WE LOVE CARPETING.

In our daily life, often non-experts do not even realize how many products are based on plastic; in some cases, like that of this new success story, someone can be led to confuse a plastic material with another type of material, as often happens in the world of textiles.

Our client is a major company, a European leader in the carpet and rug industry. In this specific case we focused on a single screw extruder equipped with a 130-30 L/D plasticizing unit; the screw was a barrier mixing design needed to process PP + Colour 0.8-4% + U.V. protector 4-5% with a 265kw motor. We were called due to problems with colour dispersion and poor lamination above 100 rpm.

After a careful on-site analysis by our technicians, without having to modify the extruder structures, barrel or motor of the extruder, a dedicated screw profile has been designed and developed and, today, after more than 6 months of tests with various types of materials, using additives and colourants of different kinds, using trimming recovery, it was found that:
• at the same rpm we obtained an output + 15% compared to the old screw;
• better lamination and homogenization of both coloured and transparent materials;
• eliminated areas with overheating and on parallel the degradation and burns of the melted mass;
• better dispersion and homogenization with savings on additives quantity;
• engine overload above 115 rpm has been completely eliminated;
• energy savings calculated over 6 months of approximated 7%;
• increased use of recovered trims for the feeding by 20%.

We are always glad to prove ourselves alongside our customers, especially when ideas turn into success for us and in great savings for our customers.