Case Studies
How Lesun Components Solve Real-World Twin-Screw Extrusion Challenges.
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Highly-Filled Calcium Carbonate Masterbatch Compounding Twin-Screw Extruder Screw
A masterbatch manufacturer using highly-filled calcium carbonate compound (CaCO₃ loading of 75–80%) on machinery that runs more than 7,000 hours annually had to reduce long-term operating costs without compromising output or quality. This is a classic high-load, high-wear twin-screw application, and the objective was a more stable, less expensive operation rather than just increased throughput.
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Glass-Fiber-Reinforced Engineering Plastics Compounding Twin-Screw Extruder Screw
A compounder of glass-fiber-reinforced engineering plastics (PA6, PA66, PBT and PP-GF with 20 to 50% glass loading) for automotive, electrical/electronic and industrial structural parts required to meet tight mechanical, dimensional and batch-to-batch consistency requirements. In a reinforced system the major problem is not the glass loading, it’s getting the fiber fully wet-out and evenly distributed while keeping as much effective fiber length as possible.
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Flame-Retardant Compound Production Twin-Screw Extruder Screw
A compounder that manufactures flame-retardant engineering plastics (PA6, PA66, PBT, PP, ABS, and PC/ABS) for new-energy vehicles, electrical/electronic, connector, and appliance applications required products that consistently met UL94 V-0, GWFI, and GWIT while maintaining mechanical performance, appearance, and long-term reliability.
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ABS Compounding for a Major Petrochemical Producer Twin-Screw Extruder Screw
The ABS plant of the client, a significant petrochemical producer, is designed to produce 600,000 tonnes of ABS resin annually. This facility is one of the country's major ABS resin production bases. The line employs a variety of mid-to-large co-rotating twin-screw pelletizing systems, with machine sizes ranging from Φ58 mm to Φ177 mm. These systems are capable of conducting melt homogenization, mixing, devolatilization, and pelletizing.
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Cold-Formed High-Torque Screw Shafts Project Twin-Screw Extruder Shaft
Cable insulation and high-performance crosslinked polyolefins are trending toward high-filler, high-reactivity systems. In twin-screw extrusion, XLPE and silane/peroxide cross-linking systems exhibit coupled high-viscosity flow and reaction behavior, while in high-filler ATH/MDH systems (>50%), system resistance rises dramatically, keeping the equipment in a prolonged high-torque load condition.
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