quality Twin Screw Extruder & Recycling Plastic Pelletizer manufacturer

Overview A global automotive parts supplier successfully improved the mechanical properties and dimensional stability of its parts by compounding nylon (PA66) with glass fibers using a twin-screw extruder. This case highlights the process, challenges, and benefits of glass-reinforced nylon production. Background The customer, a Tier 1 supplier to the automotive industry, was looking for a high-strength material for under-the-hood parts that could withstand high temperatures, mechanical stress, and chemical corrosion. Unfilled nylon lacked the required rigidity, while pre-mixes were costly and lacked flexibility for product-specific adjustments. Solution The company invested in a high-torque twin-screw extruder with a customized screw configuration optimized for fiber dispersion and melt uniformity at Henglan Machinery Technology Co., Ltd. (the Company) in Nanjing, China. Nylon 66 base resin is fed into the main hopper, while chopped glass fibers (30% by weight) are fed from the downstream side feed port to prevent fiber breakage. The extruder is equipped with a vacuum degassing system to remove moisture and volatiles, ensuring a stable and high-quality melt. Processing temperature was tightly controlled within the range of 270-290°C. Challenges Fiber breakage: Minimizing the shortening of glass fiber length during compounding is critical to maintaining mechanical strength. Moisture sensitivity: Nylon is extremely hygroscopic. Pre-drying and degassing during processing are critical to prevent hydrolysis and voids. Homogenous dispersion: Achieving uniform fiber distribution without agglomeration is critical for mechanical properties and surface quality. Results Mechanical properties: PA66 + 30% GF composites have tensile strengths exceeding 150 MPa and excellent dimensional stability. Production efficiency: In-house compounding reduces raw material costs by 20% compared to purchasing pre-compounded materials. Customization flexibility: Manufacturers can now fine-tune glass fiber content, additives (such as flame retardants or impact modifiers), and color to customer specifications. Conclusions This project demonstrates the value of in-house nylon + glass fiber compounding using a twin-screw extruder. It enables automotive suppliers to improve part performance, reduce material costs, and gain greater flexibility in product development.    

Overview A leading PET bottle manufacturer in Southeast Asia successfully upgraded its production line by integrating masterbatch coloring technology, enhancing product quality and achieving greater color consistency. This case study explores the implementation process, challenges faced, and the benefits gained from this technological advancement. Background The company specializes in producing PET bottles for the beverage industry, supplying to major brands across the region. With increasing demand for vibrant and uniform bottle colors, the manufacturer sought to improve its traditional coloring methods, which often led to color inconsistency and high wastage rates. Solution Implementation After evaluating various options, the company opted for masterbatch coloring during the extrusion process. Using a twin-screw extruder, PET resin was mixed with color masterbatch directly during melt processing. This method ensured even dispersion of pigments, resulting in consistent color throughout the material. The twin-screw extruder’s high shear and mixing capabilities were crucial in achieving this uniformity. Additionally, the extruder allowed precise control over the pigment load, minimizing material waste and reducing production costs. Challenges and Solutions One of the initial challenges was optimizing the masterbatch ratio for different color intensities. Through multiple test runs and adjustments to the extrusion parameters, the ideal mixture was established, ensuring vibrant colors without affecting the PET’s mechanical properties. Furthermore, staff training was conducted to familiarize the production team with the new process, enhancing efficiency and reducing errors during color changes. Results and Benefits Improved Color Consistency: Masterbatch coloring significantly enhanced color uniformity across all PET bottles. Reduced Waste: The precise control of pigment dispersion minimized material wastage, cutting costs by 12%. Enhanced Production Efficiency: Faster color transitions and reduced downtime boosted overall productivity. Sustainability: The process also supported the company's sustainability goals by reducing pigment waste. Conclusion The integration of masterbatch coloring with twin-screw extrusion proved to be a game-changer for the manufacturer. It not only elevated the quality of PET bottles but also contributed to cost savings and environmental sustainability. This case study demonstrates the value of technological upgrades in modern plastic manufacturing.