Air-cooled granulator with a twin-screw extruder

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.