As the high-performance new materials industry moves toward greater automation and localization, project delivery efficiency and integrated production-line capabilities are becoming increasingly important for equipment suppliers.
Recently, KYMACH completed the delivery and commissioning of six high-performance plastic compounding lines for Zhejiang Jushen New Materials Co., Ltd.
From the construction of the steel platforms to the start-up of the production lines, the complete project was completed in approximately one month, demonstrating KYMACH's capability to provide integrated engineering, equipment, and commissioning services for compounding projects.
Zhejiang Jushen New Materials Co., Ltd. is a subsidiary of Junyuan Holding Group focusing on the development and production of high-performance specialty new materials. The company has also established a joint laboratory with the Zhejiang University Yangtze River Delta Smart Oasis Innovation Center.
For this project, the customer placed particular emphasis on process visibility, operator-friendly design, plant cleanliness, and overall system integration. The requirements therefore extended beyond the performance of individual machines to the design and coordination of the complete production facility.
KYMACH became involved during the early project stage and provided an integrated production-line layout and engineering solution. The objective was to identify potential installation and operation issues during the design stage and reduce rework and material waste during implementation.
During installation and commissioning, the project teams coordinated the different stages of construction, equipment installation, commissioning, and production preparation. From steel platform construction to the production lines being ready for operation, the main project was completed in less than one month.
The project includes six high-performance compounding lines, each configured according to its specific application and production requirements.
The nylon compounding lines were designed for small-batch, multi-formulation production.
One of the main challenges was material handling. Due to the relatively small production batches and frequent formulation changes, fully automated material conveying was not practical for all materials, making manual feeding necessary.
Another challenge was the installation of three production machines side by side while processing materials with different colors. During manual feeding and material handling, the risk of cross-contamination therefore needed to be minimized.
The line design was developed with both operator convenience and easy cleaning in mind.
A recessed design was incorporated into the steel platform around the feeding areas, providing easier access for manual feeding and equipment cleaning.
At the same time, the feeding area of each production line was physically separated and equipped with an independent dust extraction system. This arrangement helps minimize the transfer of dust and material between adjacent production lines and supports consistent product quality.
In addition, a separate HK36 high-torque twin-screw extruder was configured as a pilot machine for new formulation trials.
The pilot line allows the customer to evaluate new formulations under processing conditions similar to those of the production equipment before scaling up. This creates a practical laboratory-to-production development path, helping the customer establish process parameters before introducing new formulations to the larger production lines.
The three production lines and the pilot extruder therefore form an integrated workflow:
Formulation Development → Pilot Testing → Process Validation → Production Scale-Up
This approach provides flexibility for product development while supporting subsequent large-scale production.
Another production line is based on the HK73MT high-torque twin-screw extruder and is designed for highly filled PE/PP compounds with a filler content of up to 65%.
The main process challenge was to maintain effective dispersion and devolatilization while achieving high production throughput.
To address these requirements, KYMACH optimized the equipment configuration and process layout, including:
Optimization of the L/D ratio
Precise positioning of the liquid injection port
Optimization of the vacuum venting position
Customized screw configuration
The combination of these measures was designed to improve dispersion and devolatilization in the highly filled system while supporting high-throughput production.
The process is also designed to remove volatile components from the material during extrusion, helping the customer meet both production and product-quality requirements.
The project also includes an HK36MT twin-screw extruder installed in the joint laboratory of Zhejiang University Yangtze River Delta Smart Oasis Innovation Center.
As the laboratory equipment is used for research and development, screw configurations need to be changed frequently for different experimental programs. The limited installation space and availability of spare screw elements presented additional challenges.
KYMACH's laboratory technical support team provided assistance with screw configuration selection, screw-element replacement, and on-site process support.
This support allows the laboratory to carry out different formulation and processing trials more flexibly while making better use of the available installation space.
At present, five lines at the customer's site have entered operation, including four production machines and one pilot machine, while the additional HK36MT unit is operating at the joint laboratory.
The project covers multiple stages, from overall line design and equipment integration to installation, commissioning, and process support.
Through a turnkey project approach, KYMACH helps reduce the coordination requirements associated with multiple equipment suppliers and provides the customer with a more integrated route from plant layout to production.
This project demonstrates the importance of integrating equipment design, plant layout, material handling, process requirements, and commissioning into one coordinated project.
For different applications within the same facility, KYMACH provided different equipment configurations and supporting solutions, ranging from high-torque production extruders for reinforced nylon compounds to high-throughput equipment for highly filled PE/PP compounds and pilot-scale systems for formulation development.
KYMACH congratulates Zhejiang Jushen New Materials Co., Ltd. on the opening of its new facility on July 16.
Going forward, KYMACH will continue to provide integrated twin-screw compounding and extrusion solutions, supporting customers in developing new materials, scaling up formulations, and moving from process development to stable industrial production.
Tel: +86-25-52706155
E-mail: info@kymach.com
No.59 West Tianyuan Road, Jiangning, Nanjing, Jiangsu Province, China
English 
日本語 
한국어 
français 
Español 
русский 
português 
العربية 
中文
