Single screw extruders

Single screw extrusion is a process used to shape a plastic product until the desired form is obtained. This process uses a screw inside a barrel to continuously push the plastic through a profile die. Single screw extruders are characterised by the type of screw: parallel, where the diameter remains unchanged along the entire screw length, and variable diameter, where the diameter increases proportionally along the screw length until it reaches its maximum width at the end facing the die.

The screw is a fundamental component of the plastic extrusion line. The screw is set in a heating barrel and the plastic raw material through the screw is conveyed, melted, and finally forced through a die head in a formed shape.

Screw extruders, as used in the polymer processing and food industries, are used to form raw materials in a desired shape or profile through a die head. Possible shapes to be extruded are pipes, pellets, window & doors profiles and pet food.

In a twin screw extruder, the material is transferred by forward movement, whose level depends on the proximity between the two screws, while in a single screw extruder the material is generally dragged along the process line. Beyond the number of screws, the difference lies in the fact that twin screw extruders offer a wider range of functions in terms of raw materials and operating conditions. Twin screw extruders also provide better mixing capacity, which supports the processing of more complex materials.

Single screw extruders are more ideal in extruding more common and simple materials. Single screws are also less expensive and require less energy throughout the process compared to twin-screw extruders. Single screw is the better choice when the material doesn’t need much mixing.

Bausano offers the E-GO Series, with a wide range of screw diameters and L/D ratios optimised for all application needs in the profiles and pipes sectors. Each model can be customised with screws designed for the most demanding polymers and with modular accessories for high performance extrusion lines. The E-GO version is also available for coextrusion, always ensuring maximum precision and operational continuity.

E-GO technology transforms thermoplastic material through a high precision screw, which plasticises, homogenises and conveys the polymer under constant digital control. The molten material is pushed through the extrusion head, which defines the geometry of profiles and pipes with absolute precision, ensuring quality and repeatability for every production batch.

E-GO extruders are designed for maximum compatibility with rigid and plasticised PVC, HDPE, LDPE, PP, ABS, PC, PMMA, TPE, filled materials, recycled materials and special blends. Bausano screw customisation makes it possible to process even the most innovative formulations, while maintaining quality and efficiency.

E-GO extruders are the benchmark choice for the production of pipes for water, gas, electrical cables and irrigation systems, as well as technical profiles for windows, ducts, skirting boards, roller shutters, automotive and furniture components. The Bausano modular approach covers every market need, from technical products to the infrastructure sector.

E-GO single screw extruders stand out for simple use, reduced management costs and very high energy efficiency, thanks to proprietary induction heating with consumption reduced by up to 35%. Bausano solutions overcome the traditional limits of single screw technology, ensuring homogeneous mixing, production continuity and adaptability even to more complex materials. E-GO reliability and customisation provide a real competitive advantage, without compromising performance.

An E-GO includes screw and barrel in treated steel for wear and corrosion resistance; induction heating system or ceramic band heating system; high efficiency motor; precision gearbox; forced or gravimetric feeding; advanced digital control for temperature, pressure, torque and absorption; custom extrusion head; optimised cooling unit. All elements are designed and produced in house according to Bausano standards.

Multizone temperature control enables precise management of polymer melting and homogenisation, eliminating the risk of degradation or surface defects. Bausano digital adjustment ensures an immediate response to production variations, reducing waste and optimising final quality.

The screw, designed through flow simulations and material analysis, is the key element that enables perfect melting and mixing, constant conveying and maximum output. Bausano screws are optimised to minimise wear and consumption and to maximise stability and productivity, even with compounds and recycled materials.

E-GO technology is used in construction, infrastructure, furniture, automotive, medical and packaging sectors. Its ability to process advanced and recycled polymers responds effectively to the needs of ecological transition and circular production.

Selection is based on material type, required diameter and thickness, desired productivity and automation level. Bausano provides complete technical support, configuring each line according to production objectives and always ensuring the most efficient and sustainable solution

 PVC, HDPE, LDPE, PP, ABS, PMMA, PC, TPE, filled and recycled compounds, polymer blends and specific materials for multilayer pipes and technical profiles. Each extruder can be configured around each formulation.

Instability, surface defects or quality drops are solved through digital control, optimised screws and intelligent parameter monitoring. Automatic response to anomalies reduces waste and machine downtime, ensuring continuity and maximum quality, even during material and format changes.

E-GO integrates energy saving induction heating, advanced digital control, custom screw design through rheological analysis and automation compatible with Industry 5.0 principles. Integration with SPHERA and IoT systems enables real time monitoring and continuous optimisation, supporting sustainability and industrial competitiveness.

Bausano provides a routine maintenance plan that includes screw and barrel inspection, control of heating and cooling zones and inspection of the extrusion head. Bausano technical service offers training, spare parts and software updates, minimising downtime and maintaining constant performance over time.

The price of a Bausano E-GO single screw extruder for pipes and profiles is determined by several technical and production factors, always assessed according to the customer’s specific needs and required applications. The main factors include the starting material, which may be virgin granules, recycled material, compound or blend, the expected hourly output, screw diameter, L/D ratio and technical line configuration, such as the presence of degassing systems, advanced automation or forced feeding. The type of final product, the required precision level and the choice of dosing systems, whether gravimetric, volumetric or customised, also influence the overall value of the system. Downstream equipment such as cooling benches, cutters, stackers or calibration systems also contributes to defining the final cost. In general, the price of a Bausano E-GO single screw extruder for pipes or profiles may range from around 80,000 euros for compact and standard configurations to over 300,000 euros for complete, highly customised lines intended for specialist or high productivity production. Each project is always developed on a custom basis by the Bausano team, which analyses production needs and proposes the most suitable technical and economic solution to maximise investment value.

Because E-GO combines energy efficiency, extreme customisation, continuous innovation, direct technical support and Made in Italy construction quality. Bausano solutions ensure stable, sustainable and competitive production, ready for the challenges of the most advanced markets and clearly distinct from traditional alternatives.