Facing The Pain Points Of The Granulation Industry: COLOWE's Efficient Twin Screw Extrusion Solution Leads A New Chapter in Sustainable Production
Introduction: Common Challenges in the Global Plastic Granulation Industry
In the global trend towards a circular economy, the plastic granulation industry is standing at a crossroads of transformation. On the one hand, environmental regulations are becoming increasingly strict, and more than 120 countries and regions around the world have implemented plastic restriction orders or plastic taxes; On the other hand, market demand continues to grow, and it is expected that by 2025, the size of China's recycled plastic market will reach 165 billion yuan. In this context, plastic pellet manufacturers face many challenges such as low production efficiency, unstable product quality, high energy consumption, and difficulty in adapting to new material development. How to break through bottlenecks and achieve green, efficient, and cost-effective production has become a common focus of attention in the industry.
1. Industry Status and Policy Drivers
1.1 Global environmental policies accelerate industrial upgrading
In recent years, the global plastic industry has undergone profound changes. China's national standards such as the "Design Guidelines for Recyclable Plastics" have been officially implemented since February 1, 2026. Driven by policies, the concentration of industries continues to increase, and although the number of enterprises above designated size accounts for less than 10%, they contribute more than 60% of the industry's output value. These changes require granulation equipment to have higher flexibility, stability, and energy efficiency performance.
1.2 Technological bottlenecks constrain industry development
Many plastic pellet manufacturers are still using traditional equipment and facing many technical challenges:
·Poor plasticization: causing lumps in the product, resulting in breakage under traction force
·Poor exhaust: Materials that are damp or gases generated by the decomposition of additives are trapped in the material strip, forming hollow or broken strips
·Uneven mixing: serious black spot problem, reducing product quality
·Excessive energy consumption: Traditional equipment has low energy efficiency and production costs continue to rise
·Poor adaptability: difficult to handle new raw materials such as recycled materials and biobased materials
2. COLOWE Overall Solution
2.1 New modern factory, consolidating manufacturing foundation
In response to the increasing demand for efficient extruders in the global market, Nanjing Kelongwell Chemical Machinery Co., Ltd. has invested in the construction of a new large-scale modern chemical plant. This strategic measure not only increases production capacity, but also pushes the manufacturing standards of co rotating twin screw extruders to new heights. The new factory integrates precision manufacturing, large-scale production, and green technology to provide customers with cost-effective and environmentally friendly plastic extruder solutions, laying a solid physical and technological foundation.
2.2 Core advantages of COLOWE solution
COLOWE's efficient twin screw extrusion granulation solution is built around four core values:
Excellent process adaptability
Our co rotating twin screw extruder adopts a modular design, which optimizes the screw configuration (such as using mixing elements such as kneading blocks and toothed discs) and cylinder temperature control system to ensure full melting and homogenization of the material. Whether it's general-purpose plastics (PP, PE, ABS), engineering plastics (PA, PC, PBT), thermosensitive materials (such as PVC and biodegradable materials), or high filling ingredients (filling ratios up to 80%), they can all be easily handled.
Significant energy efficiency improvement
By optimizing screw design, adopting efficient transmission systems, and heating and cooling schemes, the Cologne Weil high-efficiency extruder significantly reduces energy consumption per unit product. This design not only directly reduces customer operating costs, but also reduces carbon emissions, fully in line with global environmental goals.
Excellent stability and reliability
Equipped with precise temperature control system (multi-stage independent PID control), high torque drive system, and advanced PLC control system, ensuring high stability and repeatability of processing parameters. Our 75D high torque co rotating twin screw extruder has consistently produced over 1.5 tons per hour in PET material testing, far exceeding the expected target.
Intelligent production support
The production system of the new factory is also practicing intelligence. In the future, we plan to integrate richer digital interfaces and sensors into factory equipment, providing hardware foundation for customers to build smart factories, achieve predictive maintenance, and trace process data.
3. Key technology: Innovative design of COLOWE co rotating twin screw extruder
3.1 Advanced co directional meshing principle
The core of the Kelongwell co rotating twin screw extruder lies in the two screws meshing with each other and rotating in the same direction. This design creates complex material flow paths, allowing materials to undergo strong shearing, squeezing, and mixing during transportation. Compared to single screw or counter rotating twin screw, it has better self-cleaning ability, more uniform melt temperature control, and more flexible modular screw combination possibilities.
3.2 Professional solutions for industry challenges
Solve the problem of poor plasticization
By precise temperature control and optimized screw design, the material is fully plasticized. Control the temperature according to the process requirements, and increase it appropriately when the temperature is found to be low; By appropriately reducing the screw and traction speed, the heating and plasticizing time of the plastic can be extended; Use screw cooling water to enhance the plasticization and compactness of plastics.
Improve the exhaust volatilization effect
In response to the hollow and broken strip problems caused by poor exhaust, the Cologne Weil twin screw devolatilization extruder provides vacuum exhaust ports in multiple sections to efficiently remove moisture or small molecule impurities, ensuring the purity and high performance of the final particles.
Prevent the formation of black spots
By optimizing the screw combination and process parameters, reduce material carbonization caused by local overheating or excessive shear; Ensure regular cleaning of natural and vacuum exhaust ports to prevent the accumulation of carbonization materials; Improve the wear and corrosion resistance of screws and barrels, and reduce the generation of impurities caused by equipment wear.
4. Actual performance data of COLOWE equipment
4.1 Breakthrough performance of high torque series extruders
The KLWE 75D high torque co rotating twin screw extruder performed excellently in the PET material water flow granulation process test:
·The output has remained stable at over 1.5 tons per hour, far exceeding the expected target
·Full particles, consistent size, and uniform color
·Extremely low moisture content, fully in line with downstream application quality standards
·The entire line runs smoothly, with precise control of melt pressure and temperature
4.2 Supporting Sustainable Material Production
With the deepening of the concept of circular economy, the demand for recycled materials in high-end application fields is increasing day by day. For example, the recently launched TROGAMID by Evonik ® R transparent polyamide is an innovative material made from recycled plastic. The efficient twin screw granulator from COLOWE is an ideal platform for processing post consumer recycled plastics (PCR), biobased materials, and biodegradable materials. Through precise process engineering, we help customers transform these "new" materials into high-value products and turn environmental commitments into commercial advantages.
5. Frequently Asked Questions from Customers
Q1: As a customer who is new to twin screw extruders, how can COLOWE help us choose the right equipment?
A1: For new customers, we not only provide equipment, but also offer process solutions. Our engineering team will gain a deep understanding of the materials you plan to handle (whether traditional resins, biobased materials, or recycled materials), target production rates, and product requirements, and then recommend suitable models (such as screw diameter, aspect ratio, power configuration) and provide preliminary process parameter recommendations. We can also arrange training on the principles and operation of twin screw extruders.
Q2: How does the Cologne Will equipment perform in terms of energy efficiency? What is the connection between this and environmental goals?
A2: Energy efficiency is one of our core design goals. By optimizing screw design, adopting efficient transmission systems, and heating and cooling schemes, the Cologne Weil high-efficiency extruder aims to minimize energy consumption per unit product. Lower energy consumption not only directly reduces customer operating costs, but also means reducing carbon emissions, which is fully in line with global environmental goals.
Q3: Does the new factory support customized equipment requirements?
A3: Yes, modular design is the foundation of our technology. The stronger processing capabilities of the new factory enable us to respond more flexibly to customized needs. Whether it's special screw combinations, feeding port positions, exhaust solutions, or specialized designs for specific materials such as high viscosity elastomers, we can leverage our professional experience and manufacturing platform to jointly develop the most suitable customized twin screw extrusion solutions with our customers.
Q4: How does the Cologne Will equipment handle the issue of impurities in recycled plastics?
A4: Our co rotating twin screw extruder is equipped with a reinforced screw core shaft and highly wear-resistant and corrosion-resistant screw components, which can withstand the impurities that may exist in the recycled material. Meanwhile, optimized screw design and process parameters can reduce material degradation and carbonization. For recycled materials with high impurities, we suggest adding pre-treatment equipment at the front end and forming a complete production line with our plastic extrusion granulator.
6. Looking to the future: Joining hands to create a new era of sustainable manufacturing
During the critical period of green transformation in the global plastic industry, Kelongwell will continue to strive for innovation and promotion of efficient and environmentally friendly plastic processing technologies. Our new factory is not only an expansion of production capacity, but also a comprehensive investment in precision manufacturing and sustainable technology.
We are well aware that modern plastic machinery must be environmentally responsible. Kelongwell high-performance co rotating twin screw extruders are helping global customers translate environmental commitments into competitive advantages. By providing high-performance twin screw extrusion equipment that is technologically advanced, reliable in operation, and environmentally friendly, we not only help customers improve product quality and production efficiency, but also work together with global partners to promote the transformation of the entire plastic processing industry towards a greener and smarter direction.
Choosing Kelongwell means choosing a cost-effective, sustainable, and future oriented path for plastic granulation. Let's work together to turn challenges into opportunities and shape a new pattern of plastic circular economy.
Explore more: If you are looking for a twin screw extrusion granulation solution that can improve production efficiency, reduce energy consumption, and adapt to future material trends, please feel free to contact our technical team for personalized solution recommendations tailored to your specific needs.
