For compounders, the performance of a production line is measured not only by equipment specifications, but also by its ability to process different materials efficiently, switch between formulations smoothly, and consistently produce products that meet the required quality standards.
Recently, KYMACH successfully completed a comprehensive pre-shipment trial for a customer in Kazakhstan.
The customer is planning to establish a compounding pilot and production line in Kazakhstan and required one extrusion system capable of processing a wide range of formulations. Particular attention was given to product quality, automation, processing stability, and formulation flexibility.
Following technical discussions, process evaluation, and equipment selection, the customer chose the KYMACH HK63MT high-torque co-rotating twin-screw extruder, configured for 600 rpm operation with a specific torque of 12.5 Nm/cm³.
Before shipment, the customer brought their own raw materials to KYMACH for a comprehensive pre-shipment material trial. The complete system operated continuously for 7 days, during which 10 different formulations were tested, with approximately 10 tons of raw materials processed.
The trials were completed successfully. The equipment operated steadily, feeding and discharge remained consistent, the automated process ran smoothly, and formulation changes could be carried out efficiently. The test results met the customer's expectations, and the equipment successfully passed the customer's on-site acceptance.
The complete production line has now completed its pre-shipment preparations and is ready for delivery to the customer's plant in Kazakhstan.
To comprehensively evaluate the processing capability of the extrusion system, the customer tested 10 different formulations, using approximately 10 tons of raw materials in total.
The main materials tested included:
PPR + 25% glass fiber reinforced compound
PPR + 60% TiO₂ white masterbatch
HDPE + 60% calcium carbonate filled compound
PP + 50% barium sulfate / calcium carbonate filled compound
PP + 60% calcium oxide filled compound
PP + 65% talc filled compound
Other modified formulations, for a total of 10 formulations
The trials covered a wide range of processing conditions, from high-flow and low-MFI resins to glass-fiber reinforced compounds, highly filled mineral formulations, and recycled-material processing.
The successful trials demonstrated the ability of one extrusion system to accommodate multiple formulations and processing requirements.
One of the customer's main concerns during the project was not only production capacity, but also the formation of air bubbles in the final pellets.
Certain highly filled formulations and recycled materials can introduce moisture, entrained air, or volatile components during processing. If these components are not effectively removed, they may result in bubbles or voids inside the pellets, potentially affecting product appearance, mechanical properties, and subsequent processing performance.
To address this issue, KYMACH's technical team optimized the process according to the characteristics of different materials, including:
Screw configuration
Feeding and material addition sequence
Vacuum devolatilization
Temperature settings
Overall process parameter matching
Through continuous trial production and process adjustment,the bubble forming issue was mitigated via process adjustments under these trial conditions, and the customer confirmed the results.
For plastic compounding, stable plasticization, effective devolatilization, and appropriate process control are essential in addition to sufficient production capacity.
In addition to the main extrusion system, the project includes a relatively comprehensive automated production system covering multiple stages of the process.
The system includes:
Automatic raw material conveying
Automatic weighing and loss-in-weight feeding
Water-cooled strand cooling
Strand pelletizing
Vibratory screening
Automatic packaging, including both small-bag and big-bag packaging
The integrated automation system helps reduce manual intervention while improving formulation changeover efficiency and feeding consistency. It also provides a suitable foundation for the customer's future continuous production requirements.
During the multi-day trials covering a wide range of formulations, the complete production line operated steadily. Feeding and discharge remained consistent, pelletizing performance was stable, and the system demonstrated convenient formulation changeover.
The project uses the HK63MT co-rotating twin-screw extruder, with key features including:
600 rpm high-speed operation, balancing production capacity and process stability
12.5 Nm/cm³ specific torque, suitable for glass-fiber reinforcement, highly filled formulations, and higher-viscosity materials
Modular screw design, allowing the screw configuration to be adjusted according to different formulations and processing requirements
Effective plasticization, dispersion, and devolatilization, supporting a wide range of complex formulations
High level of automation and line integration, suitable for continuous industrial production
The combination of high torque, flexible screw configuration, and integrated automation allows the HK63MT to handle a broad range of compounding applications within one production platform.
For KYMACH, the delivery of an extrusion system is not limited to the equipment itself. It also includes process support throughout the project.
From formulation analysis, equipment selection, and screw configuration to material trials, process optimization, and complete line delivery, KYMACH works closely with customers to address practical processing requirements and support the transition from trials to stable production.
This Kazakhstan project is another example of how systematic material testing and process optimization can help customers evaluate a multi-purpose compounding line before shipment.
KYMACH will continue to provide twin-screw extrusion equipment and integrated compounding solutions for customers in the global plastics industry, supporting a wide range of applications from reinforced compounds and highly filled materials to masterbatch and recycled-material processing.
Tel: +86-25-52706155
E-mail: info@kymach.com
No.59 West Tianyuan Road, Jiangning, Nanjing, Jiangsu Province, China
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