A leading manufacturer of medical polymer materials and hygiene products in East China faced a critical processing challenge during the development of a new material formulation.
The new formulation required tight control of processing temperature, mixing uniformity, and continuous production stability. Maintaining consistent processing conditions was essential to achieving the target material properties and ensuring reliable downstream production.
The material is used in applications related to medical and hygiene products, including advanced wound care materials and medical protective products. This placed additional demands on the consistency and stability of the compounding process.
For the customer, the challenge was not simply to process the formulation.
The objective was to establish a stable and controllable twin screw extrusion process capable of meeting the material's demanding processing requirements.
To address these requirements, KYMACH provided a high-performance twin screw extrusion system as the core of the processing solution.
The equipment was configured to provide stable torque, precise temperature control, efficient mixing, and reliable continuous operation.
Several key design features were directly related to the customer's processing requirements.
The extruder is equipped with a 13.5 Nm/cm³ high specific torque gearbox, combined with high-strength, high-torque material shafts.
This configuration provides a strong mechanical foundation for processing high-viscosity and highly filled materials, supporting effective melting, plasticization, mixing, and homogenization.
For demanding medical polymer formulations, stable torque transmission is important for maintaining consistent processing conditions as material characteristics change throughout the extrusion process.
Temperature control was another key requirement of the application.
The system combines imported heating elements with optimized spiral cooling channels in the barrel to provide responsive temperature regulation across the processing sections, from the feeding zone through to the die.
For temperature-sensitive polymer materials, accurate temperature management helps control the relationship between processing temperature, residence conditions, and material properties.
The barrel liners and screw elements are manufactured from wear-resistant materials, providing additional durability for long-term production.
The extruder is designed for a rated screw speed of up to 1,000 rpm, providing flexibility for different processing conditions and production requirements.
A low-noise, energy-efficient permanent magnet synchronous water-cooled motor is used as the main drive system, combining high-speed operation with reduced operating noise and efficient power utilization.
The system is also equipped with an improved side vacuum extraction system designed to remove volatile components and low-molecular-weight substances generated during processing.
Effective vacuum devolatilization helps improve process stability and can contribute to improved material quality and pellet consistency, depending on the formulation.
The successful processing of the new material was achieved through the combination of equipment performance and process engineering.
During commissioning, KYMACH engineers worked closely with the customer's technical team to establish suitable operating conditions for the formulation.
Key process factors included:
Screw configuration
Screw speed
Feeding rate
Barrel temperature profile
Melt processing conditions
Vacuum devolatilization
Mixing and homogenization conditions
Rather than relying on equipment specifications alone, the process was adjusted according to the actual material behavior observed during production.
This approach allowed the customer to move from formulation development toward a more stable and repeatable continuous twin screw extrusion process.
The project demonstrates the importance of matching twin screw extruder design with the specific characteristics of advanced polymer formulations.
For medical and hygiene material applications, equipment selection is only one part of the process. Temperature control, mixing uniformity, material residence behavior, feeding stability, and process consistency must also be considered as an integrated system.
KYMACH's experience in polymer compounding and twin screw extrusion allows equipment configuration and process development to be considered together.
Through stable equipment operation and close cooperation between the KYMACH engineering team and the customer, the new material was successfully brought into continuous production.
The project provided the customer with a practical extrusion solution for its new formulation and further demonstrated the application of high-performance twin screw extrusion technology in demanding polymer material processing.
For new polymer materials, the path from formulation development to industrial production often requires extensive process validation and optimization.
KYMACH supports customers throughout this transition with:
Formulation Evaluation → Equipment Selection → Screw Configuration → Process Development → On-Site Commissioning → Stable Production
By combining extrusion equipment with process engineering experience, KYMACH helps customers address complex material processing challenges and develop practical routes from new material formulation to continuous production.
KYMACH — Precision twin screw extrusion technology for advanced polymer processing.
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
