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

Overview A global automotive parts supplier successfully improved the mechanical properties and dimensional stability of its parts by compounding nylon (PA66) with glass fibers using a twin-screw extruder. This case highlights the process, challenges, and benefits of glass-reinforced nylon production. Background The customer, a Tier 1 supplier to the automotive industry, was looking for a high-strength material for under-the-hood parts that could withstand high temperatures, mechanical stress, and chemical corrosion. Unfilled nylon lacked the required rigidity, while pre-mixes were costly and lacked flexibility for product-specific adjustments. Solution The company invested in a high-torque twin-screw extruder with a customized screw configuration optimized for fiber dispersion and melt uniformity at Henglan Machinery Technology Co., Ltd. (the Company) in Nanjing, China. Nylon 66 base resin is fed into the main hopper, while chopped glass fibers (30% by weight) are fed from the downstream side feed port to prevent fiber breakage. The extruder is equipped with a vacuum degassing system to remove moisture and volatiles, ensuring a stable and high-quality melt. Processing temperature was tightly controlled within the range of 270-290°C. Challenges Fiber breakage: Minimizing the shortening of glass fiber length during compounding is critical to maintaining mechanical strength. Moisture sensitivity: Nylon is extremely hygroscopic. Pre-drying and degassing during processing are critical to prevent hydrolysis and voids. Homogenous dispersion: Achieving uniform fiber distribution without agglomeration is critical for mechanical properties and surface quality. Results Mechanical properties: PA66 + 30% GF composites have tensile strengths exceeding 150 MPa and excellent dimensional stability. Production efficiency: In-house compounding reduces raw material costs by 20% compared to purchasing pre-compounded materials. Customization flexibility: Manufacturers can now fine-tune glass fiber content, additives (such as flame retardants or impact modifiers), and color to customer specifications. Conclusions This project demonstrates the value of in-house nylon + glass fiber compounding using a twin-screw extruder. It enables automotive suppliers to improve part performance, reduce material costs, and gain greater flexibility in product development.    

Overview A leading PET bottle manufacturer in Southeast Asia successfully upgraded its production line by integrating masterbatch coloring technology, enhancing product quality and achieving greater color consistency. This case study explores the implementation process, challenges faced, and the benefits gained from this technological advancement. Background The company specializes in producing PET bottles for the beverage industry, supplying to major brands across the region. With increasing demand for vibrant and uniform bottle colors, the manufacturer sought to improve its traditional coloring methods, which often led to color inconsistency and high wastage rates. Solution Implementation After evaluating various options, the company opted for masterbatch coloring during the extrusion process. Using a twin-screw extruder, PET resin was mixed with color masterbatch directly during melt processing. This method ensured even dispersion of pigments, resulting in consistent color throughout the material. The twin-screw extruder’s high shear and mixing capabilities were crucial in achieving this uniformity. Additionally, the extruder allowed precise control over the pigment load, minimizing material waste and reducing production costs. Challenges and Solutions One of the initial challenges was optimizing the masterbatch ratio for different color intensities. Through multiple test runs and adjustments to the extrusion parameters, the ideal mixture was established, ensuring vibrant colors without affecting the PET’s mechanical properties. Furthermore, staff training was conducted to familiarize the production team with the new process, enhancing efficiency and reducing errors during color changes. Results and Benefits Improved Color Consistency: Masterbatch coloring significantly enhanced color uniformity across all PET bottles. Reduced Waste: The precise control of pigment dispersion minimized material wastage, cutting costs by 12%. Enhanced Production Efficiency: Faster color transitions and reduced downtime boosted overall productivity. Sustainability: The process also supported the company's sustainability goals by reducing pigment waste. Conclusion The integration of masterbatch coloring with twin-screw extrusion proved to be a game-changer for the manufacturer. It not only elevated the quality of PET bottles but also contributed to cost savings and environmental sustainability. This case study demonstrates the value of technological upgrades in modern plastic manufacturing.  

Customer BackgroundA leading automotive parts manufacturer required production of high-strength, heat-resistant dashboard brackets. Existing production lines faced high energy consumption (28% electricity cost) and material dispersion issues (89% yield rate). Innovative Solutions1️⃣ Specialized Alloy Processing: Custom 38:1 L/D two-stage twin-screw extruder with ±1°C temperature control enabled stable blending of ABS/PC alloy (60:40 ratio), achieving melt flow index deviation

An auto parts manufacturer needs to produce nylon (PA6) fuel pipes with high temperature resistance and high dimensional stability, requiring the wall thickness error of the extruded finished product to be ≤0.1mm and the long-term temperature resistance to be ≥130℃. With the trend of lightweight automobiles, the demand for the application of PA6 materials in fuel systems has increased sharply, but traditional extruders have problems such as large temperature fluctuations and uneven plasticization. Solution:Use our TSE-95B twin-screw extruder, configured with:1. Intelligent zoned temperature control system8-stage independent temperature control module, real-time adjustment of the temperature of each section of the screw (±1℃ accuracy), solve the problem of thermal degradation during high-temperature processing of PA6, and improve the stability of the material melt flow index (MFI) by 30%.2. Dual-channel barrier screwSpecially designed mixing section and exhaust section improve the dispersion of PA6 and glass fiber reinforcement (when the glass fiber content is 30%, the dispersion uniformity is >95%), and the finished product tensile strength reaches 180MPa.3. Energy consumption optimization moduleIntegrated servo drive system, energy saving 22% compared with traditional extruders, electricity cost reduced by 15 yuan/hour during continuous production. Project results:Successful mass production of PA6 fuel pipe, wall thickness error controlled within ±0.08mm, temperature resistance up to 135℃ (ASTM D638 standard);Customer production line efficiency increased by 40%, annual production capacity exceeded 2 million meters;The case was certified as a Tier 1 supplier in the automotive industry and has been mass-produced with new energy vehicles.

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.