KTD large-capacity extruder production line: How to achieve efficient energy saving and stable production?

In the plastic, rubber, composite materials and other industries, the production efficiency and energy consumption level of large-capacity extruders directly affect corporate profits. KTD large-capacity extruder production line achieves a perfect balance between efficient energy saving and long-term stable operation through innovative design, intelligent control and process optimization.

1. Three core technologies for efficient energy saving

High-torque and low-energy consumption screw design

Optimized thread structure:

Adopt barrier screw or double-wave screw design to improve plasticization efficiency and reduce melt temperature fluctuation (within ±1°C).

With high-alloy steel barrel, wear resistance is increased by 3 times and equipment life is extended.

Energy saving effect:

Energy saving of 15%~25% compared with traditional extruders (actual measured data).

Intelligent temperature control system

Precise segmented temperature control:

Independent PID temperature control module in 6~8 zones, response speed increased by 50%.

Air cooling + water cooling dual mode to meet different material requirements (such as PVC requires strict temperature control).

Direct drive motor technology

Eliminate the reduction box:

Direct drive screw, transmission efficiency reaches 98% (traditional gearbox is only 90%).

Noise is reduced to below 75 decibels, suitable for clean workshops.

2. Guarantee of stable production

Modular design, convenient maintenance

Key components (such as screws, heating rings) adopt quick-release structure, and replacement time is shortened by 60%.

Online monitoring system warns of abnormalities such as bearing vibration and motor load in real time.

Adaptive feeding system

Automatically adjust the feeding speed according to the melt pressure feedback to avoid "hunger" or "overload".

Particularly suitable for recycled materials or highly filled materials (such as calcium carbonate filling more than 50%).

Intelligent shock-absorbing base

The hydraulic damping device absorbs 80% of vibration and protects the foundation of the factory.

Continuous operation for 3000 hours without offset record.

3. Maintenance points of KTD large-capacity extruder production line

• Daily maintenance (each start/stop operation)

Pre-start inspection

Raw material pretreatment: Ensure that the plastic particles are dry and free of impurities to avoid unstable extrusion caused by moisture or foreign matter.

Equipment status confirmation: Check that the screw, barrel, and die are not damaged, the lubrication system has sufficient oil, and the heating system temperature control instrument is normal.

Preheating specification: Set the temperature according to the process requirements, and keep warm for 10-20 minutes after reaching the set value to ensure uniform heating.

Monitoring during operation

Parameter tracking: Pay attention to current, pressure, and temperature data in real time, and adjust or shut down immediately when abnormal.

Lubrication management: Regularly replenish the lubricating oil of the reducer and bearings, and use grease that meets the standards.

Shutdown cleaning

Residual material removal: Use cleaning materials or special cleaning agents to clean the screw and barrel to prevent carbonization.

Cooling system maintenance: After turning off the heating, wait until the temperature drops to a safe range before turning off the power to avoid high temperature damage to the components.

• Regular maintenance

Comprehensive disassembly and inspection of key components

Screw and barrel: Check wear, repair or replace screws with severe wear.

Transmission system: Check belt/chain tension, clean dust and oil, and adjust to the best condition.

Electrical and temperature control system calibration

Heating element: Test the sensitivity of heating coils and thermocouples, and replace aging components.

Instrument calibration: Regularly calibrate temperature control instruments to ensure data accuracy.

Cooling system maintenance

Scale cleaning: Disassemble the cooling water pipeline, remove scale on the inner wall to prevent blockage.

Sealing inspection: Replace rusted or leaking pipes.

• Special maintenance of key components

Screw maintenance

Anti-deformation storage: Hang or lay flat when out of use for a long time to avoid bumps and deformation.

Surface treatment: Apply anti-rust grease after shutdown to prevent oxidation.

Reduction box maintenance

Gears and bearings: Check wear and replace qualified lubricating oil.

Sealing: Replace oil-leaking gaskets in time.

Electrical safety

Line inspection: Tighten loose connections to prevent malfunctions caused by poor contact.

• Special scenario handling

Sudden power outage: After power is restored, it needs to be reheated to the process temperature and kept warm to avoid cold start and damage to the screw.

Foreign matter handling: Install a magnetic frame on the hopper to prevent metal impurities from entering the barrel.