📋 Case Study

High-Viscosity Polymer Melt Extrusion in Twin-Screw Processing

Non-uniform melt temperature leading to die swell variation and gauge banding

🏗️ Project Overview

Biodegradable PLA packaging line upgrade in Germany

🎯 Challenge

Non-uniform melt temperature leading to die swell variation and gauge banding

🔧 Design Approach

Implemented segmented barrel heating with real-time rheometry feedback; applied power-law modeling of shear-thinning behavior

📐 Design Diagram

AI-generated project design illustration

📐 Key Calculations

Shear Rate at Die Exit

4Q/πR³

Result: 1200 s⁻¹

Controls extensional viscosity and draw resonance

📊 Results

±1.2% thickness uniformity (vs. ±4.8% baseline), 11% throughput increase, 30% lower motor load variance

💡 Lessons Learned

• •Power-law index n < 0.4 demands precise thermal management
• •Die design must account for elastic recovery (die swell)

✅ Key Takeaways

• 1Power-law index n < 0.4 demands precise thermal management
• 2Die design must account for elastic recovery (die swell)