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Extruder for rubber and silicone
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Extruders, devices and industrial lines for rubber and silicone > Extruders for rubber and silicone
Rubber and silicone extruders 90 mm with a two-component extrusion head

Rubber and silicone extruders 90 mm with a two-component extrusion head

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Rubber and silicone extruders 90 mm with a two-component extrusion head
Rubber and silicone extruder 90 mm with a straight head
Rubber and silicone extruder 90 mm with a cross head
Rubber and silicone extruder 90 mm
Extruder for rubber and silicone 45 mm
Rubber and silicone extruder 90 mm
Rubber and silicone extruder 60 mm
Rubber and silicone extruder 32 mm
Rubber and silicone extruder 90 mm
Rubber and silicone extruder 60 mm
Extruder for rubber and silicone 45 mm
Rubber and silicone extruder 90 mm
Rubber and silicone extruder 90 mm with a cross head
Rubber and silicone extruder 32 mm
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Extruder for rubber and silicone

Rubber extrusion allows for a high level of customization and results in products with excellent uniformity and strength.

This is the preferred method of processing rubber by most manufacturers. Extruded rubber profiles are appreciated by manufacturers and customers from many industries, including: electronics, automotive, aviation, household appliances, military, sports, marine and flooring. In these industries, extruded rubber parts are used e.g. for moisture control, air conditioning, insulation, joining parts, protecting floors and waterproofing, and work as parts of many machines.

Rubber extruders produce a wide variety of shapes and products that are invaluable in everyday life, such as rubber trims, rubber gaskets, extruded rubber gaskets, rubber floor mats, rubber grommets, connectors, bumpers and much more. In general, rubber extrusions are valued as sealants and gaskets because they offer such excellent flexibility, impermeability and resilience. In industry, rubber moldings are used in cars, machines, bicycles, space shuttles and submarines. In warehouses and production plants, rubber rolls, sheets and rods absorb noise and vibrations caused by moving machinery. The scope of application of extruded rubber products seems to be unlimited.

Our goal is to exceed our customers' expectations by providing good customer service with high-quality extruders and rubber extrusion and vulcanization lines.

Technical data of the device
Extruder model  BLACK 150  GREEN 150  BLACK 120  GREEN 120  BLACK 90  GREEN 90  BLACK 60  GREEN 60  BLACK 45  GREEN 32  
Screw diameter  [mm]  150  150  120  120  90  90  60  60  45  32  
Plasticizing system  14-22  14-22  14-22  14-22  14-22  14-22  14-22  14-22  14-22  14-22  
Rotational speed  [rpm]  37-49  37-49  50-42  50-42  55-72  55-72  60-80  60-80  80-105  100-130  
Maximum torque  [Nm]  48,500  38,000  28,000  21,000  11,000  9,000  3,800  3,100  1,300  520  
Power  [kW]  220-300  150-225  130-190  95-130  65-95  50-78  25-38  20-30  11-15.5  7.5-11  
Capacity  [kg / h]  800-1100  800-1100  480-700  480-700  300-400  300-400  100-120  100-120  30-45  15-18  
Maximum pressure  [bar]  700  400  700  400  700  400  700  400  400  400  
Heating and cooling zones  3-6  3-6  3-6  3-6  3-6  3-6  3-6  3-6  3-6  3-6  
Closed circuit pressure heaters  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  
Maximum working temperature  ℃  Depends on the used heating and cooling units [90/150/200 ℃]  
Temperature measurement accuracy  ℃  ± 0.1            
Temperature measurement resolution  ℃  0.1            
Temperature control  PID controlling the heating and cooling power  
Hydraulic Lockout  Option  Option  Option  Option  Option  Option  Option  Option  Option  Option  
3d head mount  option  option  option  option  option  option  option  option  option  option  
Energy consumption module  option  option  option  option  option  option  option  option  option  option  
process visualization and data logging software  option  option  option  option  option  option  option  option  option  option  
Reinforced feed roller structure  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  Yes  
constant friction  1.07  1.07  1.07  1.07  1.07  1.07  1.07  1.07  1.07  1.07  
friction variable  option  option  option  option  option  option  option  option  yes  yes  
Pallet rubber belt feeder  option  option  option  option  option  option  option  option  option  option  
Remote control  option  option  option  option  option  option  option  option  option  option  
Ethernet  option  option  option  option  option  option  option  option  option  option  
Control  Real-time PLC processor working in a distributed architecture, equipped with a touch screen  
Safeguard  yes [overload, short circuit protection, electric shock protection] - Main and safety switch  
 
Important performance characteristics
The unique method of attaching the head to the extruder supports the heads while maintaining centering
Facilitates operation [cleaning, screen replacement and tool change].
Reinforced, easy-to-use rubber or silicone belt feeding system.

Large diameter pressure roller operates with friction = 1.07 is equipped with a tempering system and reinforced bearings for long reliable operation
Heads with precise drive for changing the position of the male drive eliminates inconvenient tools and human work.

The head can be used in three configurations [optional equipment required].
High efficiency and thermal efficiency of the plasticizing system.
Ważne cechy użytkowe
We offer extruders made in configurations tailored to the needs of customers.
We offer extruders and heads highly personalized - adapted to the specific expectations of the customer.

We design individual technical solutions for our clients.
Industrial extruders can be equipped with their own drive, which allows for independent passage. Changing the position of the extruder in the line can be controlled wirelessly.
On the left side, there is a view of a wedge lock with a hydraulic drive, which, in combination with the 3D head suspension, greatly reduces the effort required to operate the device.

On the right, there is a view of a mechanism that compensates for changes in cylinder length due to temperature changes, eliminating mechanical stresses.
Ważne cechy użytkowe
We use high-efficiency reducers designed for long-term operation of Rossi, Nord and Lenze
We only use pressure heating and cooling units from reputable manufacturers
To control devices and lines, we use PLC controllers from B&R [ABB Group] and Siemens
We use energy-saving electric motors from Siemens, Lenze and Nord to drive the extruders
We use modern Ethernet Powerlink and ProfiNet communication buses
It is possible to integrate the control system with devices
Ważne cechy użytkowe
Technical description

Extruded rubber products are lightweight, flexible, extremely durable and durableExtruded rubber parts are ideal for use in a myriad of harsh or extreme environments such as high temperature environments or applications with significant chemical exposure The continuous rubber extrusion process allows parts to be produced in various lengths and shapes in a relatively economical way and with very little material waste.


Zamak Mercator is a manufacturer of single-screw extruders with screw diameters from 32 mm to 120 mm in the range of L/D to 22 The construction of the extruders is based on innovative design assumptions, modern components and is based on many years of experience gained in the rubber and silicone processing industry Our extruders are durable, reliable and repeatable Preparation time for subsequent tasks is short due to the high thermal efficiency of the plasticizing system.

Changes in preset parameters are reliable, repeatable and fast All measurement data is reliable Industries including automotive, aerospace, medical and construction use custom profiles and molded products to seal or dampen vibration Whether it's gaskets or window seals, you need quality custom profiles to meet your design and performance requirements.

Technical description of extruders for rubber and silicone:

  1. The main drive of the extruders
    We use modern AC motors in 120 Hz or 87 Hz technology to drive the extruders. These motors have an increased range of speed control, especially in the low speed range, and provide a constant maximum torque in the entire speed range. An important element of the drive is a frequency converter [inverter] We use inverters of renowned manufacturers, tailored to customer expectationsOur drives [motor + inverter] save electricity, e.g. compared to DC drives, which are still popular in extruders from many manufacturers, they save up to 10% of electricity.

  2. thrust bearing
    It is a key element of the construction of extruders, it determines the maximum working pressure and the reliability and durability of the device. Thrust bearing must work reliably under heavy load for many years Thrust bearings are designed by Zamak Mercator to transfer forces four times greater than the pressure in the extruder cylinder for many years yearsThe thrust bearing works directly with the cylindrical gear.

  3. Module for feeding a belt of rubber, granules or rubber or silicone billets
    An extremely important subassembly of the rubber extruder, it affects the efficiency, product quality, reliability, ergonomics of the operator's work. The module developed and designed in our company is adapted to work with tape, granulate or rubber and silicone billets. The body of the charging module has an efficient system of channels through which the coolant The rubber feeding roller is equipped with a high torque transmission gear, bearings and seals to ensure reliable operation. The feeding roller is cooled.

  4. Rubber belt feeding module, granules or rubber or silicone billets - independent drive
    The key element of the feeding system is the feeding roller. In rubber extruders with screw diameters of 32 and 45 mm, the feeding roller has an independent electric motor drive.This technical solution allows you to set frictions, i.e. the relationship between the speeds of the screw and the feeding roller in any range. .

  5. Cylinder and worm module
    Extruder cylinders are designed to work at a pressure of 1000, 700 or 400 bar Each cylinder is equipped with a system of channels for the heating and cooling medium, which ensures effective operation and ensures heating and cooling of all connection flanges [elimination of unheated and uncooled zones]
    The screw is designed in such a way as to optimally homogenize the mixture and transmit high torque, which is important for achieving high efficiency. Inside the screw there is a channel through which the heating and cooling medium flows. The heating and cooling unit controlling the temperature of the screw is additionally equipped with a pump with increased parameters to ensure efficient operation of the system.

  6. Heating and cooling units [thermoregulators]
    Eco-friendly thermoregulators that we use in our extruders have excellent technical parameters and are easy to use at the same time. The maximum operating temperature is 90°C, 120°C, 150°C when using water. The highest quality components guarantee operational reliability and the highest possible accuracy of thermostating.
    The hydraulic installation of thermoregulators is made of stainless steel and copper, which guarantees reliable operation.

  7. Digital control system
    Based on many years of experience, our automation department has developed software to manage extruders and entire testing linesOur software allows you to steer, control and manage extrusion processes
    Continuous control of extrusion parameters such as: pressure, temperature, revolutions, torque, energy consumption, allow you to control and steer the process and line devices. You can add to this the ability to save parameters to the database for later analysis and archiving, displaying graphs on-line and working in the company network and even globally
    Our software can be adapted to the expectations of our customers. The process can be controlled from the touch screen on the device console or in the Ethernet network.
    To implement our solutions in the field of automation and drives, we use our own programs and devices from Bernecker + Rainer Industrie Elektronik GmbH and Lenze Drives GmbH, we also cooperate with many other reputable companies. It is possible to integrate our devices with control systems of devices from other manufacturers.

Key advantages of Zamak Mercator rubber and silicone extruders:

  1. Highest yield at the lowest possible extrusion temperature.

  2. Wide range of extruders to handle virtually any application.

  3. Robust, durable, highly reliable mechanical design.

  4. Specially designed gum belt feeding system for better extruder feeding.

  5. Large-diameter feed roller bearing arrangement tight.The design includes many unique features and is easy to maintain.

  6. Temperature profiling with heating and cooling channels in the hopper, cylinder and screw.

  7. The extruders are designed for a maximum pressure of 700 bar.

  8. Reinforced thrust bearing, suitable for continuous operation at 700 bar.

  9. Digital control system with PLC and HMI touch panel operator.

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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

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