Extrusion & Compoundierung

Extruders for different process engineering tasks

Our research group has extruders of various types and sizes for every process engineering task. The machinery includes single- and twin-screw machines, kneaders, tandem, and laminating lines. This means that our experienced staff can cover a wide range of processing and compounding tasks from laboratory to pilot plant scale. There is also an extensive range of fittings and tools at hand for the plants.

Markus Schirmer | Polymer Engineering Bayreuth

Contact: M.Sc. Christian Brütting
Phone: +49 921 55 7482
Mail: christian.bruetting@uni-bayreuth.de

The Buss Kneader is a unique compounding extruder. Its most outstanding feature is a special operating principle in which the screw shaft performs a synchronous back-and-forth movement in the axial direction with each revolution. This sinusoidal motion sequence is made possible by a special gear. The characteristic kneading blades on the screw shaft work together with fixed kneading teeth or bolts in the kneader housing. As a result, the raw material components are sheared between the kneading blades and the kneading teeth over an unusually short process length. The oscillating screw shaft also ensures intensive product exchange in the axial direction through multiple dividing, folding, and reorientation of the kneading mass.


Lab-scale Kneader
Process Length [[L/D]] 20

Screw Diameter [mm] 30

max. Screw Speed [U/min] 500

Power [kW] 7,5

Throughput [kg/h] 5 – 25

Conveyor Screw
Diameter [mm] 40

Length [L/D] 6

Temperature Controll
Temperature Range [° C] up to 400

Heating System Electric

Cooling Air

Fittings Vacuum Degassing, Gravimetric three-component Dosing System K-Tron, Water Bath, and Strand Granulator

COntact: Markus Schirmer

Phone: +49 921 55 7480

Mail: markus.schirmer@uni-bayreuth.de

BUSS Ko-Kneter | Polymer Engineering Bayreuth

This small laboratory unit of Dr. Collin’s has a slot die and a roller and winding unit. The system is designed for processing standard thermoplastics, as the cylinder temperature is limited to 300° C. The system is mainly used for teaching in the practical film extrusion course for students of materials science.

Single-screw extruder Collin:

Screw Diameter [mm] 20

L/D 25

Maximum Speed [1/min] 180

Maximum Torque [Nm] 94

Processing Temperatures [°C] Up to 300

Heating Zones 5

Throughput [kg/h] ≤ 1 – 5

Roller Group Chill-Roll:
Chill Roll Diameter [mm] 72

Chill Roll Width [mm] 190

Maximum Nozzle Width [mm] 100

Maximum Traction [N] 260

Maximum Drwaing Speed [m/min] 14

Location: University of Bayreuth

Contact: Sebastian Gröschel

Phone: +49 921 55 7462

Mail: sebastian.groeschel@uni-bayreuth.de

Collin Techline Folienextruder

The filament extruder is a single-screw extruder for the production of 3D printing filaments. Even high-temperature thermoplastics can be processed precisely and reproducibly with this system. We process the manufactured filaments further with our additive manufacturing systems.

 

Screw Diameter Lab-scale Kneader [mm] 20
L/D 25
Speed max. [1/min] 200
Torque max. [Nm] 124
Throughput [kg/h] 4
Processing Temperatures [°C] up to 400
Haeting System Electric
Cooling Air
Fittings Water Bath, Laser Thickness Measurement and Take-off unit with Winding Function
Location NMB Module 1 – Bayreuth
Contact Markus Schirmer, Phone.: (+49) 921 / 55 7480 or 7550

This machine is a co-rotating twin-screw extruder. It is used for the production of compounds from thermoplastics, additives or fillers, as well as the production of polymer blend systems on a laboratory scale. Thanks to the flexibly adjustable screw geometry, the shear energy acting on the plastic melt during processing can be variably adjusted. In this way, the influence of individual screw elements on the dispersion of the fillers or the blend morphology can be specifically investigated. In addition to compounding, rheological tests can be carried out on the materials processed by means of an expansion nozzle.

Processing Method
Compounding, Foaming, Rheological Investigations (Expansion Nozzle, Capillary Rheometer)

Screw Diameter [mm] 20

[L/D] 40

Speed max. [1/min] 400

Torque max. [Nm] 55

Heating Zones 6

Throughput [kg/h] 1 – 5

Fittings
Melt Pump, Rheotens, Granulator, Water Bath, Mass Kneader

Contact: Sebastian Gröschel

Phone: +49 921 55 7462

Mail: sebastian.groeschel@uni-bayreuth.de

Doppenschnecken-Extruder | Brabender DSE 20/40 | Polymer Engineering Bayreuth

This co-rotating twin-screw extruder enables us to compound additives, glass, and fillers into polymer matrix systems, or process thermoplastics into blends quickly and efficiently on a pilot plant scale. Thanks to the flexibly adjustable screw geometry, the shear energy acting on the plastic melt during processing can be variably adjusted. In this way, the influence of individual screw elements on the dispersion of the fillers or the blend morphology can be investigated in a targeted manner. Thus, we can respond to a variety of compounding tasks by adjusting screw configuration. In addition, the extruder barrel has two injection points for feeding physical blowing agents, which enable the screening of different formulations for the production of thermoplastic foams. The compounding of high-temperature thermoplastics such as PEEK is also possible with this line configuration.

Screw Diameter [mm] 225

L/D 44

Speed max. [1/min] 1200

Torque max. [Nm] 212

Processing Temperature [° C] up to 400

Heating Zones 10

Throughput [kg/h] 10 – 100

Fittings
Inclined spraying Head with Hole Strip 2 x Ø 4 mm, 4 x Ø 4 mm Hole, Vacuum System for Degassing (22 m3/h at 100 mbar), 2 Sampling Plates, optionally 2 Side Feeders, 2 Injection Points for liquid Dosing, two Gravimetric Dosing Units

Contact: Sebastian Gröschel

Phone: +49 921 55 7462

Mail: sebastian.groeschel@uni-bayreuth.de

Location: University of Bayreuth

Doppelschnecken-Extruder | Werner und Pfleiderer ZSK 26 MCC

The Collin extrusion line is a tandem setup consisting of a ZK 25 P twin-screw extruder and an E 45 M single-screw extruder. The other equipment includes a melt pump, gravimetric feeders, a gas metering station, and a pump for liquid metering (e.g. blowing agent).

With this plant, granulate and microgranulate in various sizes can be produced, but also foams and particle foams. We are currently using the system primarily for foam extrusion and particle foam production on a pilot plant scale.

TWIN-SCREW EXTRUDER

Screw Diameter [mm] 25

Barrel Length [d] 42

Processing Temperature [°C] up to 450

Throughput [kg/h] up to 15

Torque [Nm] 90

Speed [1/min] 460

Processing Method
Compounding, Foam Extrusion

Fittings
Collin Plate Calibrator, Maximator, Wide Slot Nozzle, Two-Component Dosing Unit

SINGLE-SCREW COOLING EXTRUDER
Screw Diameter [mm] 45

Barrel Length [d] 30

Processing Temperature [°C] bis 450

Throughput [kg/h] up to 15

Torque [Nm] 1200

Speed [1/min] 240

Processing Method
Foam Extrusion

Location: University of Bayreuth

Contact: Sebastian Gröschel

Phone: +49 921 55 7480

Mail: sebastian.groeschel@uni-bayreuth.de

Tandem-Extrusionsanlage | COLLIN | Polymer Engineering Bayreuth

This tandem extrusion line consists of a co-rotating twin-screw extruder and a single-screw extruder. Another single screw can be coupled to the end of the single-screw extruder via a co-extrusion block and the plant can be expanded to a tridem plant.

The line was funded as part of a research project for the production of a thermoplastic printed circuit board. The aim was to produce a three-layer substrate material for conventional printed circuit boards, the core consisting of foamed thermoplastic and the cover layers of compact high-temperature thermoplastic. Of course, this plant configuration can also be used to process other thermoplastics.

TWIN-SCREW EXTRUDER

Screw Diameter [mm] 41

Barrel Length [d] 43

Processing Temperatures [°C] up to 400

Throughput [kg/h] up to 50

Processing Methods
Compounding, Foaming

Fittings
Collin Smoothing Unit, Maximator, Granulator, Slit Die

COOLING EXTRUDER
Screw Diameter [mm] 50

Barrel Length [d] 30

Processing Temperatures [°C] up to 400

Fittings
Collin Smoothing Unit, Maximator, Granulator, Slit Die

COEXTRUDER
Screw Diameter [mm] 50

Barrel Length [d] 30

Processing Temperatures [°C] up to 400

Fittings
Collin Smoothing Unit, Maximator, Granulator, Slit Die

Location: Neue Materialien Bayreuth GmbH

Contact: Markus Schirmer

Phone: +49 921 55 7480

Mail: markus.schirmer@uni-bayreuth.de

Tandem-Extrusionsanlage | Reifenhauser | Polymer Engineering Bayreuth

The laboratory-scale flatbed laminating press is a double belt press with integrated contact heating and cooling. The materials to be laminated are gently heated in the process. The length of the heating zone results in a relatively long dwell time in the laminating press, which leads to optimal bonding with high adhesion performance. Immediately after the heating zone, the laminated material can be pressed with the calender rollers or calibrated to a desired final thickness. To stabilise this bond, the laminated material is cooled down while still inside the laminating machine. Due to the flat throughput and the precise height adjustment, even solid sheets up to a material thickness of 15 mm can be laminated.

Laminator RPS-L 600
Working Width [mm| max. 580

Throughput-Speed [m/min| 0,5 – 7

Pressure Laminating Roll [N/cm²| 0 – 40

Pressure Roll Rubber Lining [Shore A| ca. 70

Level Adjustment [mm| – 3 bis + 5

Height Adjustment [mm| 0 – 25

Heaters, 2 each for Upper and lower Heating [Control Zones] 4

Contineous Operating Temperature (Heating) [°C] max. 200

Short-term Operating Temperature (Heating) [°C] max. 230

Processing Temperature [°C] up to 400

Cooling Water above and below

 

Location: University of Bayreuth

Contact: Markus Schirmer

Phone: +49(0)921 55 74 80

Mail: markus.schirmer@uni-bayreuth.de

Kaschieranlage | Polymer Engineering Bayreuth

The process is unique as it allows direct lamination in one step. The system consists of a single-screw extruder and a special laminating unit. This allows copper foils to be laminated directly onto a substrate material. These extruded semi-finished products can be further processed by companies in the electrical industry. It is possible to simultaneously impregnate glass and carbon fibre mats with this system.

Screw Diameter Lab-scale Kneader [mm] 30
L/D 20
Speed max. [1/min] 180
Torque max. [Nm] 94
Throughput [kg/h] 4 – 25
Processing Temperatures [°C] up to 450
Heating System electric
Cooling Air
Fittings Calender with Drawing Unit
Location NMB Modul 1 – Bayreuth

Contact

Phone

Markus Schirmer

+49 921 / 55 7480 od.7550

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