Plastic Compounding

Plastic Compounding process

Plastic compounding is a process of melt blending plastics with other additives. Many additives can be used during the extrusion process to enhance processing characteristics of the polymer or to alter product properties. Such additives include lubricants, thermal stabilizers, antioxidants, radiopacifying agents, and colorants. The final product is called a compound or composite. During the compounding process heat is important as well the mixing capabilities, for this reason co-extruders or Twin-Screw Extruders are the most suitable in plastic compounding. Compounding is also used in the recycling process using scrap feedstock material that can be added into the process of compounding for compounding and regranulation purposes of recovered plastic materials.

The basic steps in compounding extrusion process are:

Recipe determination, ratio of additives and polymer to be mixed
Mixing and Melt mixing
Extrusion and Cooling
Pelletizing

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Bausano Compounding Lines

Bausano Extruders for compounding, or pelletizing, are an important part of polymer processing. It is a complex processing method for obtaining materials with specific properties (including melt index, oxidation induction time and mechanical properties) during processing.
Compounding is the best method for modifying the characteristics of engineered thermoplastics. With the help of a Bausano machine for plastics melting, it is possible to change the characteristics, such as:

Physical
Electric
Thermal
Aesthetics

The properties of plastic pellets can be specifically influenced by adding functional fillers and additives. Stabilizers, for example, often make it possible to produce and process compounds in the extrusion step without harming the material. Reinforcing fibers provide the required mechanical properties of the component. Depending on the desired property profile, powders, granulates, fibers and low to high viscosity liquids or gases can be incorporated, even in supercritical condition. To choose the right fillers or additives many research tests are carried out from Bausano’s R&D department and technical department.

Plastics compounding involves an intricate process with multiple stages. These may include determining additives ratio, high-speed mixing via a Bausano twin-screw extruder, melt mixing, and cooling, all before final pellet cutting and packaging. Generally, a range of different materials can be used, especially with Bausano Extruders. Most common materials include:

Polypropylene
Polypropylene
Polyvinyl chloride
Polystyrene
Expanded polystyrene
Polyethylene terephthalate
Polyurethane
Acrylonitrile butadiene styrene (ABS)
Nylon

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Pelletizing Process

Through Bausano pelletizing processes, a base resin is converted into a desired plastic form with properties that make it more effective, efficient, and uniform. The introduction of additives and agents as well as other products, including anti-abrasion additives, can enhance the product of the finished resin.

The pelletized material is then processed into a plastic part, through processes including molding or extrusion. Typically, compounding is done on twin-screw extruders, like Bausano MD Twin screw Extruders.

This can be a co-rotating or counter-rotating design. Other options include single-screw extruders, kneaders, and mixers.
The hopper will transport the material to the mold. The screw itself is confined to a barrel which has different zones that can be heated depending on the properties of the resins.

Finally, the Bausano granulation head breaks the threads into the desired pellet size.

There is a diverse range of products available, depending on the additives and fillers integrated while processing the polymers.
There are several criteria to consider in reference to each type of raw material and the right Partner for understanding the criteria of the different pellet raw material processing is Bausano

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