CaCO3 high-filler twin screw extruder for PP and PE

This equipment is a heavy-duty twin screw extruder specially developed for the high filling process of PP and PE calcium powder, mainly used for large-scale and continuous production of high filling masterbatch. Nanjing Kelongwell Chemical Machinery Co., Ltd. is based on core technology in the field of high filling, and systematically optimizes the dispersion, wetting, and wear resistance of calcium carbonate powder and polyolefin matrix when mixed in high proportions. This model is suitable for preparing masterbatch with a filling ratio of up to 70%~85%, ensuring excellent dispersion effect, stable production capacity, and longer equipment life even under extreme working conditions.

·Ultra high filling capacity: adopting optimized screw configuration and cylinder structure, specially designed for PP and PE calcium powder filling ratio of 70%~85%, ensuring that inorganic powder is fully encapsulated and evenly distributed in the polymer matrix.
·Enhanced Wear resistant Design: The cylinder comes standard with a bimetallic alloy liner (hardness 60~65 HRC), and the screw components are coated with powder metallurgy and tungsten carbide, effectively addressing the high wear caused by calcium powder filling. The lifespan of key components is increased by 30%~50% compared to conventional models.
·High torque transmission system: equipped with German technology high torque gearbox, the specific torque can reach 18 Nm/cm ³, providing sufficient shear force and dispersion energy for high filling masterbatch, overcoming the processing bottleneck of high viscosity materials.
·Precise temperature control and exhaust: a combination of segmented electric heating and water cooling, combined with high-precision PID control, to meet the thermal sensitivity requirements in high filling masterbatch processing; The multi-stage vacuum devolatilization device effectively removes water vapor and small molecule volatiles caused by calcium powder filling, ensuring that the granules are dense and bubble free.
·Flexible feeding and process adaptation: Weight loss or volumetric feeding systems can be selected according to the characteristics of the powder, supporting lateral feeding and main feeding coordination to ensure stable entry of high proportion powder into the barrel, avoiding bridging and backflow.

Noted: Details depend on your requirements and need.

Compared with conventional plastic granulators (such as ordinary color masterbatch production lines or low filling blending equipment), this twin screw extruder has essential advantages in dealing with high filling masterbatch production:
·Matching between torque and dispersion: When faced with a high proportion of calcium powder filling, ordinary granulators often experience a decrease in production capacity or poor dispersion (resulting in "white spots" or "white lines") due to insufficient torque. This model uses high torque transmission and customized screw combination to ensure that even at a filling rate of over 75%, the powder and resin can still achieve nanoscale dispersion.
·Differentiation of wear resistance life: The cylinder and screw of ordinary granulators wear extremely quickly under calcium powder filling conditions, and often need to be replaced after six months of operation. Our wear-resistant solution (bimetallic cylinder+wear-resistant coating screw) extends the service life of the equipment by more than twice under the same filling amount, significantly reducing maintenance costs.
·Targeted design for exhaust efficiency: High proportion calcium powder filling can easily introduce free water and gas, and insufficient exhaust capacity of conventional granulators can cause product foaming and breakage. This machine adopts multi-stage large volume vacuum devolatilization to ensure the density and apparent quality of the granules.
·Integrity of process customization: Unlike the "one size fits all" configuration of general granulators, we provide full process customization from screw configuration, cylinder opening position to temperature control strategy based on the specific formula of high filling masterbatch for customers (powder mesh, activation degree, carrier melt index).

·BOPP film: used for producing high opacity, high rigidity, and high filling masterbatch to reduce the unit cost of the film.
·Non woven fabric: provides an economical filling solution for spunbond or meltblown non-woven fabrics, improving breathability and hand feel.
·Injection molded products: products that require reduced shrinkage and improved dimensional stability, such as automotive interior parts, hard packaging, and household appliance components.
·Extruded profiles: Polyolefin extruded products such as window frames, pipes, and cable trays are filled with calcium powder to achieve rigidity improvement and cost optimization.
·Woven bags/geotextiles: Polypropylene woven bags are filled with masterbatch to enhance stiffness and reduce raw material costs.

Nanjing Kelongwell Chemical Machinery Co., Ltd. provides in-depth OEM/ODM customization to ensure that each twin screw extruder accurately matches the high filling masterbatch production needs of customers:
·Customization of aspect ratio: Based on the filling amount, powder particle size, and carrier flowability of PP and PE calcium powder filling formulas, customize the optimal aspect ratio within the range of 44-56.
·Joint design of screw configuration: Based on the degree of powder activation and dispersion difficulty, design specialized kneading blocks, reverse elements, and toothed disc combinations to achieve efficient distribution and dispersion.
·Feeding system integration: customized anti bridging feeding device and lateral feeding machine for the flowability characteristics of ultra-fine calcium powder filling (1250 mesh~3000 mesh).
·Personalized control system: Optional PLC based fully automatic control system, integrating energy consumption monitoring, process formula management, and remote operation and maintenance functions to meet the digital needs of the factory.

Q1: What is the maximum proportion of calcium powder filling that this twin screw extruder can support?
A: For PP/PE carriers, this model can stably support a calcium powder filling ratio of 70% to 85% in the production of high filling masterbatch. The specific limit depends on the mesh size of the powder (usually 1250 mesh or more is easier to fill), the degree of surface activation treatment, and the melt index of the carrier resin. We suggest confirming the mass production process through laboratory formula validation.

Q2: How to solve the problem of equipment wear when processing high proportion calcium powder filling?
A: Ordinary plastic granulators wear extremely quickly when facing calcium powder filling, mainly due to dry grinding of the powder and metal surface, as well as abrasive wear under high shear. Our twin screw extruder adopts three layers of protection: ① The cylinder body is lined with high nickel chromium alloy bimetallic, with a hardness of over 60 HRC; ② The screw components are made of powder metallurgy high-speed steel (CPM) and coated with tungsten carbide coating; ③ Optimize the feeding position in the process to ensure that the powder and melt are fully wetted before entering the high shear zone, reducing dry grinding. Actual operational data shows that the lifespan of key components is extended by more than 50% compared to conventional models.

Q3: What are the core differences in structure between your equipment and ordinary plastic granulators?
A: Most ordinary granulators are designed for low filling (<30%) or pure resin modification, and their torque safety factor, wear resistance level, and exhaust capacity cannot meet the demanding requirements of high filling masterbatch. Our twin screw extruder is specially designed for calcium powder filling, from the gearbox (high torque), cylinder (bimetallic), screw (wear-resistant material) to the vacuum system (multi-stage high pumping speed). Simply put, using a regular granulator for high filling usually only yields 1/3 to 1/2 of our model, and the screw wear rate increases exponentially.

Q4: Can this device be compatible with both PP and PE carriers for producing calcium powder high filling masterbatch?
A: Okay. Our twin screw extruder is equipped with flexible screw combinations, which can match the rheological properties of PP (high viscosity) and PE (low viscosity) separately by adjusting the number and arrangement of shear blocks. Whether you produce PP calcium powder filled masterbatch or PE calcium powder filled masterbatch, we will provide targeted screw configuration and temperature control strategy based on the carrier type to ensure optimal dispersion effect and yield.

Q5: Can you provide screw process support for calcium powder with different mesh sizes?
A: Yes, we not only provide equipment, but also offer full process support. Nanjing Kelongwell Chemical Machinery Co., Ltd. has a professional high filling material process laboratory, which can customize screw element combinations, feeding methods, and temperature settings according to the calcium powder filling mesh number (such as 1250 mesh, 2000 mesh, 3000 mesh), activation degree, moisture content, and carrier resin grade you use, ensuring stable production in the shortest possible time and achieving ideal dispersion level and yield indicators.