Industrial extruding machine in operation

Extruding Machine Operations

Comprehensive guidelines for safe and efficient operation of plastic screw extruding machines

During the operation of a plastic screw extruding machine, intense friction occurs between the machine body,机头, screw, and materials, making various components prone to wear. Improper operation can easily cause premature damage to the extruding machine. Therefore, it is crucial to follow the operational requirements when using an extruding machine to ensure longevity, safety, and optimal performance.

This guide provides detailed instructions for the proper use and maintenance of your extruding machine, covering everything from pre-startup preparations to routine maintenance and identification of common wear parts. Adhering to these guidelines will help maximize the lifespan of your extruding machine while ensuring safe operation and high-quality output.

1. Pre-Startup Preparation for the Extruding Machine

Technician preparing extruding machine for operation

Before starting the extruding machine, the following preparations must be completed to ensure safe and efficient operation:

1
Pre-dry the materials for extrusion production. Further drying may be necessary depending on the material's moisture content and the specific requirements of your extruding machine.
2
Carefully inspect the equipment, water, and electrical systems to ensure they are in normal, safe, and reliable condition before operating the extruding machine.
3
Preheat the机头, machine body, and screw of the extruding machine to the temperature required by the process. Simultaneously, turn on the cooling jacket at the bottom of the hopper and introduce cold water.
4
Allow the extruding machine to reach a constant temperature for a period before starting. The temperature indicated by the extruding machine's control instrument is ahead of the actual temperature of the material. If the machine is not allowed to reach a constant temperature, the instrument may show the required temperature, while the actual material temperature is lower. Adding material at this point would cause excessively high melt viscosity due to the lower actual temperature, creating axial overload that could damage the extruding machine or even cause personal injury.
5
When each part reaches the specified temperature, tighten the connecting bolts of the机头 while hot and check the connection status to ensure no leakage occurs during operation of the extruding machine.
6
Inspect the hopper and remaining materials for foreign objects, especially metal and other hard debris that could damage the screw or barrel of the extruding machine.
7
Replace with a clean filter screen before starting the extruding machine. Check that the机头 meets the product type and size requirements and that all机头 components are clean.
8
Ensure all parts requiring lubrication have sufficient lubricating oil to maintain proper functioning of the extruding machine.
9
Clean the operation site, keep the main machine, auxiliary equipment, and operating platform tidy. Arrange raw materials, products, and tools in an orderly manner around the extruding machine.
10
Start all rotating equipment and check that they are operating normally before initiating full operation of the extruding machine.

2. Maintenance and Care During Extruding Machine Production

Extruding machine in production with operator monitoring

To ensure the normal operation and extend the service life of the extruding machine, the following practices should be observed during production:

1
Do not allow the extruding machine to run empty for an extended period after startup, as this may scratch the screw or barrel.
2
Ensure the cleanliness of raw materials. Strictly prevent metal debris or other hard parts (such as screws) from falling into the feed opening, which could damage the screw or barrel of the extruding machine.
3
Maintain continuous and uniform feeding when operating the extruding machine. Ensure the hopper always contains sufficient material. If continuous feeding cannot be guaranteed, stop the extruding machine immediately. Never operate the extruding machine without material in the hopper.
4
After a new extruding machine has been running for several hours, retighten the V-belts to prevent slipping during operation.
5
During the continuous long-term operation of the extruding machine, regularly check the lubrication and temperature rise of all parts. Continuously monitor the equipment's operation and stop immediately for inspection if any abnormal phenomena occur.
6
In case of power failure during production, which stops the main drive and heating systems, when power is restored, the extruding machine's barrel sections must be reheated to the set temperature and maintained for a period before restarting. Starting the extruding machine with insufficient temperature can cause hard material in the barrel to damage the equipment.
7
After purchasing an extruding machine, read the instruction manual thoroughly to understand and follow the specified operating requirements. Operators should also familiarize themselves with the machine's safety protection devices to take timely measures in case of overload or other situations.
8
After stopping the extruding machine when processing olefin materials, it is not necessary to clean the screw, barrel, and机头 each time. However, when processing easily decomposable materials such as PVC, the remaining material in the screw, barrel, and机头 must be cleaned immediately after each production run. Alternatively, you can add non-decomposable material to push out the easily decomposable residual material. If the extruding machine will not be used for an extended period, thoroughly clean all material and apply anti-rust oil to the surfaces of the screw, barrel, and机头 that come into contact with materials. Store the screw by hanging it vertically.
9
When processing materials that tend to stick, such as polyethylene or cellulose acetate, removing the screw (or removing large screws) after processing may be difficult. In such cases, use a screw-type screw extractor. Never strike the screw with a hammer, as this could damage the screw of your extruding machine.

3. Common Issues and Hazards in Extruding Machine Operation

Mechanical Contamination Risks

Metal foreign objects or small metal parts (such as screws or small wrenches) can fall into the feed opening of the extruding machine, leading to shutdowns or damage to the screw and barrel. Implement strict material inspection protocols and use magnetic separators to prevent such contamination in your extruding machine.

Lubrication System Failures

Lubrication system failures, such as oil shortage or severe oil leakage, can cause bearings to seize due to overheating or gears to wear severely from excessive heat. Establish regular lubrication checks and maintenance schedules for your extruding machine to prevent these issues.

Material Decomposition Issues

Processing PVC materials in an extruding machine is particularly prone to thermal decomposition. The hydrogen chloride gas produced during decomposition can severely corrode the surfaces of the barrel, screw, and机头 flow channels. Proper temperature control and timely cleaning are essential when processing such materials in your extruding machine.

Improper Restart After Power Loss

After a power outage, restarting the extruding machine without ensuring the material has reached the required temperature can have serious consequences. At best, the motor may shut down due to overload protection; at worst, it can damage safety pins, keys, or even severely damage the screw or barrel of the extruding machine. Always verify proper temperatures before restarting.

4. Wear Parts and Common Spare Parts for Extruding Machines

To ensure production efficiency, an extruding machine should be equipped with essential wear parts and common spare parts for timely replacement when components become damaged. Maintaining an inventory of these items for your extruding machine minimizes downtime and ensures continuous production.

Component	Description	Replacement Considerations
Screw	The screw is the core component of the extruding machine and is also a wear part. After a period of operation, the screw will wear, reducing extrusion output and quality.	Regular replacement or repair is necessary. Order replacements in advance. For production of various materials, have different screws suitable for each material type.
Barrel	When processing materials with a high proportion of hard fillers (such as calcium carbonate, glass fiber, silica, etc.), both the screw and barrel of the extruding machine will experience significant wear.	Keep barrels as spare parts for your extruding machine to enable immediate replacement when wear occurs.
Heating Coils	Heating coils are essential heating elements for each section of the extruding machine.	Record the specifications and quantities of all heating elements in the extruding machine's equipment file and purchase spares for immediate replacement when needed.
Bearings	Thrust bearings and main reducer bearings are critical for the proper functioning of the extruding machine.	Maintain spare bearings for your extruding machine to prevent prolonged downtime due to bearing failure.
Seals	Various seals throughout the extruding machine are prone to damage during operation.	Keep seal replacements as spare parts for regular maintenance or emergency replacement in your extruding machine.
Drive Belts	Drive belts in the extruding machine are susceptible to loosening, breaking, and wear.	Have replacement belts available for your extruding machine to quickly replace them when they fail.
Connecting Bolts	Various connecting bolts on the extruding machine are prone to damage during operation and maintenance.	Purchase spare bolts according to their specifications to ensure you have the correct replacements for your extruding machine.

Best Practices for Extruding Machine Longevity

Proper operation and maintenance of your extruding machine are essential for maximizing its lifespan and ensuring consistent production quality. By following these guidelines, you can significantly extend the operational life of your extruding machine while minimizing downtime and repair costs.

Remember that each extruding machine may have specific requirements based on its design and intended use. Always refer to the manufacturer's manual for machine-specific instructions and recommendations.

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