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Distributor / authorized representative that deals with supply & delivery of extruders (extrusion lines) to industrial enterprises of Russia

Engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), Russia, has been successfully working with a number of Russian industrial enterprises at the local market for more than 20 years. Since the company’s founding, it has acquired immense engineering experience, market reputation, and has realized more than a hundred large-scale projects at the industrial plants in Russia. Our company is continuously in search of new business partners, who consider Russian market investment-attractive and want to boost their sales in the region, as well as expand their field of activities and enter a new international level. 

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We are interested in cooperation with the manufacturers of extruders (extrusion lines), who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.

The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your extruders. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.

Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.

Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for extrusion lines, will submit a market overview for extruders that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your extrusion lines and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.

Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of extruders (extrusion lines) in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for extruders as per Russian and other EAEU countries’ requirements.

Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your extrusion lines into the future projects.

The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.

Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of extruders. They will also provide necessary training and guidance for the customer’s personnel.

Extruders (extrusion lines). A brief overwiew

Extrusion method. Process and application. Extrusion line

Extrusion is a continuous process, in which a molten material is pushed through a forming tool (a die, extrusion head or hole) to produce finished products. The material used is characterized by high viscosity, while the products obtain the cross-section required.

In other words, extrusion may be defined as an integrated physico-chemical process that is induced by mechanical forces, high temperature and moisture. When the material overcomes inner friction and deforms, heat is generated. This heat as well as external heating is used to warm the processed raw material up. The composition and humidity of the processed material, as well as pressure, temperature, intensity and duration of exposure onto the raw material are the variable parameters of the extrusion process. Cold molding, thermal treatment and “hot extrusion” method (molding) may be regarded as the main extrusion methods.

Extrusion as well as plastic melting under pressure belongs to the one of the most popular methods of plastic products’ manufacturing. Almost all main types of polymers can be processed by extrusion: thermoplastics, elastomers, thermosetting materials.

Extrusion is widely used in food processing industry, for manufacturing of various types of pasta and noodles. In polymers processing industry, extrusion is used for manufacturing of pipes, film, cable sheath, optic systems elements, rubber compounds, plastics, ferrite products, and etc. This technology is also widely used for manufacturing of thermal insulating materials. Extruded expanded polystyrene is used for insulation of railroad ties, foundations, concrete structures. Usage of this insulation reduces a possibility that the soil surface might deform due to frost penetration.

Products are formed in extrusion lines, which are the most popular type of equipment for plastics processing. Usually, the line consists of several extruders, special extruding tools and some additional devices.

Single screw, twin screw piston and disk extruders are the main types of equipment for polymers processing by extrusion. There is also a blown film extruder, which operates as a component of blown film plants.

Behavior of polymer material during extrusion

Let us take a pelleted raw material during extrusion, performed on a single screw extruder, as an example of polymer behavior. This process involves sequential plasticization and movement of the material by the screw due to rotation in the heating barrel. There are three zones of the heating barrel:

  • Feed zone. Pelleted or powdered polymer to be processed is fed into the space between the screw flights where it is compacted;
  • Melting zone. The melting of raw material takes place at  the barrel surface and plasticizes as a result, until a mixed melt has been created. The pressure is mainly increased in the border area, between the feed zone and the melting zone. Here, the compressed material forms the plug and slides down the screw (the material coming in the solid state from the feed zone is melted in the melting zone). This plug increases pressure as a result, used for overcoming the meshes resistance and to mold the profile.
  • Metering zone. The molten polymer is homogenized, but it still consists of solid and molten particles. By the end of the zone, the raw material becomes fully homogenous and is pushed through the forming die.

Division of the heating barrel by zones is provisional and demonstrates a specific purpose of such section of the screw. The barrel is also provided with heating zones, whose borders might differ from the borders of screw zones. Conditions during the solid raw material movement from the feeding hopper and filling the space between flights (below the hopper funnel) are very important for the material movement.

The raw polymer to be extruded might come in powder, pellets or band form. Bands are generally used in the industrial waste treatment sector and are processed on the extruders with metering devices. Uniform dosing provides for high quality of the raw material. It is the pelleted material that is commonly processed by the extrusion. This particular type of a raw material is an optimal choice for machine feeding. Pellets do not float and do not form plugs in the hopper. They are easier to homogenize and plasticize as well.

Special metering devices are used to feed the hopper during processing of multicomponent materials:

  • Screw (volumetric);
  • Vibrational;
  • Weighing.

The flow ability of the material is highly dependent on humidity (the higher the humidity, the lower the flow ability). Therefore, it is recommended to dry hygroscopic materials prior to feeding them into the extruder.

The machine throughput is significantly increased by mechanisms for force-feeding the raw material from the hopper into the heating barrel. While the raw material compacts in spaces between the screw flights, air is forced out and escapes through the hopper. If air was not completely forced out, there will be unwanted cavities in the finished products.

If the barrel operates for a long time, the hopper and barrel under the hopper funnel might overheat. If this is the case, pellets will stick together and will stop feeding into the screw. To decrease the barrel temperature, there are cavities for cooling water. Usually only the feed zone is cooled in extruders.

Main parameters of extrusion process

The following parameters are usually classified as the main parameters of extrusion: temperature in the machine’s zones, temperature of the head zones and cooling modes of the extruded profile.

Parameters of the screw are usually regarded as the main process parameters of the extrusion machine:

  • Length;
  • Diameter;
  • Ratio of the screw length to its diameter;
  • Rotation speed;
  • Screw profile.

The factor of resistance to the polymer melt flow is the main characteristic of the forming tool, which consists of a head and a gauging unit.

The operation efficiency can be regarded as overall factor of any extrusion machine. The operation efficiency is determined as the ratio between throughput and consumed power.

Overview of extruders. Equipment

An extruder is a machine intended for forming of plastic materials by pushing them through a forming tool. The extruder is equipped with the following mechanisms:

  • Screw pair with heaters, thermocouples, casings and fans;
  • Reducer with thrust bearing unit;
  • Asynchronous motor;
  • Control panel;
  • Welded frame.

The extruder is the main equipment included into combined extrusion lines, which are intended for manufacturing of a wide variety of plastic products. Pellets, flakes or agglomerate are the raw material used for extrusion lines. The basic material melts and then pushed through a forming tool.

Extrusion machines can be single-screw, twin screw, multiple screw, and disk or piston type depending on the operating element.

Classification and types of extruders. Main operating elements of extruders (screw, disk, piston)

Main types of extrusion machines are represented by the following machines:

  • Single-screw,
  • Twin screw,
  • Piston
  • Disk machines.

There are also multi-screw extruders, blown film extruders and special extrusion lines for pipes production. Depending on the extruder type, the main operating element is a screw (worm), disk or piston. Extruders are equipped with multi-purpose screws, which are able to process various types of plastics. Otherwise, they can be equipped with special-purpose mechanisms. There are screws with replaceable elements, which are adapted for manufacturing of specific compounds.

Single-screw extruders are the most frequently used equipment in extrusion lines. This type of machines produces films, sheets, pipes, and various profiles. Installing barrier screws significantly increases the throughput of such machines due to increase of heat transfer ratio from the barrel to the melt. A feed zone with spur or spiral thread as well as water cooling system provide for decrease of energy consumption, while the extruder’s throughput is increased.

When it is necessary to process hygroscopic polymers, a single-screw extruder is equipped with special degassing zones. Various types of systems can be used to cool the machine barrel: oil, air or water medium. Depending on specific production needs, a single-screw extruder can be equipped with a discrete control system, programmable controllers system or touch displays.

Double screw extruders are represented by conical and parallel machines. Conical extruders are intended for processing PVC into powder or pellet forms to manufacture profiled products. This type of machines can generate the pressure, which provides for high homogenization of PVD melt during a short operating cycle. In extruders, which are working with PVC, screws are rotating towards each other In the result of that, the material is fed into the barrel and the internal friction decreases while the polymer temperature does not. The special system controls the barrel’s temperature. Automatic screw chargers feed the raw material into extruders. These machines can be customized with various control systems, drying hoppers and raw material chargers.

Parallel extruders are used in cases, when it is necessary to mix several types of polymers. The liquid cooling system, included into construction of these extruders, provides for precise adjustment of the polymer melt’s temperature. Replaceable screws, distributing and mixing elements allow easily adopting the machine for operation with various types of compound.

Piston (without the screw) extruders are rarely used because of low plasticization ability and pressure. These machines are mainly used with PTFE. They are expensive and complex, such equipment requires vast floor space and comprehensive servicing.

Similar to piston extruders, disk extruders are rarely used. During operation, such extruders move raw polymer and the pressure increases due to the material’s adhesion to moveable parts of the machine structure. This extruders can be single-disk or multi-disk ones. The multi-disk machine allows increasing the melt pressure on the output much higher than the melt pressure in regular single screw extruder. Nevertheless, this advantage is incomparable to the multi-disk machine because of its construction complexity.

Film extruders produce various types of films: regular polyethylene films, heat shrinkable, multilayer, reinforced, polypropylene etc. These products are highly demanded in modern commercial activities. Component parts of this equipment depend on the type of processed material and the film purpose.

Extrusion equipment for production of pipes is in high demand in modern production facilities, since there is a great demand for polymer pipes in the construction sector. Extrusion lines produce water, gas, sewer, drainage and other types of pipes. The line might be equipped with single-screw or double screw mechanisms depending on the raw material type. Crushers, coolers etc. are optional equipment for lines.

Principle of extruders operation

Extrusion is performed by the main operating element (for example, a screw). The forming die is installed on the outlet from the barrel. Chambers and screws are mounted depending on the task. There is a feed chamber, where raw materials and additives are loaded, closed chambers with openings for pressure and temperature measuring and chambers for liquid additives injection and sampling.

To provide for additional resistance during the material’s movement and to enhance mixing thereof, the screw can be equipped with special elements. The operating zone of the extrusion machine is subdivided into three zones:

  • Feed zone;
  • Melting zone;
  • Product extrusion zone (or metering zone).

The operation principle of an extruder can be described as follows. The polymer to be processed is fed into the feed zone, or, to be more precise, into cavities between the screw flights. As the new portion of material is fed, it compresses. Then the screw rotates and moves the material into the melting zone, where the material melts and softens, thus enhancing mixing. The compressed material forms the plug and slides along the screw. Due to the plug, the pressure builds up. The pressure is used for overcoming the meshes’ resistance and to form the profile. The raw material is completely homogenized and pressed through the forming die in the metering zone.

Modern extruders can perform dry (cold), warm and hot extrusion. The operation principle of an extruder may vary, depending on the technology used.

Extruder models differ by the structural design of elements of the operating section, by availability of additional systems that change extruders’ process capabilities, by the number of operating chambers, by the designs of drives and chargers, and etc.

Design. Extruder main elements

extruding lines

The main elements of an extruder are as follows:

  • Barrel, equipped with operating elements;
  • Operating element (screw, disk or piston), placed in the barrel;
  • Feed unit for the raw material to be processed;
  • Drive;
  • Temperature maintaining and setting system;
  • Other instrumentation and adjusting devices.

Extruder designs might differ by the following parameters:

  • Functional;
  • Thermodynamically;
  • Mechanical;
  • Geometrical.

The operating section of these machines includes a set of screws with backing washers, sequentially arranged between them. Screws and washers are fastened on the pin by the bolt with conical head. Special galleries are made on the inner surface of the operating section casing to prevent rotation of the raw material during movement. The casing outlet is equipped with a conical nut with a hole. By manipulating the gap between the conical parts of the bolt and nut on the output, or by manipulating the outlet diameter, it is possible to adjust the temperature of material being processed.

Screw extruders are the most commonly used in the industrial sector. The screw catches the material and moves it from the charging chamber along the whole length of the machine. During movement, the product is compressed at first, then it is heated, plasticized and, finally, homogenized. The pressure of such extruders varies from 15 to 100 MPa. The structural design of these machines might be stationary and equipped with a rotating barrel, with vertical or horizontal arrangement of the screw. To enhance homogenization of the material, the screws are equipped with additional devices: teeth, disks, cams, flutes etc.

The food processing industry widely uses extruders equipped with fully meshed screws, which rotate in the same direction. In such design, apexes of one screw are going into hollows of another one.

Double screw self-cleaning extrusion machines are characterized by quicker start of the screw and operation and by increased speeds. The pressure rarely increases in these machines, since the product does not accumulate. In single screw machines, the pressure increases more often, because the material can accumulate in the flights. This leads to irregular products ejection from the extruder.

Feed, melting and metering zones of extruder

During extrusion, the material is sequentially plasticized and moved by the screw due to rotation inside of the heating barrel. Therefore, the heating barrel is divided into the feed zone, melting zone and metering zone (pressing out).

Pelleted or powdered polymer to be processed is fed into the space between the screw flights and then compacted.

In the melting zone, the processed raw material melts in the areas where it touches the barrel’s surface and plasticizes as a result, which provides for a mixing effect. The pressure is mainly increased in the border area, between the feed zone and the melting zone. Here, the compressed material forms the plug and slides down the screw (the material is solid in the feed zone and melts in the melting zone).

In the metering zone, is homogenized, but it still consists of solid and molten particles. By the end of the zone, the raw material becomes fully homogenous and is pushed through the forming die.

Division of the heating barrel by zones is provisional and demonstrates a specific purpose of such section of the screw. The barrel is also provided with heating zones, whose borders might differ from the borders of screw zones. Conditions during the solid raw material movement from the feeding hopper and filling the space between flights (below the hopper funnel) are very important for the material movement.

Extruder benefits

The high throughput, cost efficiency, easy operation, installation and starting of the equipment, and long life are the benefits of extruders. b units and mechanisms, as well as low operational costs, are the advantages of this equipment. Minimum number of personnel is required to install and start this machine at a facility. Depending on the production needs, these machines can produce high-quality film of various thickness.

Application of extruders

Extruders are widely used in various sectors of modern industry:

  • Printing and lamination;
  • Polymer films production (for green houses, for bags etc.);
  • Production of multilayer films for storage of food and pharmaceutical products and chemicals;
  • Production of polystyrene and polypropylene sheets;
  • Production of PVC heat shrinkable film, which is used for packaging of bakery and confectionery products, printed materials, office supplies and other goods.

Extrusion line for pipes production

Extruders for pipes production are one of the most demanded types of equipment for polymers processing. These machines are widely used because of a high demand for polymer pipes in the construction sector. Extrusion lines produce water, gas, sewer and other types of pipes. These lines might be equipped with single-screw or double screw machines. Crushers, coolers etc. are optional equipment for lines.

Effective homogenization of product

Homogenization during the extrusion is a process, during which the raw material is being mixed, until it becomes maximally homogenous in order to produce high-quality finished product.

Final homogenization of the material during extrusion happens by the end of the melt metering zone (pressing out). To ensure more effective material homogenization, screws are equipped with special devices: flutes, teeth, cams, discs etc. Planetary-milling extruders are equipped with additional set of screw, which rotate around the central spindle.

Degassing in extruder

One of the challenging issues that occur during processing of the raw material by extruders is formation of bubbles. It is caused by unwanted impurities in the feedstock. This issue is solved by degassing extruders (often they are single-screw) or degassing chamber, which are mounted onto extrusion machines (often they are double screw).

Operation of the degassing extruder or degassing chamber involves evaporation of residual monomers and solvent from the processed material. These machines are mainly used for production of thermoplastics. The design of such extruder provides for feeding the material to be outgassed from the screw drive side; and then the degassed raw material moves to the end of the screw. After the material is fed, the pressure decreases and the material is outgassed under atmospheric pressure or vacuum, which is provided due to deeper form of the screw thread. To increase the degassing efficiency, the extrusion machine is equipped with the barrel and screw, whose diameters are increased after the degassing zones.

Degassing is intended for obtaining polymers with small content of solvent or monomer. This will provide for higher quality of the produced raw material.

Maintenance of extruders

The extrusion equipment as a whole is characterized by customer friendly maintenance. The single-screw extruder repair and servicing involves only replacement and cleaning of filter screens, replacement of oil in the drive, repair of heating barrels and replacement of electric fuses. After the extruder had been put into operation during the time period specified by the manufacturer, it is necessary to disassemble it and to replace the barrel and screw (if necessary). The list of the documentation required for the extruder includes the manufacturer’s certificate, electric diagram, assembly drawing and instruction manual.

Gearboxes and polymeric equipment
Bevel gearbox
Casting machines, injection molding machines
Gearboxes. Main description
Gearmotors
Parallel-shaft gearbox
Polymer substance press, preforming machines
Roll mills, calenders
Planetary gearboxes
Variable-speed drive
Worm gearbox

Upon becoming the official distributer of extruders (extrusion lines), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (extruders) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.

We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.

We are always open for cooperation, so let’s move forward together!

Intech GmbH SARLIntech GmbH SARL