Parts by Extruder Brand
Precision-Engineered Replacements Across Multiple Brands and Models
Operating twin-screw extruders from multiple brands in the same manufacturing plant, alongside high-filler formulations and corrosive material processing, is now the norm, not the exception. Replacement parts for Coperion, Leistritz, KraussMaffei, JSW, and other twin-screw extruder platforms are not simply copied in dimensions. An extruder part must meet mechanical fit, power transfer, processing performance, and long-term operating stability all at the same time.
Lesun matches significantly more than the geometry of screw elements and barrels, drawing on extensive reverse-engineering experience and a large equipment database. We manage the precision of essential torque-transmission interfaces – shaft splines and keyways, and optimize the design around material system, heat treatment and operating circumstances, resulting in a replacement part that is highly compatible and reliable with the original equipment.
Geometric matching
Lesun accurately replicates the Do/Di ratio, screw intermeshing clearance, and key geometric parameters of each machine by employing a parameter database and precise measurement. This ensures that the screw configuration is closely aligned with the processing chamber of the equipment, thereby preventing the running risks associated with abnormal clearance, localized shear concentration, or unstable conveying.
Mechanical interface matching
Precise control of dimensional tolerances and fit accuracy for shaft splines, keyways, and other torque-transmission interfaces supports reliable torque transmission, secure axial positioning, and consistent assembly performance under high-torque, high-load operating conditions.
Process performance matching
Systematic analysis of equipment parameters, screw configuration, and process conditions ensures that the replacement solution is consistent with the original processing window, ensuring that shear energy input, mixing performance, melt-pressure stability, and residence-time distribution remain consistent. This ensures that formulations and processes transfer smoothly.
Material and service-life matching
Lesun provides the material system, heat treatment, and surface-strengthening scheme that are most appropriate for the conditions in high-filler, high-wear, and high-corrosion environments. This optimizes the service life of the parts while maintaining the stability of the equipment.
Digital reverse engineering and high accuracy measurements
In addition to sophisticated CNC machining, Lesun is also equipped with a reverse engineering system based on 3D laser scanning, projection scanning and digital inspection, which provides physical data collection, 3D modelling, parameter analysis and accuracy verification.
- Precision measurement: multi-dimensional data collection and 3D modelling successfully restore important structural properties of worn parts, aged parts and parts with no surviving drawings, providing a dependable basis for the construction of new parts.
- Tolerance Optimization and Accuracy Control: In the reverse development process, wear analysis and engineering knowledge are employed to examine and optimize essential fit dimensions, interface tolerances and structural parameters to ensure replacement parts fulfil assembly requirements and run reliably.
Industry experience & global database
Lesun has gathered a dedicated database built over 20 years in the industry, including all the major twin-screw extruder platforms globally, including screw configurations, geometry, power interfaces and essential design parameters for different brands and sizes of machines. Lesun uses comprehensive parametric modelling and engineering mapping to translate the design philosophy of various OEM platforms into standardized production solutions, ensuring rapid development, exact matching and stable delivery of screw pieces, shafts and barrels.
Full-chain process and material control
Lesun has a whole system process including material selection, heat treatment, precision machining and performance verification. Heat treatment is paired with high-performance alloy steels and HIP powder-metallurgy material solutions to precisely match wear and corrosion resistance to the load, temperature and wear environment at each functional stage.
Supply-chain advantage across brands
Lesun offers one-stop parts supply across several equipment platforms to help customers streamline spare-parts procurement, decrease inventory complexity, increase maintenance response and optimize the total cost of ownership (TCO) during the whole life cycle of its twin-screw extruders.
