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In plastic extrusion field, Tandem Extruder and Cascade Extruder refers to the same extrusion machines, also called two-stage extruders which is the more common term people tend to use.
(The Granuwel twin-stage extruder consists of a GTE high-speed co-rotating twin-screw mixer and a GDS series low-speed single-screw extruder.
The GTE twin-screw provides excellent distribution and dispersion mixing capabilities, thoroughly combining raw materials and achieving precise temperature control. The GDS single-screw offers stable high-pressure extrusion at low temperatures. These two components are arranged vertically and orthogonally to work together, achieving efficient plasticization and uniform mixing while avoiding the problem of overheating degradation. Such an extrusion production line enables the implementation of relatively complex processing techniques. )
Due to their excellent dispersion, shearing, mixing, plasticization, and compounding capabilities, tandem extruders are widely used in industries such as plastics, rubber, cables, pipes, and hose manufacturing.
In tandem extrusion processes, the combination use of twin-screw extruders and single-screw extruders is very common, as this way leverages their respective advantages. Specifically, twin screw extruders can thorough lt melt and mix materials while single-screw performs well in homogenizing and stabilizing extrusion. This combination increase the product quality and output while saving cost to a certain extent.
To choose suitable tandem extruders/cascade extruders, some factors like production needs, product quality, extruder performance and cost effectiveness must be taken into consideration.
Granuwel Two Stage Extruder Machine
Types and Applications of Two Stage Extruders
- Mixing and Granulating: The first stage is a twin-screw extruder, and the second stage is a single-screw extruder. This configuration is mainly used for granulating materials such as PVC, XLPE, halogen-free flame-retardant cable compounds, shielding materials, and high-concentration black masterbatches.
- One-Step Mixing and Extrusion: The first stage is a twin-screw extruder, and the second stage is a single-screw extruder. This setup is primarily used for wood-plastic composite profiles, plastic sheets, and other similar applications. In these cases, the single-screw extruder has a longer length-to-diameter ratio and a larger motor.
- Two Stage–Twin-Screw Mixing: Both the first and second stages are twin-screw extruders. This configuration is mainly used for devolatilization of polymers and post-dehydration treatment of rubber. The characteristics of this equipment include an ultra-long length-to-diameter ratio (exceeding 68:1) and a large exhaust barrel opening.
Clear Your Production Needs
First, you have to specify the type of materials and product specifications and out, because different products may require different types of extruders, such as corotating twin screw extruders, counter-rotating twin screw extruders, or single screw extruders with screws of different L/D ratios.
Choose Suitable Extruder Types and Configuration
For different materials, you need to select different types of extruders. It can be difficult if you are new to the extrusion field, but you can consult some extruder and solution suppliers like us, Granuwel. Professional extrusion machine experts like us usually have extensive experience in helping customers with demanding extrusion processes by recommending the best suitable extruders, screw designs, number of stages, power, material formulas, and solving some other problems that customers will encounter in production.
Budget and ROI
Balance your budget with the extruder’s features, durability, and long-term operational costs.
If you purchase your tandem extrusion machine from a reliable factory like Granuwel, you can save a lot. With a self-operate extrusion machine manufacturing factory, we, Granuwel, is able to offer an affordable price.
Advantages of Using Granuwel Tandem Extruders & Cascade Extruders
Improved Efficiency
The Granuwel tandem extruder, consisting of two or more extruder units connected in series, features a first-stage GTE high-speed, co-rotating twin-screw mixer and a second-stage GDS low-speed single-screw extruder. The twin-screw design ensures uniform mixing and plasticization of materials during processing. Meanwhile, the single-screw high-pressure extrusion operates at low speeds and low shear rates to avoid overheating issues. This configuration allows for continuous processing with minimal downtime, thereby enhancing overall production efficiency. The first extruder can perform primary functions such as mixing, while the second can handle more complex tasks like devolatilization or compounding.
Better Control of Process Parameters
The sequential nature of Granuwel cascade extruders provides better temperature, pressure, and screw speed control. With this precise control Granuwel cascade extruders is capable of processing sensitive materials and achieving high-quality products.
Flexibility in Material Processing
Granuwel two stage extruders can handle a wide range of materials, including thermoplastics, rubber, and composite materials. The system’s flexibility allows for the mixing and melting of different polymers or additives, facilitating the production of complex formulations.
Enhanced Product Quality
With the ability to process materials in stages, Granuwel two stage extruders can achieve better mixing, uniformity, and dispersion of additives. This results in a more consistent product with improved properties like better tensile strength, elasticity, and durability.
Energy Efficiency:
By optimizing material flow and reducing the number of extruder stages required, Granuwel two stage extruder soften consume less energy compared to single-screw systems. This energy efficiency leads to cost savings and a lower environmental footprint.
Devolatilization Capabilities:
The design of Granuwel casade extruders allows for the efficient removal of volatile substances from materials, such as moisture, solvents, or other impurities. This is particularly useful in industries like food processing, pharmaceuticals, and plastics.
Higher Throughput:
Because tandem extruders can handle larger volumes of material in a shorter period, they are ideal for high-throughput production environments. This makes them suitable for large-scale operations, where high production rates are required.
Lower Maintenance and Operating Costs:
While Granuwel cascade extruders may have higher initial investment costs, their ability to produce high-quality products with fewer interruptions can lead to lower long-term maintenance and operating costs. The reduced wear and tear on components due to better material flow can also extend the lifespan of the equipment.
Space Savings:
Granuwel tandem extruders can combine multiple processing stages into a single machine configuration, reducing the need for separate pieces of equipment. This helps save valuable floor space in manufacturing facilities.
In summary, tandem extruders offer enhanced efficiency, flexibility, and control over material processing, making them ideal for applications that require high-quality, large-volume production with reduced energy consumption and operational costs.
Feel free to contact Granuwel if you intend to purchase high qualityTandem Extruders, Cascade Extruders and Two Stage Extruders.