China Nanjing Henglande Machinery Technology Co., Ltd. Company Cases

50B twin-screw extrusion granulation production line for PP + calcium carbonate project was successfully accepted [KunShan,China, 20250319] – The 50B twin-screw extrusion pelletizing production line has successfully passed its acceptance test for the PP + calcium carbonate project, marking a significant milestone in advanced polymer processing technology. The project, designed to enhance the performance and cost-effectiveness of polypropylene (PP) composites through the addition of calcium carbonate, has undergone rigorous testing to ensure stability, efficiency, and high-quality output. With the adoption of state-of-the-art twin-screw extrusion technology, the production line has demonstrated exceptional dispersion capabilities, improved mechanical properties, and enhanced processing efficiency. Industry experts and technical teams conducted thorough evaluations of the production process, focusing on key parameters such as material homogeneity, energy efficiency, and output consistency. The results confirmed that the 50B twin-screw extrusion pelletizing line meets and exceeds industry standards, reinforcing its reliability in large-scale industrial applications. A spokesperson for the project team expressed enthusiasm about the successful acceptance, stating, “This achievement underscores our commitment to innovation and quality in polymer compounding. The optimized formulation and cutting-edge technology ensure superior product performance and sustainability.” The successful commissioning of this production line is expected to drive further advancements in modified plastics, catering to a wide range of applications across industries such as automotive, packaging, and construction. Moving forward, the project team aims to explore additional material formulations to expand the versatility and functionality of PP composites. This milestone highlights the ongoing evolution of polymer manufacturing, setting new benchmarks for efficiency, quality, and environmental sustainability in the industry.

Project Background An international engineering plastics manufacturer needed to produce high-performance PA (Nylon) and PC (Polycarbonate) materials for automotive parts and electronics industries. Traditional single-screw extruders faced issues such as uneven mixing and low production capacity, failing to meet the client’s demands for high quality and efficiency. To address this, we recommended a high-efficiency twin-screw extruder and provided a customized solution. Material Description PA (Nylon): Known for its high strength, wear resistance, and heat resistance, widely used in automotive parts, gears, and bearings. PC (Polycarbonate): Features high transparency and impact resistance, commonly used in electronic housings, optical lenses, and medical devices. Technological Innovations Efficient Mixing TechnologyThe twin-screw extruder adopts a co-rotating design, ensuring thorough material mixing during extrusion and eliminating the uneven mixing issues of traditional single-screw extruders. By optimizing the screw structure, the dispersion and compatibility of PA and PC materials are significantly improved, resulting in more stable product quality. Modular DesignThe equipment features a modular screw and barrel design, allowing quick adjustment of process parameters based on the characteristics of different materials (e.g., viscosity, melting point), catering to the diverse production needs of PA and PC. Intelligent Temperature Control SystemEquipped with a high-precision temperature control system, it monitors and adjusts the temperature of each heating zone in real time, ensuring PA and PC materials are extruded at optimal temperatures to avoid degradation or performance loss. Energy EfficiencyBy optimizing the drive system and heating methods, the equipment reduces energy consumption by 15% while minimizing waste generation, aligning with eco-friendly production standards. High Output CapacityThe high-speed design and high torque output of the twin-screw extruder increase the production efficiency of PA and PC materials by 30%, meeting the client’s large-scale production demands. Project Results Product Quality: The mechanical properties and appearance of PA and PC materials meet international standards, significantly improving customer satisfaction. Production Efficiency: Capacity increased by 30%, delivery cycles shortened, and the client’s market competitiveness enhanced. Energy Savings: Energy consumption reduced by 15%, production costs decreased, and client profitability improved. Client Feedback “The twin-screw extruder not only solved our technical production challenges but also helped us achieve efficient and energy-saving production goals. The stability and flexibility of the equipment have given us a competitive edge in the market.” Conclusion With its efficient mixing, modular design, and intelligent temperature control technologies, the twin-screw extruder has demonstrated exceptional performance in engineering plastic production. Whether for PA or PC materials, it enables high-quality and high-efficiency production, creating greater value for customers. This case study highlights the advantages of the twin-screw extruder through material descriptions and technological innovations, making it suitable for promotion on platforms like TradeKey to attract potential clients.

A Mexican plastics manufacturing company wanted to expand its product line, particularly in the area of thermoplastic polyurethanes (TPUs), which are used in a wide range of industries such as automotive, footwear, and electronics because of their excellent elasticity, abrasion resistance, and transparency. In order to improve production efficiency and product quality, the company decided to invest in a cast TPU twin-screw extrusion line with underwater pelletizing. Solution: The selected line is equipped with a high-performance twin-screw extruder with powerful mixing and plasticizing capabilities, capable of effectively handling TPU materials with different viscosities and compositions. The line also included underwater pelletizing equipment, which utilizes a water stream to rapidly cool and cut the TPU melt, ensuring uniform pellet shape and a smooth surface. Implementation process: Equipment installation and commissioning: The production line was successfully installed and commissioned in the company's factory. The technical team conducted comprehensive tests on the extruder, cooling system and pelletizer to ensure that all components operated in harmony. Optimization of Process Parameters: According to the characteristics of TPU, the technicians adjusted the extrusion temperature, screw speed and water flow rate to ensure optimal processing conditions and efficient production. Production trials: Several rounds of trial production were conducted to collect data to analyze pellet quality and production efficiency. After several rounds of adjustments, the optimal process parameters were finalized. Results: Improved product quality: The underwater pelletizing process significantly improved the uniformity and smoothness of the TPU pellets, and customer feedback indicated that the quality of the pellets met the needs of the high-end market. Increased production efficiency: The production line achieved a stable high output, increasing the daily output by 30% and effectively reducing the production cost. Enhanced market competitiveness: By providing high-quality TPU pellets, the company has successfully opened up new customers and increased its market share in the industry. Summary: By introducing a cast TPU twin-screw extrusion line and an underwater pelletizing process, the company not only improved its product quality and production efficiency, but also strengthened its competitiveness in a highly competitive market. This success story demonstrates the importance of modern equipment and processes in the plastics manufacturing industry.

A plastics manufacturer was committed to improving its processing efficiency and product quality in the production of engineering plastics and high-performance polymers. Because its existing twin- and three-screw extruders exhibited problems with uneven mixing, low throughput, and high energy consumption when processing high-viscosity materials, the company decided to explore solutions for optimizing its screw elements.   The Challenge: Uneven mixing: Due to the poor configuration of the existing screw elements, the material was not adequately dispersed, resulting in inconsistent final product quality. High energy consumption and low efficiency: The high energy consumption and low throughput of the current screw design increased production costs. Insufficient wear resistance: Screw elements wear out quickly when handling highly abrasive materials, leading to frequent replacements and high maintenance costs. Solution: The manufacturer worked with our company to redesign and optimize the extruder's screw portfolio. The new configuration included: High-efficiency conveying element: Increases material transfer rates and reduces stagnation and backflow. Special Mixing Elements: Multiple mixing elements have been added to the screw to improve dispersion and mixing of the material to ensure uniformity. Wear-resistant materials: Screw elements made of highly wear- and corrosion-resistant materials to extend service life and reduce replacement frequency. Results: Quality Improvement: The new screw configuration significantly improves the homogeneity and dispersion of the material, resulting in a more consistent quality of the final product. Improved energy efficiency: Due to the optimized component mix, the extruder's energy consumption has been reduced by approximately 20% and productivity has increased by 30%. Cost savings: More wear-resistant materials and optimized design reduce element replacement and downtime, saving maintenance and replacement costs. By using optimized screw elements, the manufacturer not only solved its existing production challenges, but also significantly improved the performance and overall productivity of its equipment, earning it more customer trust and market share in the high-performance plastics market.

The client is a company dedicated to producing high-quality PET (polyethylene terephthalate) masterbatch. These color masterbatch are used in products such as plastic packaging, fibers, and preforms to provide consistent color and enhanced performance for the final product. With the increasing demand for high-quality and environmentally friendly products in the market, customers have decided to upgrade their PET masterbatch production process to increase production, optimize product quality, and reduce energy consumption.   Project objectives Enhance production capacity: By optimizing equipment and processes, increase the production of PET masterbatch to meet the growing demand in the market. Improve product quality: Ensure the color uniformity and dispersion of color masterbatch to enhance the appearance and performance of downstream products. Improve energy efficiency: By applying energy-saving technologies, reduce energy consumption in the production process and lower operating costs. Challenge Pigment dispersibility: In the production of PET masterbatch, the uniformity of pigment dispersion is crucial, as uneven dispersion can lead to inconsistent color in the final product. Heat sensitive material processing: PET is sensitive to temperature changes and requires precise temperature control during production to prevent material degradation or affect color quality. High energy consumption issue: The production process of color masterbatch includes high-temperature melting and mixing, which usually consumes high energy and requires optimization to improve energy utilization efficiency. Solution Industries has chosen an efficient twin-screw extruder known for its excellent mixing and dispersing capabilities, which can meet the production needs of high-quality PET masterbatch. Key characteristics of twin-screw extruder Efficient mixing system: Through a specially designed screw structure, the pigment is uniformly dispersed in the PET substrate, ensuring the color consistency of the masterbatch. Precise temperature control system: using multi-stage temperature control technology to precisely control the temperature of each processing stage, preventing material degradation and color instability. Energy saving design: equipped with an energy recovery system and optimized heater design, significantly reducing energy consumption. Process optimization Pre mixing process: Introducing advanced pigment pre mixing technology to ensure preliminary uniform mixing of pigments and PET raw materials before entering the extruder, improving the color consistency of the final product. Automated control system: An automated production control system has been installed to monitor and adjust key process parameters in real-time, such as temperature, pressure, and screw speed, to ensure consistent quality of each batch of products. Cooling and granulation system upgrade: The cooling and granulation equipment has been upgraded to ensure uniform cooling speed of color masterbatch, avoiding particle deformation or quality fluctuations caused by uneven cooling.   result Improved production capacity: Through equipment and process optimization, the output of PET masterbatch has increased by 35%, successfully meeting the growing market demand. Product quality improvement: The color uniformity and dispersion of color masterbatch have been significantly improved, resulting in improved product quality for downstream customers and more positive market feedback. Energy cost reduction: The optimized production line has reduced energy consumption by 20%, saving customers approximately $100000 in energy costs annually. Sustainable production: By improving production processes and equipment, customers not only enhance product quality and production efficiency, but also reduce carbon emissions, helping the company achieve its environmental goals. The successful implementation of this project has further enhanced the customer's competitiveness in the PET masterbatch market, and has also made significant contributions to the company's sustainable development and cost control.

our customer is a manufacturer specializing in high-performance engineering plastics. The company sought to improve its production capabilities for nylon-based composite materials reinforced with glass fiber, aiming for a consistent output of 300 kg/h.   Project Objectives Increase Production Efficiency: Achieve a stable output of 300 kg/h to meet the growing demand for glass fiber-reinforced nylon pellets. Enhance Material Properties: Ensure uniform dispersion of glass fibers to optimize the mechanical properties of the composite material. Optimize Energy Consumption: Implement energy-efficient technologies to reduce operational costs. Challenges Uniform Fiber Dispersion: Achieving consistent dispersion of glass fibers within the nylon matrix to enhance the material's strength and durability. Equipment Wear and Tear: Glass fibers are abrasive and can cause increased wear on equipment, necessitating robust machinery. Energy Costs: High energy consumption due to the processing requirements of glass fiber-reinforced materials. Solution Equipment Selection This Engineering Plastics chose our factory's H-TSE65B Co-Rotating Twin-Screw Extruder for its advanced mixing capabilities and robustness in handling abrasive materials like glass fiber. Key Features of the Twin-Screw Extruder: Efficient Mixing: The co-rotating screws provide excellent mixing and compounding, ensuring uniform fiber distribution. Wear-Resistant Components: Specially designed barrels and screws with wear-resistant coatings extend the equipment's lifespan. High Torque: Capable of processing high-viscosity materials, ideal for glass fiber-reinforced composites. Production Line Enhancements Automated Control System: Implemented a PLC-based control system for precise control over processing parameters, reducing operator intervention and improving consistency. Energy Efficiency: Utilized variable frequency drives and optimized heating zones to reduce energy consumption. Real-Time Monitoring: Installed sensors and monitoring systems to track production metrics and equipment status, allowing for predictive maintenance and minimizing downtime.

This production line is sent to Vietnam, the power of the main motor is 132 kilowatts, high efficiency and energy saving, high output, the customer specified the formula, in addition, we also help it to purchase the fiberglass, very much trust us. Objectives Improve Production Efficiency: Increase output rates and reduce cycle times. Enhance Product Quality: Achieve consistent pellet size and uniform dispersion of fiberglass. Flexibility: Allow for quick changeovers between different formulations. Equipment Overview Type 75 Twin-Screw Extruder Screw Diameter: 71.5mm L/D Ratio: 44：1 (Length to Diameter) Motor Power: 132 kW Max Screw Speed: 600 RPM Output Capacity: 500-1000 kg/h Key Features Modular Screw Configuration: Allows for customization based on the material and process requirements. High Torque Capacity: Ensures efficient mixing and compounding of nylon with fiberglass. Advanced Temperature Control: Precise heating zones ensure optimal processing temperatures. Process Description Material Feeding: Nylon Resin and Fiberglass: Fed into the extruder through a gravimetric feeder system to ensure precise ratio control. Compounding: Twin-Screw Action: Provides thorough mixing and compounding of the nylon and fiberglass, ensuring uniform dispersion of fibers. Melt Homogenization: Temperature Management: The extruder’s advanced temperature control maintains the ideal melt temperature for nylon, preventing degradation. Pelletizing: Strand Pelletizing System: Extruded strands are cooled and cut into uniform pellets, suitable for further processing. Results Increased Efficiency: Production output increased by 30%, reducing operational costs. Improved Product Quality: Consistent pellet size and superior fiber dispersion resulted in enhanced mechanical properties of the final product. Reduced Downtime: The modular design of the extruder allowed for rapid changeovers, minimizing downtime between production runs. Conclusion The implementation of the Type 75 twin-screw extruder enabled the client to significantly improve their nylon and fiberglass pelletizing process. The equipment’s flexibility, efficiency, and advanced features supported the production of high-quality composite materials, meeting the increasing demands of the engineering plastics market. Future Outlook The success of this project has paved the way for further innovations in composite material production. The client is exploring additional applications and materials to diversify their product offerings using the same extruder technology.   For more information about the testing machine, please contact us!

Our coustomer is a leading manufacturer of flexible packaging solutions, specializing in polyethylene (PE) films used for various applications including food packaging, industrial wrapping, and consumer goods. The company aimed to enhance its production capabilities by upgrading its PE pelletizing system to support an increased demand for high-quality packaging films.   Project Objectives Enhance Production Capacity: Increase the output of PE pellets to meet rising market demand. Improve Pellet Quality: Ensure consistent pellet size and quality to optimize film extrusion processes. Reduce Operational Costs: Implement energy-efficient technologies to lower production costs. Challenges Inconsistent Pellet Quality: Variability in pellet size and quality was affecting downstream extrusion efficiency. High Energy Consumption: Existing pelletizing equipment was energy-intensive, leading to high operational costs. Limited Production Capacity: The existing setup could not handle the increased demand efficiently. Solution Equipment Upgrade our customer decided to upgrade to an New extruder and Pelletizing System due to its superior cooling and pellet uniformity capabilities. Increased Production Capacity: The new system increased the production capacity by 30%, allowing our customer to produce an additional 8 tons of PE pellets per day. Improved Pellet Quality: The uniformity of the pellets improved significantly, reducing defects in the final film products and increasing the yield of high-quality films. Cost Reduction: Energy-efficient technologies led to a 25% reduction in energy costs, saving the company $150,000 annually. Enhanced Product Line Flexibility: The ability to produce various grades of PE enabled the company to expand its product offerings and enter new markets.

A Vietnamese manufacturing company dedicated to the development of elastomeric materials plans to establish a sports product line to produce molded soles for lightweight TPE shoes. The company's main challenge was to achieve stability and consistency of the molded material while maintaining excellent resilience and thermoplasticity.   To solve this problem, the company chose Nanjing Henglunde Machinery Technology Co., Ltd. in China and selected the TSE75B twin-screw machine with water ring pelletizing system for the customer's requirements. The TSE75B, with its excellent screw design of the co-rotating twin-screw equipment, ensures that the different components of the TPE material are mixed uniformly at high temperatures and high pressures. The water ring pelletizing machine further ensures that the pellets are cooled and accurately formed. The water ring pelletizer further ensures the cooling and precise molding of the granules, and efficiently avoids deformation or sticking of the granules during the cooling process.   After using TSE75B for the production of TPE foam material, the enterprise has realized the production of high-quality foam granules with uniform granule density and stable foaming effect, which ensures the light weight and high elasticity of shoe soles. Compared with the traditional equipment, TSE75B improved the production efficiency and reduced ink and material waste, significantly improving the overall efficiency of the production line.   In the end, by using the TSE75B twin-screw screw machine, the company successfully launched sports shoe soles with excellent comfort and durability, which won wide appraisal in the market. This case not only demonstrates the technical advantages of the TSE75B machine, but also proves its strong applicability in the field of elastomer materials.

A major automotive parts supplier wanted to develop TPU materials for automotive interior components with the goal of lightweighting, high abrasion resistance and impact resistance. Faced with the challenge of improving material production efficiency and ensuring consistent product quality, the company introduced a solution combining a water drawbar phase cooling system with a twin-screw machine.   The company adopted our twin-screw extruder because our twin-screw fast-screw machine has an advanced common screw design, which is capable of efficiently mixing TPU raw materials at high temperatures and ensuring their uniform plasticization. Immediately after screwing, the material enters the water slat cooling system, which guides the cooling of the TPU strips to a cured state. The precise control and high-speed cooling of the water slider system ensures the stability and smoothness of the strips and effectively avoids quality problems caused by temperature fluctuations.   After the project was put into operation, the production line ran smoothly, the production efficiency of TPU strips was significantly improved, and the dimensional accuracy and consistency of the finished products were greatly improved. In the end, the enterprise successfully launched TPU automotive parts with excellent abrasion resistance, elasticity and impact resistance, which met the strict quality standards of automobile manufacturers, while reviewing the production cycle and reducing production costs.   The excellent performance of the water drawbar cooling system and the twin-screw screw machine in the production of TPU materials has been fully demonstrated, which has won the company greater competition in the market of high-performance elastomer materials.