Why is an extruder equipped with a melt pump?

1、 The core pain point of traditional extruders: the contradiction between pressure fluctuations and energy consumption

Traditional extruders need to simultaneously undertake the triple tasks of solid conveying, melt plasticization, and metering pressurization. Under high pressure conditions such as high viscosity materials or precision filters, the screw metering section needs to establish high pressure to achieve conveying, which can easily cause two core problems: firstly, high pressure leads to intensified reflux and leakage of the melt in the screw groove, resulting in a decrease in actual conveying efficiency; The second is that severe shearing causes the temperature of the melt to soar, making temperature control more difficult and even leading to thermal degradation. At the same time, the instability of solid transportation, the compression behavior of molten materials, and changes in material rheological properties can lead to periodic fluctuations in machine head pressure, directly causing product accuracy issues such as uneven film thickness and fluctuations in pipe outer diameter, resulting in a high scrap rate.

2、 The core value of melt pump: stable pressure and precise flow control

After connecting the melt pump in series into the system, the extruder can focus on plasticization, preliminary compression, and feeding functions, while the melt pump undertakes the core task of establishing stable die pressure and precise metering output, which is equivalent to adding a "pressure isolator" and a "high-precision flow meter" to the system. On the one hand, the pressure fluctuations of the die head are effectively isolated and no longer directly affect the discharge stability of the extruder; On the other hand, the output flow rate of the melt pump is strictly linearly related to the rotational speed. By precisely controlling the pump speed through a frequency converter, near linear and high-precision adjustment of the flow rate can be achieved, and the dimensional tolerance of the product can be controlled within ± 1%, significantly improving product consistency.

3、 Comprehensive benefits after system optimization: energy conservation, quality improvement, and capacity enhancement

The introduction of the melt pump has achieved a reasonable allocation and optimization of system energy consumption. After the melt pump takes on the main pressure building function, the screw load of the extruder can be reduced by 10% -30%, allowing it to operate in a more optimal torque speed range, and the overall system energy consumption can be reduced by 15% -30%. Meanwhile, a stable pressure environment reduces the risk of material degradation and enhances the stability of product quality; Accurate flow control avoids the waste of production capacity caused by pressure fluctuations in traditional extruders, and can increase the overall production capacity of the production line by 15% -20%, achieving multiple benefits such as quality improvement, energy conservation, and increased production.

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