Problems of classical Extruder

Plastics extrusion is a high-volume manufacturing process in which raw plastic is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weatherstripping, fencing, deck railings, window frames, plastic films and sheeting, thermoplastic coatings, and wire insulation.

This process starts by feeding plastic material (pellets, granules, flakes or powders) from a hopper into the barrel of the extruder. The material is gradually melted by the mechanical energy generated by turning screws and by heaters arranged along the barrel. The molten polymer is then forced into a die, which shapes the polymer into a shape that hardens during cooling. (*)

Example of Efficiency Calculation for Classic Extruder System

Even the motor works with rated torque and rated speed. (Usually the motors are used below the rated values)

* The efficiency values are approximately average numbers.

What are the problems of classical Extruder System ?

AGING

The belts and pulleys became old and discarded.

CONTROL

The tension of belt and pulley must be checked continuously.

START - STOP

It is also a source of inefficiency to operate the vessel at different speed by changing the bond rates. (about 5% to 10% loss of efficiency)

EFFICIENCY LOSS

All type of transmission is a loss by extrusion.

MAINTENANCE NEED

Wearing down of the gears, bearings, oil change, breakdown and repair costs

POOR QUALITY

The important thing is that the right load and speed is transmitted to that the screwed mile. The torque motor communicates with the driver thousands times in one revolution, such as a servo motor, and regulates speed and torque. Asynchronous motors can’t achieve that, because of the fluctuations at the load, which causes continuous slippage, which can reduce the quality of the product.

CHILLER COOLING SYSTEM

High inverstment cost, energy cost, maintenance, stable water level (there should be no foreign matter or microorganisms in the water.)

SOLUTION : SQME Extruder Torque Motor by EMF Motor

Smart Choice no gearbox, no water cooling, just direct drive

• Direct drive system without gearbox
• Stable torque even at low speeds
• High Efficiency (even at low speed)
• Precise speed control
• No water cooling
• High Performance
• Integrated thrust bearing
• Compact design
• High torque output
• Low energy consumption
• Silent operation
• Hollow motor shaft
• No maintenance

(*) Plastics extrusion description on wikipedia