Common Faults and Solutions for High-Speed ​​Twin-Screw Extrusion Systems

High-speed twin-screw extrusion systems are widely used in plastics, rubber, food processing, chemical, and other industries. Due to their high efficiency, precision, and controllability, they occupy an important position in various production processes. However, during long periods of high-load operation, high-speed twin-screw extruders inevitably experience some common faults, affecting production efficiency and product quality.

This article will guide you through the common faults of high-speed twin-screw extrusion systems and their solutions, helping users improve equipment stability, reduce downtime, and ensure smooth production.

1. Common Fault Types
Faults in high-speed twin-screw extruders mainly include mechanical faults, thermal control system faults, electrical system faults, and material handling issues. The following details each type of fault and its possible solutions.

(1) Screw Damage or Wear
Fault Symptoms:
The screw is the most critical component in a high-speed twin-screw extrusion system.  Prolonged high-speed rotation and material friction can easily lead to screw wear or damage. Common symptoms include decreased production output, uneven material flow, and unstable extruder load during production.

Solutions:
Regularly inspect the screw surface: Regularly check the screw for excessive wear, cracks, or deformation. If the screw shows significant wear, it should be replaced promptly.

Use wear-resistant screws: Choose screws made of wear-resistant materials (such as alloys or coated materials) to increase their service life.

Optimize process conditions: Avoid excessively high material temperatures and excessive pressure to reduce the load on the screw and extend its service life.

(2) Overload and Shutdown
Fault Symptoms:
If the extruder is overloaded or shuts down, it usually causes the production line to stop, and may result in equipment overheating, abnormal current, etc. This type of fault may be related to the material, temperature control system, motor overload, or electrical wiring.

Solutions:
Check material composition and viscosity: Improper material composition, high water content, or excessive viscosity can lead to overload. Ensure that the material meets the equipment's processing capacity and specifications. Check Motor Load: Check the motor load. If overload occurs, it may be necessary to adjust motor parameters or replace the motor with one of appropriate power.

Check Temperature Control System:  Excessively high or low temperatures can cause machine overload. Regularly check the temperature control system to ensure the temperature remains within a reasonable range.

(3) Unstable Temperature Control
Fault Manifestation:
Instability in the temperature control system can lead to large temperature fluctuations in the heating zone, affecting the melting state and fluidity of the material, resulting in uneven extrusion, insufficient plasticization, and even substandard product quality.

Solution:
Check the heating zone temperature control components: Ensure that the heating zone temperature control components (such as heaters and sensors) are working properly. If a faulty component is found, replace it immediately.

Calibrate the temperature control system: Regularly calibrate the temperature control system to ensure the accuracy of the temperature sensor. Avoid temperature fluctuations caused by signal drift or sensor failure in the temperature control system.

Check the cooling system: Check if the cooling water pipes are blocked and ensure that the cooling system is working effectively to prevent system overheating.

(4) Barrel Blockage
Fault Manifestation:
Barrel blockage is one of the common problems in high-speed twin-screw extruders. Impurities in the material, viscous materials, granular materials, or excessive moisture can all lead to barrel blockage, affecting production efficiency and even causing equipment damage.

Solution:
Regularly clean the barrel: Regularly clean the residual material in the barrel to ensure there is no blockage. Thoroughly clean the equipment, especially when changing material types.

Optimize material pretreatment: Ensure the dryness and particle uniformity of the material to reduce blockages caused by excessive moisture or uneven material.

Add overload protection device: Install an overload protection device to prevent the barrel from being blocked due to excessive material accumulation.

(5) Unstable Product Quality
Fault Manifestation:
If the appearance, size, or physical properties of the product are unstable, it may be due to equipment failure or process problems. For example, the product may have bubbles, an uneven surface, or inaccurate dimensions.

Solution:
Check the fit of the screw and die: Ensure a good fit between the screw, die, and material. Wear on the screw and die can lead to uneven material flow, affecting product quality. Optimize temperature and pressure control: Unstable temperature and pressure can lead to insufficient or excessive plasticization of materials, affecting product quality. Ensure that the temperature control system and pressure control system are accurate and stable.

Check the feeding system: Ensure the quantity and stability of material supply. Fluctuating material supply can lead to unstable product quality.

(6) Electrical System Failure
Failure symptoms:
Electrical system failures usually manifest as problems such as the motor not starting, the electrical control panel malfunctioning, or overcurrent protection, which may prevent the equipment from operating normally.

Solution:
Check electrical wiring: Regularly check the electrical wiring to ensure that electrical connections are secure and free from short circuits or poor contact.

Replace faulty components: If electrical components (such as motors, inverters, and electrical control boards) are found to be faulty, they should be replaced or repaired promptly.

Regular maintenance of the electrical system: Perform regular maintenance on the electrical system, clean dust, and check electrical components to prevent electrical failures from affecting production.

2. How to prevent and extend the service life of a high-speed twin-screw extruder
Regular maintenance and upkeep: Regularly clean, inspect, and lubricate the equipment to ensure the proper functioning of the screws, molds, and electrical systems.

Optimize process parameters: Reasonably adjust production process parameters (such as temperature, pressure, and feeding rate) to avoid overloading the equipment.

Use high-quality materials: Select suitable raw materials, ensuring that the materials are pure and dry, and avoid introducing materials containing impurities into the extruder.

Train operators: Operators should receive professional training to ensure they are familiar with the equipment's operating procedures and troubleshooting methods.