International Journal of Food Science and Technology 1997, 32, 241–253 241

Velocity field in a twin-screw extruder

Serafim Bakalis & Mukund V. Karwe*

Department of Food Science, The State University of New Jersey, US

Summary Velocity measurements inside the screw channels of a co-rotating, self-wiping, twin-screw
extruder were carried out. A laser Doppler anemometer (LDA) system was used to mea-
sure tangential and axial velocity components in the translational region of one of the
screws of a twin-screw extruder. The velocity measurements were carried out using heavy
corn syrup at different screw speeds and for two forwards conveying elements differing
in their pitch. It was found that velocity profiles in the translational region were sub-
stantially affected by the pitch of the screw element, however, screw speed (30–90 r.p.m.)
did not have a significant effect on the shape of the velocity profiles. The range of veloc-
ity values in a 14 mm pitch screw element was wider than that in a 28 mm pitch screw
element. Experimentally measured velocity profiles were compared with predictions of a
one-dimensional model, which showed that the model underpredicted the velocity values,
for the 14 mm pitch element.
Keywords Corn syrup, laser Doppler anemometry, Newtonian fluid.

The flow in a co-rotating twin-screw extruder

Introduction
The use of the twin-screw extrusion process in the
manufacture of food, plastics and pharmaceutical
products has increased substantially in the last
decade. Substantial efforts have been devoted to
develop mathematical models of twin-screw
extrusion processes. The solution of these mathe-
matical models is usually obtained using different
discretizaton methods. Due to the complicated
geometry of a twin-screw extruder and complex
rheological behaviour of many of the materials
that are extruded, the numerical simulations of
three-dimensional flow in the screw channels is
carried out using a variety of methods after
employing some simplifying assumptions. These
simulations are usually computational resource
intensive.
*Correspondent: M. V. Karwe, Department of Food
Science, PO Box 231, Cook College, Rutgers, The State
University of New Jersey, New Brunswick, New Jersey
08903–0231, US. Fax: 1 1 732 932–8690.
e-mail: karwe@aesop.rutgers.edu
has been simulated using numerical methods by
several investigators (Sastrohartono et al., 1992;
Tayeb et al., 1992; Yacu, 1985; Van Zuilichem et
al., 1992). It must be pointed out that all of the
models that are developed to describe the trans-
port phenomena in an extruder must be validated
with experimental data. Very often the compari-
son is made in terms of quantities such as die
pressure and die temperature due to ease of mea-
surement of these quantities. Comparison of
experimental results with numerical predictions
on a local scale has been attempted by only a few
investigators. For example, Esseghir & Sernas
(1994) measured the radial temperature distribu-
tions in the screw channel of a single-screw
extruder, using a cam-driven thermocouple syn-
chronized with the screw shaft rotation. Another
way of making local comparisons would be in
terms of velocity distribution at various locations
in an extruder.
Most of the data for measured velocity distrib-
utions reported in the literature are for single-
screw extruders. Velocity distributions in the

© 1997 Blackwell Science Ltd

242 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe
screw channels of a single-screw extruder were
obtained either by tracing particles or ink inject-
ed in the flow (Choo et al., 1980; Eccher &
Valentinotti, 1958) or by using a non-invasive
technique such as NMR (McCarthy et al., 1992).
Eccher & Valentinotti, using photographic tech-
niques, reported some cross-wise circulatory
motion within the screw channel. The correctness
of the shallow-channel theory in a single-screw
extruder was confirmed by Mohr et al. (1961).
Numerical results obtained using a finite-
difference method were found to be in reasonably
good agreement with velocity measurements per-
formed in deep-channel screw elements by Choo
et al. (1980).
Few data for experimentally measured velocity
patterns have been published for a twin-screw
extruder. Karwe & Sernas (1996) showed that
laser Doppler anemometry (LDA) can be used to
measure velocity distributions in a twin-screw
extruder using model fluids. They measured axial
and tangential velocity profiles in the translation-
al region of a twin-screw extruder using corn
syrup for a 28 mm screw element at a fixed screw
speed of 30 r.p.m. The tangential velocity pat-
terns were compared with numerically predicted
profiles of Chiruvella et al. (1996). The measured
values were higher than the numerically predicted
values.
Karwe et al. (1997) have reported velocity mea-
surements in the nip region of a twin-screw
extruder. The measured velocity distributions
indicated a three dimensional flow. Leakage flow
between the two screws, sometimes referred to as
Figure 1 Schematic diagram of
the extruder and the LDA system.
International Journal of Food Science and Technology 1997, 32, 241–253
transfer flow, was also detected with the LDA
technique.
This paper reports velocity measurements
under isothermal conditions for a Newtonian
fluid in the translational region of a co-rotating
twin-screw extruder, for two different forwards-
conveying screw elements, differing in their pitch.
The effect of screw speed on the measured veloc-
ity distribution was also examined. Although
most food materials have a non-Newtonian
behaviour, a Newtonian fluid was chosen as a
model fluid for the initial investigation reported
in this paper. Future investigations will include
model non-Newtonian fluids.
Materials and methods
Experimental set up
The experimental set up consisting of a twin-
screw extruder and a laser Doppler anemometer
system is shown schematically in Fig. 1. A four-
beam 300-mW argon-ion LDA system (Dantec
Measurement Technology, Inc., Mahwah, New
Jersey) was used to obtain the velocity data.
Using this apparatus two velocity components
can be measured simultaneously. The movement
of the laser probe, which was used to focus the
laser beams at a desired location in the screw
channel, was controlled by a 3–D traverse inter-
faced with a micro-computer. Details of the LDA
measurement technique and the experimental
apparatus have been described by Karwe &
Sernas (1996).
© 1997 Blackwell Science Ltd
 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe 243

Velocity measurements were made in the screw

channels of a ZSK-30 twin-screw extruder
(Werner & Pfleiderer Corp., Ramsey, New Jersey).
This is a co-rotating, self-wiping, twin-screw
extruder. The internal diameter of each of the bar-
rel bores (D) was 30.85 mm and the L/D ratio was
29, where L is the total length of the screws. The
maximum channel depth for the screws is 4.77
mm. A Plexiglas window was constructed and
fitted into the vent port of the extruder to access
the flow in the screw channels for velocity mea-
surements (see Fig. 1). The screw configuration
used in these experiments was assembled by using
forwards-conveying elements (low shear) only.
The die used had two 5-mm long holes of 3.6 mm
diameter each. The hopper through which the
screws were fed was always kept full. The screw
elements in the feed section had wider screw chan-
nels as compared with the rest of the screw ele-
ments. This ensured that the two screws were
completely filled with syrup. This also resulted in
different mass flow rates at different screw speeds,
like a single-screw extruder.
LDA measurements require optically transpar-
ent materials for laser beams to penetrate and
scattered light to come out. Therefore, heavy corn
syrup (Globe corn syrup 1132, Corn-Products
International, Summit-Argo, Illinois), which is a
Newtonian fluid of 1425 kg m23 density, 1.49
refractive index and shear viscosities of 74.0, 17.5
and 0.54 Pas at 26.6, 37.8 and 48.9i8C, respec-
tively, was selected as the working fluid.
Screw elements
Velocity profiles were measured for two forwards-
Figure 2 Sketch of two types of screw elements:
(a) 28/28 along with encoder positions (b) 14/14.
conveying screw elements having pitch(mm)/
length(mm) ratios of 28/28 and 14/14. These are
shown schematically in Figs 2(a) and 2(b), respec-
tively. The shape of the screw channels is self wip-
ing and the equation describing the geometry is
given by Booy (1980).
Region of measurement
The region of velocity measurements is shown in
Fig. 3. The front and top views of a section taken
normal to the axes of the twin-screw extruder are
shown in Figs 3(a) and 3(b), respectively. The
intermeshing (nip) region is the region where the
two screw channels meet. The translational region
is the region away from the intermeshing region.
Velocity measurements reported in this paper
were carried out at the centre of the left screw as
seen in the top view. This region is about a quar-
ter turn away from the nip region.
Encoder
An encoder was used to keep track of the angular
position of the screw shaft. It was fitted on the

Figure 3 Measurement geometry:

(a) Section taken normal to the
axes of the screws and (b) Top
view as seen through the optical
window showing the nip and the
translational regions.

© 1997 Blackwell Science Ltd International Journal of Food Science and Technology 1997, 32, 241–253
244 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe
back end of the left screw shaft. The encoder gave
a 2.5 VDC pulse for every 0.72 degrees of shaft
rotation (500 pulses per revolution) and a 5 VDC
pulse at every full rotation. This signal was
received by the flow velocity analyser (FVA, in
Fig. 1) and it was combined with the measured
velocity data. A reference position of 08 was set
when the left screw lobe was vertical, as shown in
Figs 2(a) and 3(a). This was arbitrary. However,
it was not important where the 08 position was
selected as it did not affect the results. From the
encoder position, the axial location in the screw
channel where velocity data were obtained was
known. The right screw shaft had a phase
difference of 908 with respect to the left shaft.
Hence, the orientation of one screw lobe auto-
matically defined the orientation of the other
screw lobe.
Correction for refraction
Due to refraction of the laser beams at the inter-
face between air and the surface of the Plexiglas
window, and between the Plexiglas and the corn
syrup in the screw channel, a correction factor
had to be applied to the apparent location where
the laser beams meet inside the screw channels. A
schematic diagram to illustrate this is shown in
Fig. 4. The correction factor for the location of
the point of intersection of the laser beams was
derived, which is as follows:
Figure 4 Refraction of laser beams at the interfaces
between air and Plexiglas.
International Journal of Food Science and Technology 1997, 32, 241–253
Dz 1 2 sin2 u
Da
5m !
1 2 m2 sin2 u (1)
where Da is the distance the laser probe is moved
in the air; Dz: is the distance the intersection point
of the laser beams is moved in the medium hav-
ing refractive index m; and u is the half angle
between the two laser beams in air 5 98.
For sinu « 1
Dz sin u
<m5
Da sin b (2)
In the derivation of eqn 1 the refraction of the
laser beams at the interface between the Plexiglas
and the corn syrup was neglected because their
refractive indices are very close to each other, i.e.
mplexiglas 5 1.507, mcorn syrup 5 1.49.. The error due to
the approximation in eqn 2 was about 0.5%.
Results and discussion
Velocity measurements were carried out for two
forwards-conveying screw elements differing in
their pitch. They were 14 mm and 28 mm,
respectively, as shown in Fig. 2. Velocity mea-
surements were carried out at three different
screw speeds of 30, 60 and 90 r.p.m. The LDA
system was used to measure tangential, Ux, and
axial, Uy, velocity components, as shown in Fig.
3. As the screw rotated, the relative position of
the measurement volume (intersection of the four
beams) changed. Thus it was necessary to keep
track of the relative screw position, which was
achieved by using the encoder. When the screw
flights cut the measurement volume, no signal
was obtained and this appeared as a gap in the
data. When the measurement volume was moved
deeper in the screw channel (along -z direction) a
wider gap in the data was observed, because the
flight width was higher near the screw root. For
the coordinate system shown in Fig. 3, the tan-
gential velocity values are expected to be positive
and the axial velocity values to be negative.
Positive values of Uy imply flow towards the hop-
per. In this paper the velocity distributions are
presented in a dimensionless form. The velocity of
the screw root was chosen as the characteristic
velocity and the channel depth (4.77 mm) as the
characteristic length.
The zero position along the z direction was
© 1997 Blackwell Science Ltd
 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe
taken at the point where the four beams focused
on the inner surface of the barrel. The error in the
determination of z 5 0 position was estimated to
be about 0.4 mm which is about half the size of
the measurement volume formed by the intersec-
tion of the four laser beams. This will cause some
uncertainty or shift in the z direction. The top of
the screw flight has a finite width (0.5 mm) which
is larger than the width of the intersection volume
(≈ 0.2 mm). Therefore, the zero encoder position
may get slightly shifted to left or right within
different data sets. This was corrected by shifting
all the data sets by an appropriate phase shift. To
calculate the phase shift, the position of the screw
flight in each data set was identified at the encoder
angle where the first data point was obtained. This
position was slightly different in different repeti-
tions. An average encoder position was taken as
the correct position of the screw flight and all the
data set were shifted so that the first data point
appeared at the same encoder position.
In Fig. 5 the Ux* (5 Ux/Us) and Uy* (5
Uy/Us) are plotted against the angular position of
the left screw shaft, for one screw channel of a 14
mm pitch screw element, near the extruder barrel
(z 5 0), at a screw speed of 90 r.p.m. Here Us is
the screw root velocity (Us 5 V Ds, V the angu-
lar speed of the screw, Ds the screw root diame-
ter, 21.26 mm). For all the figures in this paper,
data from three repetitions are superimposed. The
screw rotates only along the x direction. Near the
screw flight, the velocity of the fluid should be
close to the velocity of the screw flight due to the
Figure 5 Axial and tangential
velocity variation with angular
position in a 14 mm pitch screw
element at a screw speed of 90
r.p.m., near the surface of the
extruder barrel (z 5 0) for corn
syrup at 27i8C and mass flow rate
0.0108 kg s21.
© 1997 Blackwell Science Ltd International Journal of Food Science and Technology 1997, 32, 241–253
245
no-slip boundary condition. Thus, near the screw
flight, the only non-zero component of the fluid
velocity is Ux*. As can be seen from Figs 2 and
3, angular positions of 08 and 1808 correspond to
measurements close to the screw flight tip. This
was confirmed by the results shown in Fig. 5.
Close to the screw flight tip (08 and 1808) the
experimentally measured Ux* value was very
close to the calculated solid body velocity Us at
the screw tip (Ut 5 V Dt, V the angular speed of
the screw, Dt the screw tip diameter, 30.7 mm).
Since the barrel of the extruder does not move,
the velocity of the fluid close to the barrel should
be zero, except when a screw flight passes by.
This was experimentally confirmed as shown in
Fig. 5. Velocity values between the flights are
close to zero near z 5 0 (barrel).
The data presented in Fig. 5 are scattered. This
scatter was observed close to the barrel and the
screw root in a number of repetitions. The scatter
in the data reduced substantially when the
measurement location was moved away from the
barrel wall and the screw root, as will be seen in
the subsequent figures. The reasons for scatter
near the walls are not clear. It could be due to
partial cutting of the measurement volume by the
walls.
In Fig. 6, Ux* and Uy* are plotted vs. angular
position near the screw root, for a 14 mm pitch
screw element, at a screw speed of 90 r.p.m. Here,
the velocity of the fluid should be close to the
velocity of the screw root due to the no-slip
boundary condition. Since the screw rotates only
246 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe

Figure 6 Axial and tangential

velocity variation with angular
position in a 14 mm pitch screw
element, at a screw speed of 90
r.p.m., near the screw root
(z 5 24.77 mm), for corn syrup
at 27i8C, and mass flow rate
0.0108 kg s21.

along the x direction, Uy* should be zero and
Ux* should be equal to the calculated screw root
velocity, as seen from the experimental results.
In Fig. 7, the variations of Ux* with angular
position are plotted for 14 and 28 mm pitch screw
elements, at a screw speed of 90 r.p.m. and at z
5 –2.32 mm, which is approximately half-way
between the barrel and the screw root. The max-
imum for the tangential velocity is seen to occur
closer to the screw flights. This velocity value
could be determined by the no-slip condition and
thus is the same for both screw elements, since
both rotate at the same angular speed. The
velocity values, for both screw elements, smooth-
ly decreased towards the middle of the channel,
where the value of the Ux* was minimum, but
not zero. In the case of the 14 mm pitch screw
element, the velocity profiles were steeper, when
compared to the 28 mm pitch screw element.
In Fig. 8, variations of Uy* vs. angular posi-
tion for 14 and 28 mm screw elements are plotted
at a screw speed of 90 r.p.m. and at z 5 –2.32
mm. Since the screw rotates only along the x
direction, close to the screw flight the Uy* values
were close to zero. The magnitude of Uy*
smoothly increased and became maximum in the
middle of the channel. No significant difference
between the Uy* velocity profiles in 14 and 28
mm pitch screw elements could be observed.
Since the mass flow rate and the cross-sectional
areas are the same for both screw elements, it is
not surprising that the Uy* velocity profiles for
both screw elementa are similar, especially in the
middle of the screw channel.
The variations of dimensionless velocity, for
the 14 mm pitch screw element are plotted in Fig.
9, at screw speeds of 60 and 90 r.p.m., at a fixed
depth (z 5 – 2.32 mm). It can be seen from the

Figure 7 Tangential (Ux*) velocity

variation with angular position in
a 14 and a 28 mm pitch screw
element, at a screw speed of
90 r.p.m., in the middle of the
screw channel (z 5 22.32 mm),
for corn syrup at 27i8C, and mass
flow rate 0.0108 kg s21.

International Journal of Food Science and Technology 1997, 32, 241–253 © 1997 Blackwell Science Ltd
 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe 247

Figure 8 Axial (Uy*) velocity

variation with angular position in
a 14 and a 28 mm pitch screw
elements, at a screw speed of 90
r.p.m., in the middle of the screw
channel (z 5 22.32 mm), for
corn syrup at 27i8C and mass
flow rate 0.0108 kg s21.

figures that no significant difference could be
observed between the velocity profiles for this
range of screw speeds. This implies that the axial
pressure gradient in the 14 mm pitch screw ele-
ment was small when compared to a 28 mm pitch
screw element.
In Fig. 10, the Ux* profiles are plotted along
the z direction, within the screw channel at the
encoder position of 90, which corresponds to the
middle of screw channel, for the 14 mm pitch
screw element, at different screw speeds. The lines
in the graph represent third order polynomials
obtained from a least square fit to the experi-
mental data. The purpose of these lines is just to
show the trends of the three velocity profiles.
Near the barrel (z/H 5 0) Ux* is zero, since the
barrel is stationary. Near the screw root (z/H 5
–1) Ux* takes the value of the screw root veloci-
ty, which is close to one. The velocity profiles at
different screw speeds are not significantly
different from each other.
In Fig. 11 Uy* velocity values are plotted along
the z direction for a 14 mm pitch screw element
at an encoder position of 90 degrees, at different
screw speeds. Since the boundaries (screw root
and barrel) do not move along the y direction
Uy* is zero.
The velocity field in the translational region in
a co-rotating twin-screw extruder is similar to the
flow in the screw channels of a single-screw
extruder (Chiruvella et al., 1996). Therefore, the
flow can be considered as the superposition of a
drag and a pressure flow. The drag flow is pro-
portional to the screw speed. The pressure flow is
a function of the die opening. Since the extruder
is fully filled, the net flow rate depends on the
screw speed for a fixed die. Therefore both com-
ponents of the flow depend on the screw speed,
but in a different way. This implies that the con-
tribution of the pressure flow, for the examined
range of flow rates was negligible in the 14 mm
pitch screw element.

Figure 9 Ux* and Uy* velocity

variations with angular position
in a 14 mm pitch screw element,
at screw speeds of 60 and 90
r.p.m., in the middle of the screw
channel (z 5 22.32 mm), for
corn syrup at 27i8C.

© 1997 Blackwell Science Ltd International Journal of Food Science and Technology 1997, 32, 241–253
248 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe

Figure 10 Ux* velocity profiles in

a 14 mm pitch screw element, for
different screw speeds, in the
middle of the screw channel
(90 degrees), for corn syrup at
27i8C. Lines represent third order
polynomials, obtained using the
least squares method.

Figure 11 Uy* velocity profiles in

a 14 mm pitch screw element, for
different screw speed, in the
middle of the screw channel
(90 degrees), for corn syrup at
27i8C. Lines represent third order
polynomials, obtained using the
least squares method.

In Fig. 12, Ux* velocity profiles are plotted
along the z direction for a 28 mm pitch screw ele-
ment, at an encoder angle of 90 degrees, for
different screw speeds. In this case the velocity
profiles seem to be significantly different when
compared with those for the 14 mm pitch screw
element. The maximum velocity seems to occur
away from the screw root. The effect of the pres-
sure flow is evident in this case. This implies that
the pressure gradients in a 28 mm pitch screw ele-
ment are higher than those generated in a 14 mm
pitch screw element, for the range of the screw
speeds considered here.
In Fig. 13, the Uy* velocity profiles are plotted
against z/H for a 28 mm screw element for
different screw speeds. As expected the velocity
values are zero at the boundary and maximum in
the middle. The screw speed did not significantly
affect the velocity profiles, though velocity magni-
tudes were different because of different flow rates.

Figure 12 Ux* velocity profiles in

a 28 mm pitch screw element, for
different screw speeds, in the
middle of the screw channel
(90 degrees), for corn syrup at
27i8C. Lines represent third order
polynomials, obtained using the
least squares method.

International Journal of Food Science and Technology 1997, 32, 241–253 © 1997 Blackwell Science Ltd

Figure 13 Uy* velocity profiles in
a 28 mm pitch screw element, for
different screw speeds, in the
middle of the screw channel
(90 degrees), for corn syrup at
27i8C. Lines represent third order
polynomials, obtained using the
least squares method.
Figure 14 Downchannel and axial coordinate systems.
Theoretical considerations
For isothermal flow of a Newtonian material, in
a single-screw channel, assuming no-slip at walls
and ignoring inertia and body forces, and for
W/D » 1, H/D « 1, the velocity profiles along the
down channel (z) and cross channel (j) directions,
in barrel moving formulation (see Fig. 14) are
given in several textbooks, and are as follows:
1 211H2 1 1H22 1
6Q Z 2
U§ theoretical 5 3Us cos f 2
WH
1H2 1 U cos f
Z
Us cos f s velocity distributions in a 14 mm pitch screw ele-
11H2 1 1H22 2
Z 2
Uj theoretical 5 s2 3Us sin fd
1H2 2 U sin f
Z channel diminish, and the assumptions employed
Us sin f s
© 1997 Blackwell Science Ltd
Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe 249
for 2H #_z # 0. All symbols are defined in the
nomenclature.
In order to compare the results derived from
this simplified analysis with the experimental
results, the experimental results were transformed
to down channel and barrel moving formulation
(Karwe et al., 1995) as follows:
U§ experimental 5
2 Ux cos f 2 Uy sin f 1 Us cos f (5)
Uj experimental 5
2 Ux sin f 1 Uy cos f 2 Us sin f (6)
The experimentally obtained velocity profiles at
a screw speed of 90 r.p.m. in the middle of the
screw channel for a 28 mm pitch screw element,
and the theoretically derived velocity profiles
shown in Fig. 15. As one can see, the experimen-
tal values were reasonably close to the theoreti-
cally obtained velocity values. In the case of the
14 mm pitch screw element, the deviation from the
predicted velocity profile was substantial as shown
in Fig. 16. This deviation can be explained by the
fact that the W/H ratio is 2.3 for a 28 mm pitch
screw element, and for a 14 mm screw element the
Z W/H ratio is 1.18. Thus, it is not surprising that
the one dimensional model which is valid for large
values of W/H did not accurately predict the
(3)
ment. Also it should be noted that the compar-
isons reported here are in the middle of the screw
Z
channel. As the W/H ratio increases the wall
effects on the velocity profile at the centre of the
(4) in the one dimensional model become valid.
International Journal of Food Science and Technology 1997, 32, 241–253
250 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe

Figure 15 Theoretical and

experimental down and cross
channel dimensionless velocity
profiles for a 28/28 screw element,
at a screw speed of 90 r.p.m., for
corn syrup at 27i8C, and mass
flow rate 0.0105 kg s21.

Figure 16 Theoretical and

experimental down and cross
channel dimensionless velocity
profiles for a 14/14 screw element,
at a screw speed of 90 r.p.m., for
corn syrup at 27i8C, and mass
flow rate 0.0108 kg s21.

Velocity contour plots for different experimen- Conclusions

tal conditions were generated from the velocity
The axial and tangential velocity profiles in the
data. In Fig. 17 contours of the dimensionless
screw channel of a co-rotating twin-screw extrud-
tangential velocity Ux* for a 14 mm pitch screw
er were significantly affected by the pitch of the
element at a screw speed of 90 r.p.m. are shown.
screw element, and indicated that in a larger pitch
As expected, velocity values close to the barrel
screw element higher tangential pressure gradients
were zero. Maximum Ux* velocity values were
are produced. The measured velocity profiles in
seen close to the screw flight. Velocity values
the middle of the screw channel of a 28 mm pitch
smoothly decreased towards the centre of the
screw element could be predicted by a one dimen-
screw channel. A slight asymmetry was observed
sional model, but this model substantially under-
in the contour. This probably was due to experi-
predicted the velocity values for a 14 mm pitch
mental error.
screw element.
In Fig. 18 contours for the dimensionless axial
velocity Uy* are plotted. The velocity values close
to the barrel were zero. Also close to the screw
Acknowledgements
root, axial velocity values were zero. Maximum
axial velocity values are observed in the middle of This is manuscript D-10127–1-96 of the New
the screw channel, but closer to the barrel. Jersey Agricultural Experimental Station. This

International Journal of Food Science and Technology 1997, 32, 241–253 © 1997 Blackwell Science Ltd
 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe 251

Figure 17 Tangential velocity

(Ux*) contours in a 14 mm pitch
screw element at a screw speed of
90 r.p.m., for corn syrup at
27i8C, and mass flow rate
0.0108 kg s21.

research was supported by state appropriations, s Screw root

U.S. Hatch Act Funds. Equipment support was t Screw tip
x Tangential direction
provided by the Centre of Advanced Food
y Axial direction
Technology, Rutgers University, New Brunswick, b Angle between the refracted laser beam and the
New Jersey. The authors would like to thank radius vector (Fig. 4)
Dr V. Sernas for useful discussions on the Dz Distance the intersection point of the laser beams is
subject. moved in the fluid
Da Distance the laser probe is moved in the air
z Down channel direction
u Half the angle between the two laser beams
Appendix
m Refractive index
Nomenclature j Cross channel direction
f Screw helix angle
D Diameter V Angular speed of the screw
H Maximum channel depth
L Axial length of the screws
Q Volumetric flow rate Superscript
U Velocity
W Maximum channel width * Dimensionless velocity

© 1997 Blackwell Science Ltd International Journal of Food Science and Technology 1997, 32, 241–253
252 Velocity field in a twin-screw extruder S. Bakalis & M. V. Karwe
Figure 18 Axial velocity (Uy*)
contours in a 14 mm pitch screw
element at a screw speed of
90 r.p.m., for corn syrup at
27i8C, and mass flow rate
0.0108 kg s21.
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Received 24 August 1996, revised and accepted 25 June 1997

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