How to optimize the production process of highly filled materials with KTD High Volume Extruder Production Line?

Main challenges in the production of highly filled materials
Highly filled materials usually contain a large amount of inorganic fillers, and the addition of these fillers will significantly reduce the fluidity and plasticity of the materials. For traditional extruders, the process of processing highly filled materials often leads to poor material performance or poor product quality due to insufficient shear force or uneven mixing. In addition, the high content of fillers may also increase equipment wear and shorten the service life of the equipment. Therefore, how to improve the processing uniformity of materials and the durability of equipment while ensuring production efficiency has become an important issue in the production of highly filled materials.

Advantages of KTD series high torque design
The 11N.m/cm³ high torque design of KTD High Volume Extruder Production Line shows great advantages when processing highly filled materials. High torque means that the equipment can provide greater mechanical force per unit volume, thereby improving the mixing effect of materials during processing. Specifically, the high torque design plays the following key roles in optimizing the production process of highly filled materials:

1. Increase shear force and enhance mixing uniformity
Highly filled materials have poor fluidity and require higher shear force to fully mix the materials during processing. The high torque design of the KTD series provides stronger shear force, ensuring uniform dispersion and mixing of materials even under high filler loads. This is essential to ensure the mechanical properties and surface quality of the product.

2. Low speed and high efficiency, reducing energy consumption and wear
Due to the strong friction of highly filled materials, traditional equipment often needs to run at high speed when processing such materials, resulting in increased wear of the equipment and increased maintenance costs. The high torque design of the KTD series allows the equipment to maintain efficient processing capabilities at low speeds. This not only reduces equipment wear, but also reduces energy consumption, thereby reducing overall production costs. In addition, low-speed processing reduces frictional heating between the equipment and the material, further avoiding thermal degradation of the material.

3. High groove depth design to increase material handling capacity
Another design highlight of the KTD series is its high groove depth structure. The high groove depth means that the material has more flow space in the screw, which can extend the residence time of the material in the screw, ensure that the material can fully contact the screw surface, and achieve better mixing effect. For highly filled materials, increasing the residence time and contact area can effectively improve the uniformity of the filler and the base material, avoid the occurrence of filler agglomeration, and ensure the quality stability of the final product. At the same time, the high groove depth design can also increase the processing capacity of the equipment, so that production efficiency is further improved.

Optimizing the production process through precise control
The flexibility of the KTD High Volume Extruder Production Line enables it to adjust the processing parameters to optimize the production process according to the different characteristics of highly filled materials. For example, the operator can flexibly adjust the screw speed, shear force and temperature control according to the filling ratio and fluidity of the material. This precise parameter adjustment capability enables the KTD series to meet the production needs of various different filled materials, whether it is a high proportion of inorganic fillers or other complex material formulations, to ensure a stable production process and high-quality output.

Improve production efficiency while ensuring product quality
The KTD High Volume Extruder Production Line can greatly improve production efficiency when processing highly filled materials while ensuring high product quality through high torque and high groove depth design. Its high torque design not only increases the shear force to ensure uniform mixing of materials, but also reduces energy consumption and equipment wear by running at low speed. The high trough depth structure further optimizes the material handling capability and increases the production line capacity.