Presentation on

Neoplast’s
NCMT Series Twin Screw Extruders &

Downstream Equipments
 Introduction
• Due to its excellent material characteristics
and its outstanding price / performance ratio, until today
PVC is the most used material worldwide for pipes or
profiles made from plastics.
• As the market is very competitive manufacturers of
RPVC/UPVC pipes or profiles have been exposed to
increasing pressure on prices and costs for years.
• At the same time higher and higher demands are made on
the product quality.

So, lets have a look at HOW Neoplast’s Conical

Twin Screw Extruders are helpful in producing
better quality PVC Pipes or Profiles !!!
Design of Conical Twin Screws

1. Feed Zone
2. Plasticizing Zone
3. Compression Zone
4. Vent Zone
5. Metering Zone
 Importance of Each Zone

• Feed Zone:
Feeding and pre-heating of the material.

• Plasticizing zone:
Heating and agglomeration.

• Compression Zone:
Sealing-off of vent zone in support of the
plasticizing process.
 Importance of Each Zone

• Vent zone:
Degassing & venting of the melt.

• Metering Zone
Completion of melting, homogenizing &
outputting of melt.
Advantages of Conical Screws
• Larger L/D Ratio:
From the illustration, it is easily understood that the
45/97mm conical screw, for example, discharges like a
parallel 45mm, feeds like a parallel 97mm & matches the
gearing of a parallel 110.
 In other words,

•A Conical 45mm extruder can match the output of

a 65 mm parallel model, the intake section has the
surface area and gentle plasticizing of a 100 mm
parallel, while only the metering section has the
excess friction and shear of a 45 mm parallel.
•The small screw front face results in a low axial
force on the screws.
•The wide screw shaft center distance at the rear -
allows space for large thrust bearings and a simple,
sturdy, distribution gearbox.
Gentle & Efficient Plastification
•The screw surface area in the
feed zone is considerably larger
than that of the parallel screw
offering a same output.
F=1250 cm2
•As a result, transmission of
heat energy and the plastification
in the feed zone is much more
efficient.
•Moreover due to larger feed
F=490 cm2 zone, plastification work is
spread out over a larger section
of the screw.
Comparison of the meshing

Surface Area

From above graph, if is evident that –

the meshing surface area is higher for conical twin
screws compare to the same diameter parallel twin
screws hence homogeneous and better melt quality.
Optimized Screw Geometry
• Digressive Pitch in the feed &
Compression Zone ensures the
continuity of compression.
• Hence in Conical Twin Screw
extruder, there is no pressure peaks,
which is in favour of a prolong life
of the Gear box.
• In the metering section, the meshing
surface area of the conical screws is
less than that of parallel screws,
giving lower shear energy input, and
in addition, the shear rate is further
reduced because of the conical screw
design.
Continuity of Compression

From the graph, it can

be derived that by
using conical twin
screws, compression
continuity can be
maintained throughout
the length of the screw
and hence better
quality of the end
product.
 Life of Gears
•The pinion gears of conical
twin screws last much longer than
those of parallel twin screws.
•The reason is – the center
distance is much larger, the gear
pinions are much larger in
diameter.
•The life of gear pinions increases
with approximately the cube of
the diameter ; which enhance
reliability.
 Exceptional Pressure Build-up

& Thrust absorbing Capability

• The metering zone of NCMT series extruder is
designed for the most efficient pressure build-up.
• In comparison with other designs, the energy
input required for pressure build-up is lower by
about one third so that the danger of overheating
is reduced dramatically.
• The axial forces arising are easily absorbed by
heavy-duty thrust bearings.
Higher Output with less stress
on the material :
• The relative small diameter of the conical screw in
the discharge zone keeps friction to a minimum and
hence conical twin screw are claimed as the ideal
choice for the sensitive materials like C-PVC.
• In India, the biggest & pioneer manufacturer of the
C-PVC pipes, M/s. Astral Polytechnik, is using only
Conical twin screw extruder and still adding on
more machines of NCMT series conical twin screw
extruders – An ample proof of absolute customer
satisfaction.
 Specific Throughput :

• A high specific output means a high material

throughput at low screw RPM means low
Power consumption.
• Moreover, low screw speeds required to
achieve specific output results in low shear
stresses, gentle plasticizing and low screw
wear.
 Ease of maintenance
• The conical twin screws are
taken out from the backward
direction. The barrel is simply
moved to the side.
• When active screw core
thermoregulation is used, the
coupling elements for the heat
transfer oil lines remain
attached to the screw tappets
& oil spillages cannot occur.
• Higher productivity – by time
saving.
 The Cincinnati Advantage
The new NCMT series of
Conical Twin Screw Extruders introduced by Neoplast
is the FIFTH Conical machine generation developed
under technical collaboration with M/s.
Cincinnati Extrusion, who have an experience of
designing more than 6000 PVC Processing Extruders.
Our customers benefit from
this experience by way of
enormous processing
latitude, extreme life & the
most favourable
price/performance ratio.
 The Cincinnati Advantage
& Neoplast’s Promise

• NCMT series extruders are designed to ensure a

higher return on your investment, i.e.
Outstanding cost-effectiveness
Higher output &
Excellent product quality.
• Neoplast offers Conical Twin Screw Extruders for
RPVC pipes, CPVC Pipes, SWR Pipes, Engineering
Profiles, Furniture Profiles & Building sections…
 Twin Screw Extruder with
Conical Twin Screws

The conical idea -

Brilliant when it was born,
and still brilliant today…

So, Lets have a look at the key features

of NCMT series Extruders…….
 Material feed
• Hopper Feeding
For easy flowing dry-blends with
constant quality & apparent
density, a sliding hopper is used
which allows for three positions
Production, Shut-off &
Emptying
•Metering Unit
Metering units enable accurate adjustment of the
screw filling factor and plasticizing capacity. They are
ideal for materials with the possibility of density
variations & particularly suitable for the processing of
regrind and pellets.
Threaded Barrel for easy
mounting of tool
The barrel is made
from Imported Nitro
Alloy steel with
hardness of 50 HRc,
which in turn undergo
Two-Stage Gas
Nitriding to achieve
Final Hardness of 70
HRc.
Barrel
Heating Cooling • The design of the barrel
system heating and cooling elements
(air power cooling), and
optimal locations for the
barrel thermocouples, ensure
accurate temperature control.
• The large surface area
cooling elements combine
the advantages of high
efficiency and minimal
maintenance.
 Screw and Barrel Life
• With a novel surface coating
technique, Neoplast is offering
extruders with exceptional
lifetimes.
• The wearing layer achieved with
this technique is denser, more
compact and less brittle than
conventional coatings applied
with customary methods.
• We guarantee for extreme
abrasion resistance.
Venting Unit
The venting port on the
barrel is coupled to
specially designed
efficient venting pump for
effective removal of air
and gases generated
during the plastification
process
 Internal Screw Core
Thermoregulation – Cimitherm
•This system is based on the heat pipe principle. Heat is
transferred back from the hot screw tip to the cold feed
zone, resulting in considerable energy savings.
•Cimitherm is a self-regulating system which adjusts to
changing heat transfer requirements & doesn’t require any
kind of adjustment.
 Top - Performance
Control Panel

• It contains the complete sequencing logic, dual

display PID temperature controllers for all extruder
and die zones, and provides for interfaces with
upstream and downstream equipments used in
extrusion.
• To guarantee optimal ease of operating, all set-point
and actual values along the extrusion line can be
processed, visualized and evaluated at a central
location.
Down Stream Equipments
For Pipe / Profile Extrusion /
Palletizing
 Die Head
Optimized for PVC formulations of tomorrow….
• Production flexibility by a modular
system of basic heads, adapters and die
sets
• Large head volume for a smooth inner
surface of the pipe / profile
• High compression ratio to prevent spider
lines & streamlined spider legs
• Automatic thermal centering for very
tight wall thickness tolerances
• Corrosion-resistant hard chrome plated
 Vacuum Sizing Tank
For Pipe Extrusion
• Various models to suit outputs from 50 to 500 kg/hr.
• Vacuum calibration chamber length 3 to 6 meter, fully or
partially under vacuum as per requirement.
• Individual headers for water & vacuum connections
• Uniform water spray with specially designed nozzles and
inline water filters.
• Single or dual strand.
• After spray cooling,
back or front seal
supporting disk, guide
rollers
can be provided.
 Vacuum Calibration Table
For Profile Extrusion
• Various models to suit various profile shapes or number
of calibrators requirements or output from 50 to 500
kg/hr.
• External tank for water drainage
• Individual headers for water & vacuum
connections
• All water wetted contact parts – SS 304
• Single or dual strand.
• Vacuum pump with
higher vacuum
efficiency
 Haul Off
• Various models to suit various pipe or
profile size or shapes with different
throughput capacity.
• Precision clamping for to avoid distortion
of product, slip less pulling of extrudate,
stronger driving mechanism, step less
or synchronized adjustable speed
• Two belts, three belts or multi belts
• Depends on product size, shape
or output; belts or chains with
customized pad shape
 Cutting Saw
• Various models to suit various pipe or profile size or
shapes with different throughput capacity.
• Different cutting system available like chopping cutter,
saw cutter, Planetary saw cutter with optional
chamfering provision.
• Specially designed cutter
for profile cutting
• All cutters are with safety
guards
• Optional saw dust
collection unit
For Pelletizing Applications
Pelletizing Head
• Suitable for soft & rigid PVC
formulations
• Die mountings available for
single or twin screw extruders
& suitable to output ranges
from 40 kg/hr to 800 kg/hr.
• Auto adjustable Spring
loaded cutter blade
• Adjustable air cooling
through efficient blower
• Guaranteed uniform
pellet size
 Pellet Cooler

• Suitable to cool soft &

Rigid PVC pellets
• Adjustable vibration, easy
cleaning & low noise
• Dust separator for dust
free pellets
• Completely cooled pellets
with reverse air cooling
• Compact, space saving &
versatile system
Applications