Product Overview

An efficient and energy-saving recycling solution designed specifically for fluffy bulk materials (LDPE agricultural film, PP ton bags, PP fibers, drip irrigation pipe materials). Using parallel twin screws in opposite directions as the first stage host, combined with short single screws as the second and third stage filtering and pressure building units, combined with permanent magnet synchronous servo motors and electromagnetic induction heating, the power consumption per ton is reduced by 30-40%, the production capacity is increased by more than 50%, and the high-energy consumption pellet machine link is eliminated.

Process Principle

Shredded bulky material is fed into the first-stage counter-rotating parallel twin screw extruder via a variable-diameter spiral forced feeder. The two screws rotate in opposite directions, forming mechanical interlocking in the meshing zone that forcibly grips and advances the material. This positive displacement conveying without slippage enables high output at low screw speeds. The material completes compaction and melting under low pressure before entering the second-stage short single screw extruder, where medium pressure is built up and coarse filtration (60-80 mesh) is performed. It then proceeds to the third-stage short single screw extruder for high-pressure development, fine filtration (120-200 mesh), and finally pelletizing extrusion. The power distribution is optimized throughout the process: the first stage focuses solely on feeding and melting without bearing high back pressure, while the latter two stages share pressure-building and filtration duties, eliminating the energy losses caused by back pressure inherent in single-screw processes.

Parts of Counter-rotating Parallel Twin Screw Compounding Extruder

Core Technical Advantages

First-Stage Counter-Rotating Parallel Twin Screw — Zero Back-Pressure Efficient Conveying. The counter-rotating parallel twin screw extruder employs positive displacement forced conveying principle with mechanical interlocking in the meshing zone and zero slippage, achieving exceptionally high volumetric efficiency. The first stage operates without filters and at zero back pressure, directing all power input toward feeding and melting. For extremely bulky materials such as PP fiber, ultra-deep screw channels are configured to perfectly match material characteristics with low-speed high-torque operation.

Permanent Magnet Synchronous Servo Motor — Significant Energy Reduction. Compared with conventional asynchronous motors, permanent magnet servo motors deliver higher efficiency across all operating conditions, power factor approaching unity, and substantially improved speed precision for precise coordination with the feeder. Taking PP fiber production line as an example, daily electricity savings amount to several hundred RMB, with the servo motor premium investment recoverable within half a year.

Electromagnetic Induction Heating — Substantial Thermal Efficiency Improvement. Compared with resistance heating bands, electromagnetic induction heating achieves thermal efficiency exceeding 90%, reducing heating time from tens of minutes to under ten minutes while improving temperature control precision by several-fold, realizing 30% energy savings. Coordinated with servo motor precision speed regulation, startup time is reduced by 50%.

Material Adaptability and Energy Consumption

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