A well-running extruder is essential for an efficient production process in the plastics and food industries. However, the costs and challenges of wear and tear on extruder parts are often underestimated. With the right approach and high-quality wear-resistant parts, you can save costs and improve the performance of your production process.
In the world of extrusion, where precision and efficiency are essential, small problems can have major consequences. Think of an end product that does not meet quality standards, waste of raw materials, or even production line downtime. These challenges typically stem from three common issues: irregular extrusion, temperature issues, and mechanical failures. Below, you can read how these difficulties arise and what you can do to solve them.
Imagine: your production line is running at full speed, but the end product shows irregularities in structure or composition. This can lead to rejection of products and unnecessary waste of ingredients.
The cause? Frequently, the concern lies in damage to the screw elements or wear of the extruder barrels. These parts play a crucial role in the transport, melting, mixing, and kneading of raw materials. When they are not in optimal condition, the extrusion process is disrupted.
Fortunately, the solution is simple: replace worn screw elements and extruder barrels. By renewing these parts in a timely manner, you can restore the consistency of the extrusion process and ensure the quality of your end product.
Another common problem is not properly controlling the temperature during the extrusion process. This can lead to products overheating or remaining too cold, resulting in loss of quality, such as poor curing or deviations in the structure.
The culprit? Poor heat conduction due to contaminated cooling channels in the extruder barrels. When these channels become clogged, temperature fluctuations occur that negatively affect the process.
The key to stable temperature control is regular maintenance. By (mechanically) cleaning the cooling channels, you ensure optimal heat conduction and prevent difficulties that endanger the quality of your product.
Mechanical failures are a third challenge. When screw elements no longer function properly, productivity decreases and the risk of downtime increases. This issue often arises from mechanical wear on the screw elements and extruder barrels, an inevitable result of intensive use and high loads. Over time, these parts lose their effectiveness, which negatively impacts the performance of the extruder.
To prevent this, regular inspection of the screw elements and extruder barrels is essential. Worn parts should be replaced in a timely manner, preferably with more wear-resistant material. This not only extends the life of the extruder but also ensures a stable and reliable production process.
The use of high-quality wear-resistant parts offers numerous benefits, including:
Long-term savings with smart choices
An example of cost savings is the choice of an extruder barrel with a replaceable wear liner. Although the initial costs are higher, this type of extruder barrel offers the possibility to replace only the wear liner, which is considerably cheaper than replacing an entire extruder barrel. Over three replacements, this can save almost 20% in costs.
About Extruder Experts
At Extruder Experts, we help companies in the plastics and food industries save costs and optimize their production processes. With affordable, flexible, and high-quality solutions, we ensure a more efficient and reliable production process.
Satisfied customers
Our customers appreciate our flexibility, competitive prices, and high-quality service. Whether it concerns wear inspections, technical support, or the delivery of parts, our partner Extruder Experts is a reliable partner that helps to optimize production processes.
Conclusion
With the right wear-resistant parts and support from our experienced partner like Extruder Experts, you can not only save costs but also improve the performance and reliability of your production process.
Contact SPS | Solids Process Solutions today and discover how we can help your company.
