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 extruder 90 mm with a straight head

Rubber and silicone extruder 90 mm with a cross head

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.

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

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.

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.

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

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:

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.
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.
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.
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. .
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.
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.
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:

Highest yield at the lowest possible extrusion temperature.
Wide range of extruders to handle virtually any application.
Robust, durable, highly reliable mechanical design.
Specially designed gum belt feeding system for better extruder feeding.
Large-diameter feed roller bearing arrangement tight.The design includes many unique features and is easy to maintain.
Temperature profiling with heating and cooling channels in the hopper, cylinder and screw.
The extruders are designed for a maximum pressure of 700 bar.
Reinforced thrust bearing, suitable for continuous operation at 700 bar.
Digital control system with PLC and HMI touch panel operator.

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

Extruder for rubber and silicone

Technical description of extruders for rubber and silicone:

Key advantages of Zamak Mercator rubber and silicone extruders:

Highest yield at the lowest possible extrusion temperature.

Wide range of extruders to handle virtually any application.

Robust, durable, highly reliable mechanical design.

Specially designed gum belt feeding system for better extruder feeding.

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

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

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

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

Digital control system with PLC and HMI touch panel operator.

Ask for contact