In the extrusion production of PP, PE, PET, PVC, and ABS plastic sheets, many enterprises have long faced common process bottlenecks: the extrusion screw conveyor comes with pulse pulsation, causing continuous fluctuations in die pressure, exceeding the longitudinal and transverse thickness tolerances of the sheet, frequent occurrence of defects such as thick and thin edges, ripples, and warping, and a large amount of raw materials becoming corner waste, making it difficult to release production line capacity.
Ordinary extruders rely on screws to build their own conveying pressure, making it difficult to offset flow fluctuations caused by feeding disturbances, temperature drift, and changes in melt viscosity. As a precision volumetric measuring and conveying equipment, the melt pump can isolate screw pulsation, stabilize pressure and flow, and is currently a core standard component of high-end wide width sheet extrusion production lines. Bart melt pump is optimized for wide width, high pressure, and high-precision sheet extrusion conditions, stabilizing flow and pressure from the melt conveying source and systematically resolving various quality pain points in sheet production.
1、 Common process pain points in sheet extrusion without melt pump
Difficulty in stable control of thickness tolerance
The screw discharge has natural pulsation, which directly causes pressure fluctuations in the mold head, uneven thickness on both sides of the wide sheet, high cutting and grading losses, and difficulty in meeting the strict tolerance indicators of high-end customers, limiting the acceptance of high-end orders.
Speed up will result in defective products
After the production line is accelerated, the flow fluctuation is further amplified, and the sheet is prone to defects such as wave patterns, surface pitting, and uneven stretching. Most enterprises can only slow down and produce conservatively, with insufficient equipment utilization and a clear capacity ceiling.
Squeezing high host load, high energy consumption and wear costs
The extrusion screw simultaneously undertakes two tasks: plasticization and high-pressure pressure building and conveying, resulting in high motor load and energy consumption; The screw, barrel, and gearbox are subjected to high-pressure conditions for a long time, leading to accelerated wear and tear. The cost of parts replacement and shutdown maintenance remains high.
Poor stability in the production of filling and recycled material formulas
When adding calcium carbonate, talc powder, and recycled materials to the formula, the melt flowability changes greatly, the discharge rate is unstable, and it is more prone to thickness deviation, color difference, and poor batch quality consistency.
Insufficient consistency in mass production
The thickness of the sheets produced in different shifts and time periods varies significantly, resulting in a large workload for finished product sorting and dual losses of raw materials and labor, which compresses production profits.
2、 The core advantage of adapting the melt pump to sheet extrusion
Stable voltage and current, precise control of sheet thickness
Based on the high-precision gear volume measurement principle, the screw discharge pulsation is isolated, and stable pressure and melt flow rate are output to the mold head, ensuring uniform thickness of the entire wide sheet, significantly narrowing thickness tolerances, improving ripple, warping, and thick thin edge defects, and stably adapting to the production requirements of high-end food grade and decorative sheet materials.
Share the pressure load and reduce the loss of the extrusion host
The extruder focuses on material plasticization, and the melt pump undertakes high-pressure pressure building and conveying tasks. The main engine load can be reduced by more than 30%, and the overall energy consumption of the machine can be reduced; At the same time, it reduces the friction and wear of screws and barrels, extends the service life of the extrusion host, and reduces unplanned downtime maintenance.
Suitable for filling and regenerating modified materials, with strong adaptability to working conditions
Adopting a widened flow channel and high wear resistant nitride gear structure, it transports molten materials containing powder fillers and recycled materials, with excellent wear resistance, less prone to material accumulation and carbonization, and small flow deviation during long-term continuous production, ensuring consistent batch quality of modified sheets.
Support high-speed continuous production and release production line capacity
After the molten material conveying state stabilizes, the production line can be safely accelerated, and the appearance and dimensional accuracy of the sheet can be controlled under high-speed extrusion. Based on the original extrusion equipment, the production capacity can be increased to better meet the demand for peak season orders.
Integrated constant temperature heating to avoid degradation and yellowing of thermosensitive materials
The pump body is equipped with an overall heating and insulation jacket, with a uniform temperature field inside the chamber, eliminating local high temperature retention, effectively avoiding thermal degradation and yellowing of heat sensitive materials such as PET and PVC, and ensuring the transparency and surface quality of the sheet.
Modular structure, easy to switch and maintain
The disassembly and assembly structure design is simple, and it can be quickly disassembled after shutdown to clean up internal material accumulation and carbonization residue. It is suitable for rapid production of multi material and multi specification sheets, shortening the downtime of material replacement.
3、 Typical application scenarios
PET transparent sheet, food vacuum forming sheet, packaging sheet production line
PP/PE foam sheet, geotextile sheet, plastic waterproof sheet extrusion equipment
PVC decorative sheet, soft and hard PVC thick sheet production line
ABS, PC electronic insulation sheet, optical thin sheet extrusion line
Extrusion equipment for filling modified sheets and recycled plastic sheets
Multi layer co extruded composite sheet and wide board extrusion system
4、 Customized selection and technical services
Zhengzhou Batte can select and match melt pumps with flow rate, pressure, and flange specifications based on production line output, sheet width, melt material, and process temperature; Equipped with a complete set of temperature control heating system and variable frequency deceleration drive unit, supporting the installation and renovation of existing sheet production lines.
All products undergo flow calibration and high temperature pressure resistance testing before leaving the factory, and can provide installation and commissioning guidance as well as long-term maintenance technical support.
To reduce the waste of sheet edges and corners, strictly control thickness tolerances, increase speed and efficiency, and reduce host wear, installing a melt pump is a cost-effective process improvement solution.
If your sheet extrusion production line has problems such as unstable thickness, corrugated warping, and limited production capacity, please feel free to consult Zhengzhou Batte for customized stable pressure measurement and melt conveying matching solutions.
Email: sale@meltpump.com
WhatsApp: +86 158 3833 1071
