Development trend of extrusion equipment for plastic machinery

Experts believe that the future direction of China's plastic machinery industry is to evolve toward integrated structures, specialization, serialization, standardization, compounding, miniaturization, large-scale production, personalization, and intelligence, while meeting the demands for energy efficiency, material conservation, and high productivity. High-speed, high-output extruders are designed to deliver greater output with lower investment, offering investors higher returns. However, increasing the screw speed of extruders brings several challenges. A shorter residence time in the screw can lead to uneven mixing and plasticization of materials, excessive shear forces that cause rapid heating, and potential thermal decomposition. This makes it harder to maintain extrusion stability, leading to fluctuations in the geometry of the extrudate. Additionally, the precision of auxiliary equipment and control systems must be enhanced, and the wear on screws and barrels increases significantly. Therefore, using high-wear-resistant or ultra-wear-resistant materials becomes essential. Issues such as improving the lifespan of components and bearings at high speeds also need to be addressed. The high efficiency of multi-functional plastic extruders is reflected in their ability to produce more with less energy and lower manufacturing costs. These machines are not only used for polymer extrusion and mixing but have expanded into fields like food, feed, electric carbon, electrodes, explosives, building materials, packaging, pulp, and ceramics. The "one-step extrusion process," which combines kneading granulation and extrusion molding into a single step, is also gaining attention due to its efficiency and cost-effectiveness. Large-scale and precise extrusion equipment helps reduce production costs, especially in applications like twin-screw granulating units, blown film lines, and pipe extrusion systems. Major national projects often rely on imported large-scale extrusion units, such as those required for ethylene projects. To meet domestic demand and support the petrochemical industry, it is crucial to accelerate the localization of these technologies. Precision is key in enhancing product quality—such as in multi-layer co-extruded films—which requires accurate extrusion. Melt gear pumps play a vital role in achieving this precision and must be further developed. Modular and specialized production allows manufacturers to better meet diverse user needs, shorten new product development cycles, and capture a larger market share. Specialized production enables fixed-point manufacturing of system modules, even through global sourcing, which improves overall machine quality, reduces costs, and accelerates capital turnover. In developed countries, intelligent and networked extruders have adopted advanced electronic and computer control systems. They monitor parameters like melt pressure, temperature, motor current, voltage, and raw material ratios in real-time, using closed-loop control for optimal performance. Some companies have implemented online remote monitoring, diagnostics, and control, enhancing process stability and product accuracy. China’s plastic machinery industry has set a clear strategy for the “Eleventh Five-Year Plan,” focusing on developing high-efficiency, energy-saving, material-efficient, environmentally friendly, large-scale, precise, and multi-layer extrusion equipment needed for national key projects and pillar industries. By improving the technical content of existing products, the industry aims to drive sustainable growth and strengthen its position in the global market.

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