Extruder Manufacturer: Asia Sun's Twin Screw Food Processing

Asia Sun is a food extruder manufacturer based in China. The company produces twin-screw extruders, which are used in the food industry to process and mix raw materials into more uniform particles. Food extruders are also used in the production of snack foods, such as puffed snacks, cereal bars, and fried foods. There are several manufacturers of twin-screw extruders in China, including Jinan Xilang Machinery Co., Ltd., Shandong SAC Smart Technology Co., Ltd., and Jiangmen PromaXX Extrusion Technology Co., Ltd. These companies offer a range of extrusion machinery and related equipment, with applications in the food, plastic, and chemical industries.

Food extruder manufacturers in China

• Jinan Xilang Machinery Co., Ltd, a professional manufacturer of extrusion machinery, industrial microwave drying equipment, and related ancillary equipment. The company offers a range of food extruders, including twin-screw and single-screw extruders, as well as puff snack food machines and fried food production lines.
• Shandong SAC Smart Technology Co., Ltd., a manufacturer of snack food production lines, twin-screw extruders, packing machines, and liquid packing machines. They offer a range of food extruders for various applications, including puffed snack food production, Cheetos/Kurkure/Niknak making, and bread crumbs production.
• Xinxing Twin Screw Machinery Co., Ltd. of Shanghai, specialising in the manufacture of complete extrusion machines for PVC/PE pipe and pelletizing lines. With over 20 years of experience, they have the capability to design and produce different extrusion lines for various raw materials and final products.
• Nanjing KY Chemical Machinery Co., Ltd., a leader in the industry with over 100 patents. They offer a range of twin-screw extruders, including the HK, SK, and ZK series, as well as the KY-Lab twin-screw extruder for small-batch production.
• Jiangmen PromaXX Extrusion Technology Co., Ltd, a Sino-German joint venture that manufactures twin-screw extruder spare parts, including screw elements, barrels, shafts, and accessories. They also provide engineering design, process optimisation, wear measurement, and screw cleaning and dismantling services.

Twin screw extruder parts

A twin-screw extruder is a machine that uses two screws to process and mix various materials, including food, plastic, and chemicals. The machine is widely used in the manufacturing industry, especially in the processing of polymers, plastics, and other materials.

The two screws in a twin-screw extruder can be of different types, including co-rotating, counter-rotating, and intermeshing. Co-rotating screws rotate in the same direction and are suitable for applications requiring high mixing and kneading action. Counter-rotating screws rotate in opposite directions, providing high compression and shear forces for applications that need them. Intermeshing screws have a specific design that allows for maximum interaction and enhances the plasticization and homogenization of the raw material.

The twin-screw extruder consists of several key components that contribute to its efficient operation and performance. Here are the main parts of a twin-screw extruder:

• Screws: The screws come in various types and configurations, including co-rotating, counter-rotating, and intermeshing. They are responsible for conveying, compressing, mixing, and heating the raw materials.
• Barrel: The screws are housed inside a heated barrel, which provides temperature control for melting and processing the material. The barrel is typically divided into multiple zones, each with independent temperature control, allowing for a precise temperature profile.
• Feeding Zone: This is where the raw material is introduced into the extruder. It ensures a smooth and consistent feeding of the material onto the screws.
• Melting and Conveying Zones: These zones combine heat from the barrel and shear forces from the screws to melt and plasticize the material.
• Kneading and Mixing Zones: These zones contain specific screw elements, such as kneading blocks or mixing sections, for intensive mixing and shearing action, ensuring thorough homogenization of the melt.
• Venting and Vacuum Zones: These zones allow for the removal of volatile components or air from the material, improving the quality and consistency of the final product.
• Die: The die is the final component where the molten and homogenized material is forced through a shaped orifice to form the desired product shape.

Overall, the twin-screw extruder's unique design and versatile parts make it highly efficient for processing a wide range of materials across different industries.

Single screw extruder suppliers

Single-screw extruders are used in a variety of applications, including the food industry, and plastics processing.

Single-screw extruder suppliers include:

• Plastex International New Energy Technology Co., Ltd.
• Ruian Weixu Plastic Machinery Co., Ltd.
• Suzhou Winsoar Science & Technology Development Co., Ltd.
• Zhangjiagang Sino-Tech Machinery Co., Ltd.
• Zhangjiagang Friend Machinery Co., Ltd.
• Qingdao Evertech Industry Co., Ltd.
• ZHEJIANG JWELL PIPE EQUIPMENT CO., LTD.
• Shandong Oufu Industry Products Co., Ltd.
• Jiangsu Aceretech Machinery Co., Ltd.
• Zhangjiagang Beierman Machinery Co., Ltd.
• LAIZHOU KEDA CHEMICAL MACHINERY CO., LTD.
• Zhangjiagang Camel Machinery Co., Ltd.
• QINGDAO OULI MACHINE CO., LTD.
• Zhangjiagang Chenxing Machinery Co., Ltd.
• Qingdao Interplast Machinery Co., Ltd.
• Jinan Linyang Machinery Co., Ltd.
• Suzhou Polywell Engineering Plastics Co., Ltd.
• Zhangjiagang Sevenstars Machinery Co., Ltd.
• Shanghai Jwell Machinery Co., Ltd.
• Zhangjiagang Qinchenyu Machinery Co., Ltd.
• Zhangjiagang Jorbin Machinery Co., Ltd.
• Ruian Weixu Plastic Machinery Co., Ltd.
• Yuyao Guotai Rubber & Plastic Machinery Co., Ltd.
• Shandong Haidai Intelligent Machinery Co., Ltd.
• Jinan Dayi Extrusion Machinery Co., Ltd.
• OSWAL ENGINEERING CORPORATION

Twin screw extruder applications

Twin-screw extruders are versatile machines with a wide range of applications across various industries. Here are some key sectors that utilise twin-screw extruders and the specific applications within those sectors:

Plastics Industry

Twin-screw extruders play a crucial role in the plastics industry, where they are commonly used for:

• Compounding, melting, and shaping various thermoplastic materials
• Producing pipes, profiles, sheets, films, cables, and other plastic products
• Processing engineering plastics, filled and reinforced compounds, and masterbatches

Rubber and Elastomer Processing

The high shear forces and efficient mixing capabilities of twin-screw extruders make them ideal for:

• Processing rubber and elastomeric compounds
• Producing rubber profiles, seals, gaskets, hoses, and other rubber-based products
• Compounding rubber with additives, fillers, and reinforcements

Food Industry

In the food industry, twin-screw extruders are used for:

• Processing and texturizing snacks, cereals, pet food, and meat alternatives
• Cooking, gelatinization, and protein texturization processes
• Producing ready-to-eat products such as breakfast cereals and expanded snacks

Pharmaceutical and Biomedical Industries

Twin-screw extruders are applied in the pharmaceutical and biomedical fields for:

• Producing drug delivery systems like sustained-release tablets and transdermal patches
• Hot-melt extrusion processes that combine active pharmaceutical ingredients with polymers for controlled-release formulations

Recycling and Reprocessing

Twin-screw extruders contribute to sustainability by enabling the recycling and reprocessing of plastic waste:

• Converting post-consumer or post-industrial plastic waste into reusable pellets or compounds
• Reducing environmental impact and promoting circular economy initiatives

Twin screw extruder maintenance

To maintain a twin-screw extruder, it is important to regularly clean and inspect the machine, particularly after long periods of use. Here is a detailed guide on twin-screw extruder maintenance:

Maintenance During Equipment Operation

It is crucial to ensure that no debris, especially hard materials such as metal and sand, enters the hopper and barrel. When opening the suction chamber cover, be cautious to prevent foreign objects from falling into the barrel. After heating, allow the twin-screw extruder to idle for a short period before starting operations, and always start the screw at a low speed.

Daily Maintenance of the Host

The oil and lubricating oil should be changed every 4000 hours. For DC motors, check and record the condition of the carbon brush monthly, replacing it if necessary. Purge the electric control cabinet once a month. Additionally, inspect the wear of the screw and barrel quarterly, and check the gearbox components, including gears, bearings, and oil seals, annually. If the machine will be shut down for an extended period, apply anti-corrosion and anti-fouling treatments.

Disassembly and Maintenance of the Twin Screw Extruder Screw

First, remove any material and coke from the screw's surface using copper plates, copper rods, or copper wire brushes. Do not use steel rods to strike the screw. Next, ensure that the material in the barrel is completely melted, remove the head, and carefully pull out the screw.

Maintenance After 500 Hours of Use

After 500 hours of operation, clean the gears and replace the lubricant in the reduction box. Gear cleaning is essential to remove any iron filings or other impurities that may have accumulated.

Maintenance During Production Interruptions

In the event of a power outage or interruption, immediately stop the main drive and heating. Once the power supply is restored, reheat each section of the barrel to the specified temperature and maintain that temperature for a period before restarting the dual screw extruder.

Maintenance After Prolonged Use

After the machine has been in use for a significant amount of time, conduct a comprehensive inspection. Check the tightness of all screws and the steering of the gauge and pointer. If the steering is complete, verify the condition of the thermocouple contacts.

Frequently asked questions