN 2x20mm

Laboratory extruder RES-2PN 2x16 mm

Laboratory extruder RES-2PN 2x12mm

Laboratory extruder RES-2PM 2x24 mm

Laboratory extruder RES-2PM 2x20 mm

RED-32 extruder for plastics

RED-25 extruder for plastics

RED-20 extruder for plastics

RED-16 extruder for plastics

Research extruders RES-2PN 2x24 mm RES-2PN 2x20 and Zamak Mercator provide scientists with a high ability to map and design industrial processes in the conditions of a research laboratory. and functionality The downscaling of the machine combined with the versatile adaptability to almost any processing task and the easy operation of the system make laboratory extruders the perfect instrument for research.

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 ensured 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.
Concurrent work.
Contra-rotating operation.
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

Device control:	HMI touch panel and PLC controller	Granule length:	2 to 5 mm
Removable cutting knife diameter:	125 mm	Cutting into petals:	0.1 to 1 mm
Maximum rotation speed of the knife:	2600/3500 obr/min	Maximum line speed of the lines:	10/20/30/40 m/min
Adjustment of the rotational speed of the knife:	Yes [Inverter]	Linear speed adjustment:	Yes [Inverter]
Number of cutting blades:	2 to 12 szt.	Security system:	Yes
Blade drive motor power:	2.2 kW	Digital PLC controller:	Yes
Line pickup drive motor power:	0.55 kW	Extruders:	Technical data of extruders included in the granulation station can be found in the laboratory section of twin-screw and single-screw extruders
The diameter of the cut lines:	1.5 to 4 mm

Granulator with water cooling and twin screw extruder

Related products:

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 ensured 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.

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.

Important functional features of laboratory twin-screw extruders.

A wide range of possibilities for conducting laboratory tests.

Concurrent work.

Contra-rotating operation.

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.

Ask for contact

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.