Key technological breakthroughs in recent years (mature engineering, suitable for external promotion)

1. Upgrading of screw mixing configuration (modular twin-screw/triple screw)

Modular twin-screw and three screw extrusion technology: segmented design of conveying section, melting section, dispersion/distribution mixing section, multi-stage vacuum exhaust section; **Controllable shearing * *, while dispersing aggregates, avoids excessive shearing that breaks the glass fiber/molecular chain.

Pin screw, barrier screw, achieve shear gradient control; Double stage mother machine (double stage extrusion), with the first stage of melt mixing and the second stage of low-temperature stable extrusion, shortens the residence time and reduces the risk of degradation. It is suitable for PLA, recycled materials, and thermal sensitive materials, and the temperature can be reduced by 10-15 ℃.

2. Interface modification and reactive extrusion (in-situ compatibilization)

Reactive blending (reactive extrusion): In situ grafting and compatibilization during extrusion process; For example, PP-g-MAH maleic anhydride grafted PP to improve the interface between PP and inorganic fillers/polar polymers; Epoxy chain extenders are used in PLA/PBAT alloys to inhibit phase separation and significantly improve toughness and stability.

Surface pre modification of fillers: Silane/aluminate coupling agent pretreatment of powders reduces agglomeration, improves matrix coating effect, and significantly enhances the mechanical properties of high filling systems.

3. High precision weight loss feeding+multi-stage vacuum devolatilization system

Multi component weight loss continuous feeding, separate metering of powder and granular materials to suppress bridging and dust, and improve formula accuracy; Supporting side feeding, adding fiberglass and thermosensitive additives in the downstream low-temperature section to reduce high-temperature degradation.

Multi level deep vacuum devolatilization efficiently removes moisture, residual monomers, and low molecular weight additives, solves VOC, frost, and air bubbles, and meets the requirements of low VOC and medical grade raw materials for automobiles.

4. Particle cutting and cooling process optimization

Underwater Particle Cutting (UWP), Air cooled Strip Granulation: High filling, high yield priority water ring cutting/underwater cutting; Thermal sensitive hydrolysis materials are granulated by air cooling, and the material does not come into contact with water throughout the process to avoid PLA/TPU hydrolysis; Mold head stabilization+dynamic tool speed matching, significantly improving particle size uniformity.

Online melt filtration system: Multi layer precision filter screen, online removal of impurities and black spots, improving the quality of recycled materials.

5. Digitization, AI, and Online Inspection (Intelligent Manufacturing Direction)

Digital twin+process simulation, simulating melting, shearing, pressure, and temperature fields in advance, shortening the development cycle of new material formulations;

Online real-time monitoring: Melt pressure, temperature, online near-infrared NIR real-time detection of composition, color, melt index, closed-loop automatic adjustment of feeding, speed, and temperature, reducing batch fluctuations to a very low level. High end automotive and medical PP modification lines have been applied.

6. Complete set of specialized technology for granulation of recycled materials

Pre treatment of recycled materials (sorting, impurity removal, dehydration)+two-stage low-temperature extrusion+controllable degradation repair (chain extender), repairing broken molecular chains. The performance of recycled PP is close to that of new materials, meeting the requirements of packaging and automotive interior reuse, and adapting to the EU EPR green regulations.