Parallel vs. Conical Extruders for PVC

Double screw extruders used for PVC pipe extrusion are available in both parallel and conical screw designs. While conical machines historically offered mechanical advantages, parallel extruders are increasingly preferred, particularly for larger sizes, especially in pvc extrusion line setups and plastic pipe machine operations.

Design and Processing Implications

The distinction between parallel and conical designs has significant implications for screw design, gearbox technology, and processing capabilities, affecting not only screw plastic extruder performance but also the quality of extruded tubing and extrusion plastic tubing.

• Parallel Extruders: For bigger extruders, parallel designs are favoured because they offer greater freedom in screw design for optimal processing. Advances in FEM calculation techniques have improved parallel gearbox designs, allowing for equal torque flexibility and achieving high reliability and long lifetime. Parallel extruders can also be more easily extended (e.g., from 22D to 33-36D) by stretching the pitches of the C-ring chambers to increase output while maintaining similar processing conditions. This flexibility is beneficial in tubing extrusion and pipe forming process applications.
• Conical Extruders: Conical machines were historically easier to design mechanically due to more space for gears and bearings. However, they are often designed primarily for mechanical reasons, which can limit processing priorities. Optimal processing, especially at higher outputs, is limited by the shorter available screw length for generating pressure in the metering zone and mixing near the screw tip. Conical machines cannot easily be made longer to increase output; their diameter needs to increase instead.

Processing Window

The processing window for conical machines can be relatively narrow, particularly when aiming for a well-gelled melt that passes tests like the DMC test. Achieving sufficient gelation for the DMC test might lead to over-fusion in the vent zone, causing air inclusions. Consequently, the melt might be processed less gelled at the vent to ensure air extraction, resulting in a melt that is borderline for the DMC test but easily passes the ASTM acetone test. Parallel designs can offer a wider processing window, which is crucial for producing co-extruded pipe and maintaining quality in the plastic sheet extruder or other extrusion setups.

Technical Specifications (Design Considerations)

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