EXTRUTEX EXCT-65 Co-Rotating Twin-Screw Extruder

65 mm Modular Co-Rotating Twin-Screw Extruder with Clamshell Barrel

The EXTRUTEX EXCT-65 is a modular co-rotating twin-screw extruder designed for continuous polymer compounding, intensive mixing, dispersion, homogenization, masterbatch production, recycling and a wide range of thermoplastic processing applications.

With a 65 mm screw diameter, the EXCT-65 provides a substantial processing platform for manufacturers requiring higher production capacity while maintaining the flexibility of a modular twin-screw system.

The machine combines a co-rotating twin-screw configuration, modular barrel sections, configurable screw and kneading elements, independently controlled temperature zones and a practical clamshell barrel design.

The clamshell barrel allows rapid access to the screws and internal processing chamber, making cleaning, inspection, maintenance, screw-element changes and product changeover considerably more convenient.

With a nominal production range of approximately 150–300 kg/h, the EXCT-65 is suitable for pilot-to-industrial production, specialized compounding and continuous manufacturing applications.

EXCT-65 Technical Specifications

Actual output depends on polymer type, formulation, screw configuration, feeding system, screw speed, temperature profile, residence time and downstream pressure.

65 mm Co-Rotating Twin-Screw Processing Platform

The 65 mm screw diameter provides the EXCT-65 with a larger processing volume and higher throughput capability compared with the smaller EXCT models.

The co-rotating twin-screw system allows the machine to combine several processing functions within one continuous extrusion process.

The screws can be configured using different conveying, kneading and mixing elements to establish the desired processing profile.

Depending on the application, the EXCT-65 can provide zones for:

• Feeding

• Conveying

• Melting

• Plasticization

• Kneading

• Distributive mixing

• Dispersive mixing

• Filler incorporation

• Additive dispersion

• Homogenization

• Degassing

• Devolatilization

• Pressure building

• Melt filtration

• Discharge

The modular architecture allows the processing configuration to be developed around the material rather than using one fixed screw arrangement for every formulation.

150–300 kg/h Production Capacity

The EXCT-65 is designed for an approximate production range of 150–300 kg/h.

This capacity makes the machine suitable for larger pilot operations, specialized industrial production and continuous polymer compounding.

The actual production rate depends on the characteristics of the processed material and the selected process configuration.

Important factors include:

• Polymer type

• Bulk density

• Melt viscosity

• Filler concentration

• Additive loading

• Moisture content

• Screw configuration

• Screw speed

• Feeding accuracy

• Barrel temperature

• Residence time

• Required mixing intensity

• Discharge pressure

• Filtration system

For this reason, the final EXCT-65 configuration should be selected according to the specific formulation and production objective.

300–500 RPM Screw Speed

The EXCT-65 provides a screw-speed range of approximately 300–500 rpm.

The operating speed can be adjusted according to the required combination of throughput, mixing intensity, residence time and mechanical energy.

Different materials respond differently to screw speed.

For applications requiring intensive dispersion, higher screw speeds may be appropriate when permitted by the material and process conditions.

For formulations requiring gentler processing or longer residence time, lower operating speeds may be selected.

The modular screw configuration allows screw speed and element arrangement to be optimized together.

28–48 L/D Processing Length

The EXCT-65 is available with 28–48 L/D configurations.

The available processing length provides flexibility for both relatively simple and more complex formulations.

A shorter configuration can be used for applications involving basic conveying, melting and mixing.

Longer configurations provide additional processing space for applications requiring multiple sequential stages.

A typical extended process may be arranged as:

Metering → Feeding → Conveying → Melting → Kneading → Dispersion → Homogenization → Degassing → Pressure Building → Filtration → Discharge

The exact configuration can be adapted according to the material and final product requirements.

Clamshell Barrel Design

The clamshell barrel provides one of the major operational advantages of the EXCT-65.

The hinged barrel can be opened to provide direct access to the twin screws and internal processing sections.

This makes a number of routine operations easier and faster:

• Product changeover

• Screw inspection

• Cleaning

• Removal of residual polymer

• Screw-element replacement

• Preventive maintenance

• Troubleshooting

• Process development

• Inspection of kneading elements

For plants producing multiple compounds, easy access to the processing chamber can help simplify changeover procedures.

The same feature is particularly valuable for R&D and process optimization because engineers can inspect and modify the screw configuration without extensive machine disassembly.

Modular Barrel Construction

The EXCT-65 uses a modular barrel concept in which individual barrel sections can be configured according to their position and function in the extrusion process.

Different barrel sections can be dedicated to specific operations.

Possible processing sections include:

Feeding Zone

Introduces and transports the raw materials into the main processing area.

Melting Zone

Provides the thermal and mechanical conditions required for polymer plasticization.

Mixing Zone

Provides distributive and dispersive mixing of polymer components, fillers and additives.

Kneading Zone

Provides additional mechanical energy where intensive mixing or dispersion is required.

Side-Feeding Zone

Can be used for introducing additional fillers, fibers or additives downstream of the primary melting zone where appropriate.

Degassing Zone

Provides a dedicated area for removing moisture, air and volatile components.

Homogenization Zone

Stabilizes the melt before the final pressure-building section.

Pressure-Building Zone

Generates the pressure required for filtration and downstream equipment.

This modular structure allows the EXCT-65 to be adapted to different processing sequences.

Independent Barrel Temperature Control

The EXCT-65 can use independently controlled temperature zones along the barrel.

Each zone can be adjusted according to its specific processing function.

The temperature profile is important because polymer processing often involves several different thermal stages.

For example, the feeding area may require controlled temperatures to prevent premature melting, while the melting zone requires conditions suitable for plasticization.

Mixing zones may require carefully controlled melt temperatures to achieve the desired viscosity and dispersion.

The downstream sections can then be optimized for degassing, homogenization and pressure stabilization.

Electrical heating and controlled cooling can be provided for the individual barrel zones according to the machine configuration.

Modular Screw and Kneading System

The EXCT-65 uses a configurable screw system that allows different screw and kneading elements to be combined.

This enables engineers to establish specific processing zones within the same extruder.

Conveying Elements

Conveying elements transport materials through the barrel and control the movement of the material through each processing section.

Melting Elements

Melting sections provide controlled plasticization of the polymer before intensive mixing.

Kneading Elements

Kneading blocks increase mechanical interaction and can provide higher mixing intensity when required.

Mixing Elements

Mixing elements provide controlled distributive and dispersive mixing of polymer components.

Homogenizing Elements

Downstream elements can improve melt uniformity before discharge.

Degassing Elements

The screw configuration around a vacuum zone can support devolatilization and removal of volatile components.

Pressure-Building Elements

The final screw sections can generate the pressure required for filtration and discharge.

This modular screw architecture gives the EXCT-65 considerable flexibility for different formulations.

Complete Compounding Process

The EXCT-65 can be configured to perform the principal stages of a continuous compounding process.

1. Metering and Feeding

The process begins with controlled feeding of polymer and formulation components.

Depending on the formulation, the system can handle:

• Polymer pellets

• Powders

• Mineral fillers

• Pigments

• Additives

• Fibers

• Recycled materials

Multiple feeding points can be considered where additional materials need to be introduced downstream.

2. Conveying

The first screw sections transport the materials through the barrel.

The conveying configuration can be selected according to the required feed rate, filling level and residence time.

Stable conveying contributes to consistent processing conditions and formulation control.

3. Melting and Plasticization

The polymer is progressively converted from a solid material into a homogeneous melt.

Thermal energy from the barrel and mechanical energy generated by the screws work together to achieve controlled melting.

The melting configuration can be adjusted according to polymer type and formulation.

4. Dispersion and Mixing

Once the polymer is molten, intensive mixing sections can disperse fillers, pigments and additives throughout the polymer matrix.

Both distributive mixing and dispersive mixing can be incorporated into the screw configuration.

This makes the EXCT-65 suitable for formulations such as:

• Filled polymers

• Masterbatch

• Polymer blends

• Additive concentrates

• Reinforced compounds

• Mineral-filled materials

• Recycled compounds

5. Degassing and Devolatilization

Some materials contain moisture, trapped air or volatile components.

A dedicated degassing zone can be incorporated into the EXCT-65 configuration where required.

Vacuum-assisted devolatilization can help remove unwanted volatile components from the melt.

This can be particularly important when processing recycled polymers or moisture-sensitive materials.

6. Homogenization

Following intensive mixing and degassing, the melt can pass through a homogenization section.

The objective is to achieve a consistent and stable melt before the final discharge stage.

7. Melt Screening

When required, the EXCT-65 can be integrated with a melt-screening or filtration system.

This can help remove contaminants and unmelted particles before the melt enters the pelletizing or forming equipment.

For recycling applications, melt filtration can be an important part of the overall process.

8. Pelletizing or Semi-Finished Production

The homogenized melt can be transferred to an appropriate downstream system.

Depending on the final product, the EXCT-65 can be integrated with:

• Strand pelletizing systems

• Water-ring pelletizers

• Melt filtration systems

• Sheet dies

• Profile dies

• Customized extrusion equipment

The downstream configuration is selected according to the material and final product.

Applications of EXCT-65

The EXCT-65 is suitable for a broad range of thermoplastic processing applications.

Typical applications include:

• Polymer compounding

• Masterbatch production

• Color masterbatch

• Filler masterbatch

• Calcium carbonate compounds

• Mineral-filled compounds

• Polymer blending

• Additive dispersion

• Reinforced plastics

• Glass-fiber reinforced compounds

• Engineering plastics

• Recycled polymer compounds

• Recycling and re-compounding

• Specialty polymer formulations

• R&D and process development

• Pilot production

• Continuous industrial production

The final screw configuration and processing parameters should be selected according to the specific formulation.

Recycling and Re-Compounding

The EXCT-65 can also be configured for recycling and re-compounding applications.

Recycled polymers can contain moisture, contaminants, variable particle sizes and inconsistent material properties.

The modular processing system allows suitable stages to be incorporated for:

Feeding → Melting → Mixing → Degassing → Filtration → Homogenization → Pelletizing

A vacuum degassing zone can be used where required, while downstream melt filtration can help remove unwanted solid contaminants.

The appropriate configuration depends on the source and quality of the recycled material.

R&D and Industrial Production

The EXCT-65 provides a bridge between pilot-scale development and industrial production.

Its 150–300 kg/h capacity range provides sufficient production capability for commercial trials, specialty products and continuous manufacturing while retaining the flexible architecture associated with the EXTRUTEX modular twin-screw series.

Engineers can evaluate different:

• Screw configurations

• Screw speeds

• Feeding rates

• Temperature profiles

• Mixing intensities

• Residence times

• Degassing conditions

• Filtration systems

This allows the processing parameters to be established according to the formulation and production target.

Wear-Resistant Components

The internal components of the EXCT-65 can be selected according to the material and processing environment.

Standard screw, kneading and barrel components can use suitable nitrided steel materials.

For applications involving highly abrasive fillers or corrosive formulations, enhanced wear- and corrosion-resistant materials and surface treatments can be specified.

This is particularly relevant when processing:

• Calcium carbonate

• Glass fiber

• Mineral fillers

• Wood fiber

• Ceramic fillers

• High-filler compounds

• Recycled materials

The component material should be selected according to the actual formulation, operating conditions and expected service requirements.

Main Advantages of EXCT-65

65 mm Co-Rotating Twin Screw

Provides a larger processing platform for higher-capacity polymer compounding.

150–300 kg/h Capacity

Suitable for pilot, specialized and continuous industrial production.

300–500 rpm Screw Speed

Provides flexible control of mixing intensity and processing conditions.

28–48 L/D

Allows different processing lengths and multi-stage configurations.

55 / 75 kW Motor Options

Provides flexibility in selecting the drive configuration for the required process.

Clamshell Barrel

Fast and convenient access to screws and processing zones.

Modular Screw Configuration

Allows conveying, melting, kneading, mixing, dispersion, degassing and pressure-building sections to be configured according to the application.

Independent Temperature Zones

Provides separate thermal control of different barrel sections.

Flexible Processing Platform

Suitable for masterbatch, filled compounds, polymer blends, recycling, specialty compounds and other thermoplastic applications.

EXTRUTEX EXCT-65

The EXTRUTEX EXCT-65 is a 65 mm co-rotating twin-screw extruder developed for flexible, continuous polymer compounding and advanced thermoplastic processing.

With 300–500 rpm screw speed, 28–48 L/D configurations, 55/75 kW motor options and an approximate production capacity of 150–300 kg/h, the EXCT-65 provides a higher-capacity platform while maintaining the modularity and accessibility of the EXTRUTEX EXCT series.

Its modular screw and barrel system allows the complete processing sequence to be configured around the material, from feeding and conveying through melting, kneading, mixing, dispersion and homogenization to degassing, filtration and final discharge.

The clamshell barrel provides convenient access to the screws and processing chamber, supporting easier cleaning, maintenance, inspection and product changeover.

EXTRUTEX EXCT-65 — A modular 65 mm co-rotating twin-screw platform for controlled, flexible and high-capacity polymer compounding.