Reducing Energy Costs

Focus on Extrusion Efficiency

Extrusion is not only a final forming process for products but it is also an intermediate process for many other processes such as injection molding, blow molding and blown film. The cost-effective operation of extrusion screws is therefore essential for a high proportion of the plastics processing industry.

The initial cost of energy-efficient extruders may be higher but it will give rapid returns on the small extra investment. Options such as high-efficiency motors and variable-speed drives have excellent payback as both new and replacement purchases.

Whatever the age of the machine, it is essential to get the right extruder for the job and the screw diameter and design should be checked to make sure they are right for the polymer and product. Extruders run most efficiently (not only in energy terms) when operating at the design conditions for the motor and screw. The extruder should be set to run at the maximum design speed, as this is usually the most efficient setting. The screw speed should only be reduced from the maximum if there is difficulty producing good product.