USEON Twin Screw Extruders and Pelletizing Systems

Selection and quotation of USEON equipment: SAT, U+, EC and TDY twin screw extruders, Lab units, SAT-T triple screw extruders, large SAT up to 360 mm and UWP underwater pelletizing systems for compounding lines.

SAT Co-rotating Twin Screw Extruders

SAT is the main USEON co-rotating twin screw extruder series for compounding. It has a patented gearbox with online monitoring, cartridge heaters inside the barrel and two cooling inputs and outputs on each barrel. Seven sizes run from SAT40 to SAT135.

Screw diameter: 41–130 mm
Specific torque: 9–10.9 Nm/cm³
Screw speed: 400–800 rpm
Output: 150–3,500 kg/h

U+ High-Torque Twin Screw Extruders

U+ is a co-rotating platform with specific torque up to 18 Nm/cm³ for PEEK, PPSU, LCP and compounds with 40–60% glass or carbon fibre. It uses Henschel or Zambello gearboxes, a Mayr or equivalent safety coupling and 4 L/D barrels with nickel-based liners. Heating holds ±1 °C at 450 °C.

Screw diameter: 27–93 mm
Specific torque: up to 18 Nm/cm³
Screw speed: 900–1,200 rpm
Temperature: up to 450 °C

EC Energy-Saving Twin Screw Extruders

EC is built for small and medium-scale production: a permanent magnet motor with a power factor up to 0.98 and a direct-drive structure cut energy use by about 15%. The control shows energy per ton and plays back faults. Five sizes run from EC 26 to EC 75.

Screw diameter: 26.5–71 mm
Screw speed: 600 rpm
Output: 10–800 kg/h
Energy saving: about 15%

TDY Counter-Rotating Twin Screw Extruders

TDY counter-rotating screws work at low shear with fast surface renewal, so the series serves reactive extrusion, devolatilization and recycling of BOPP and BOPET film and fibre. Positive displacement forces loose films and fibres in like a pump. Six sizes run from TDY40 to TDY110.

Screw diameter: 41–108 mm
Specific torque: 4.9–5.8 Nm/cm³
Screw speed: 400–600 rpm
Output: 70–1,200 kg/h

Lab Twin Screw Extruders

Lab-20, Lab-30 and Lab-35 serve formulation work, batch samples and small lots of color masterbatch. Screw elements are geometrically similar to the production platforms, which helps scale-up. The extruder usually ships with feeding and a small pelletizing system.

Screw diameter: 22–35.6 mm
Process length: 32–64 L/D
Screw speed: up to 720 rpm
Output: 5–60 kg/h

SAT-T Parallel Triple Screw Extruders

SAT-T with three parallel screws is chosen when output is limited by feeding volume: light powders, very high filler loading and hard-to-disperse carbon black and titanium dioxide. Delivered lines run CaCO₃ at 84–85% loading. Five sizes run from SAT-T35 to SAT-T95.

CaCO₃ loading: 84–85%
Output: 50–3,600 kg/h
Main motor: 30–400 kW
SAT-T75 speed: 600 rpm

Large SAT Extruders for Polyolefins

Above the seven standard sizes, SAT continues to a 360 mm screw diameter for polyolefin finishing in polymerization plants. USEON delivered a SAT330 unit for 200,000 t/year of polypropylene and built the SAT360 for 400,000 tonnes a year. The units run 8,000+ hours a year.

Screw diameter: 130–360 mm
Output: 5–60 t/h
Screw speed: 300–600 rpm
Specific torque: 10.3 Nm/cm³

UWP Underwater Pelletizing Systems

Knives cut the melt at the die face under water, and water carries the pellets to a dryer. Knife pressure is set on the touch screen and the knives are reground automatically by set time and pressure. It suits elastomers, viscous melts and micro-pellets, in a new line or on an existing extruder.

Pellet diameter: 0.8–4.0 mm
Output: 50–8,000 kg/h
Surface moisture: below 0.1%
UPD400 output: 35–50 t/h

Choosing a Twin Screw Extruder Series

The series follows the job. SAT with 9–10.9 Nm/cm³ specific torque covers most compounding tasks, including filler masterbatch and engineering plastics.

U+ with up to 18 Nm/cm³ is chosen for PEEK, LCP and compounds with 40–60% fibre, and EC with 7.0 Nm/cm³ at 600 rpm suits color masterbatch up to 800 kg/h. The counter-rotating TDY fits reactive extrusion, devolatilization and film recycling, while Lab units serve trials and sample batches.

High-Filler Masterbatch Line

For CaCO₃ filler masterbatch at 75–85% loading the manufacturer offers SAT lines at 250–1,600 kg/h. When output is limited by the feeding volume of light powder, the SAT-T triple screw extruder is used: delivered lines run 84–85% CaCO₃, and a SAT-T75 with water ring pelletizing gives 1,800–2,200 kg/h at 84% loading.

Sizing needs the base resin, filler type and ratio, bulk density and target hourly throughput.

Choosing the Pelletizing Method

Underwater pelletizing is chosen for soft and sticky elastomers, viscous melts, micro-pellets and high throughput: pellets are near-spherical at 0.8–4.0 mm and start-up is automated.

Standard polyolefins (PE / PP) suit water ring pelletizing with 2.5–4.0 mm pellets, and rigid engineering plastics and reinforced compounds suit strand pelletizing with 2.0–4.0 mm pellets. Sizing needs the material and formulation, melt flow rate, throughput and pellet size.

From Lab Extruder to Production

Lab-20, Lab-30 and Lab-35 units with 22–35.6 mm screws and 32–64 L/D give 5–60 kg/h and run compounding, direct extrusion, devolatilization and reactive extrusion on one machine. Screw elements are geometrically similar to the production platforms, so settings scale up, though not 1:1.

Longer barrels are built for special processes: a pilot line of LAB35 and LAB30 runs L/D 74 and L/D 58.

USEON and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of USEON and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.