How does the twin-screw granulation process work in a Large Capacity High Filler Granulation Production Line?

1. Basic Principles of Twin-Screw Granulation Process
The core components of the twin-screw granulator are two parallel and intermeshing screws, which are located in a closed barrel and are responsible for mixing, melting, plasticizing, and finally extruding the raw materials. In the Large capacity high filler granulation production line, the twin-screw granulator is widely used to produce filler masterbatch, which is made by mixing plastic carriers (such as polyethylene, polypropylene, etc.) and inorganic fillers (such as calcium carbonate, talc, kaolin, etc.) in a specific proportion.

2. Pretreatment and feeding of raw materials
In the twin-screw granulation process, the pretreatment of raw materials is a key step. Usually, inorganic fillers are preliminarily mixed with plastic carriers, lubricants and other ingredients through a premixer to ensure uniform distribution of the materials. Some advanced production lines also use a multi-channel loss-in-weight feeding system, which can accurately control the feeding speed and proportion of each material according to the set formula.

3. Shearing and mixing action of twin screws
After entering the barrel, the twin screws start to rotate at high speed and mesh with each other. The materials are quickly melted and evenly mixed under the shearing, extrusion, and stirring action of the screws. Due to the extremely small gap between the twin screws, the materials are strongly mixed under high shear force, which ensures the full dispersion of inorganic fillers in the plastic matrix.

4. Melting and plasticizing process
Under the continuous extrusion of the screws, the material gradually moves to the end of the barrel and undergoes melting and plasticizing in the process. The heating system of the barrel is usually divided into multiple temperature zones, and the temperature of each temperature zone can be independently controlled to achieve the best melting effect. For mixtures containing a large amount of inorganic fillers, proper temperature control can avoid agglomeration of fillers while ensuring full melting of the plastic matrix, thereby producing filling masterbatch with excellent performance.

5. Extrusion and granulation
When the molten mixture reaches the end of the barrel, it is extruded into strips through a specially designed die head and then cut into granular products by a pelletizing device. In the large capacity high filler granulation production line, the pelletizing device is usually equipped with a cooling system, such as water cooling or air cooling, to quickly cool down and solidify the particles.

6. Control and optimization of the production process
In order to ensure the efficient and stable operation of the twin-screw granulation process, modern production lines are equipped with advanced control systems. These systems can monitor key parameters such as the screw speed, the temperature in the barrel, the flow rate and pressure of the material in real time. In addition, the production line can also adapt to the processing requirements of different materials by adjusting the geometry of the screw, the aspect ratio and the configuration of the thread.

7. Advantages of the twin-screw granulation process
Compared with the traditional single-screw granulator, the twin-screw granulation process has significant advantages in processing highly filled materials. First, the twin screw has a stronger shear force, which can disperse the filler more effectively and ensure the uniformity of the filled masterbatch. Secondly, the twin-screw granulator can handle materials with higher viscosity, which is particularly important for the production of masterbatches containing a large amount of inorganic fillers.