Ekochem Tworzywa

Plasticising systems

Plasticising systems

We specialise in designing and optimising the geometry of plasticising systems, depending on the processed material and the type of production.

We provide precise measurements and detailed technical documentation, including the selection of the best process parameters necessary to manufacture new plasticising systems and additional components for our clients.

We offer:
• Geometry optimisation adjusted to the properties of the processed material, ensuring proper transport and flow characteristics, excellent mould homogenization and low power consumption,
• Design of new geometries for all types of plasticising systems,
• On-site wear and tear measurement,
• Comprehensive technical consulting.

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Frequently
Asked Questions

A plasticising system is the most crucial part of an extruder – a screw and a cylinder whose aim is to heat up and plasticise processed material. As time goes by, these components suffer wear and tear caused by friction, temperature, and contamination. This results in lower efficiency and quality of granulate. That is why we use hardened materials, offer a wide range of spare parts, and provide maintenance, so that our plasticising systems can be used for a long time.

The quality of a plasticising system directly affects the quality of granulates. A well-designed and maintained system guarantees full plasticisation, even distribution of additives, and a stable process, which translates into granulates with uniform colour, characteristics, and mechanical properties. A system which is worn out or improperly selected causes loss of efficiency, higher energy consumption, and, most importantly, lower quality of the granulate.

Our maintenance offer in Poland is really quick – the response time is usually 24-48 hours, while standard maintenance or calibration typically takes just a few hours, one day at the most. After the repairs, we run tests and process calibration and issue a manufacturer’s warranty covering new or regenerated parts.

We do. Our offer includes wear and tear analysis of plasticising systems, component regeneration (both screw and cylinder), as well as optimisation of their geometry. These allow for restoring full efficiency of a machine or even improving process parameters, as compared to the original design.

Wear and tear is diagnosed by measuring the backlash between the screw and the cylinder, visual inspection of working surfaces, and an analysis of working parameters (efficiency, torque, energy consumption). For medium wear and tear, we recommend regeneration. When wear and tear exceeds permissible values and lowers granulate quality, we advise replacement.

Precise production and delivery dates are determined individually after the machine specifications have been approved. Please contact our technical and sales departments to estimate the lead time.

Our plasticising systems are made of nitriding steel, bimetallic designs, and have hardened coatings (e.g., carbides, stellite). Nitriding steel is suitable for pure materials, bimetallic systems are recommended when dealing with recyclates and medium contamination levels, and hard coatings are best used for highly abrasive materials (e.g., with mineral filling or glass fibres).

Yes, when ordering a new plasticising system, certain design modifications are possible. These include changes to screw geometry, L/D ratio, and additional mixing or degassing zones, allowing for increasing output and adjusting the process to the customer’s requirements.

Screw geometry is designed with material type and purity in mind. We consider bulk density, moisture level, contamination level, and end product requirements. The tolerances are adjusted to ensure optimal homogenisation, degassing, and efficiency with minimum energy consumption.