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Single-screw extruder zone temperature selection for optimized performance

Article · January 2008

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 SINGLE-SCREW EXTRUDER ZONE TEMPERATURE SELECTION
FOR OPTIMIZED PERFORMANCE
Sam L. Crabtree, Mark A. Spalding, and Calvin L. Pavlicek
The Dow Chemical Company, Midland, MI, USA
Abstract
Optimization of the barrel temperature profile is key
to the stability and economics of plasticating, single-screw
extrusion processes. Although the procedures for
optimizing the temperatures have been known for many
years, most descriptions do not show actual process data.
This paper provides both the procedure and processing
data for a 63.5 mm diameter extruder.
Introduction
Global economic forces are reducing the profitability
of many converters. Innovative converters, however, have
introduced new products to the market place and have
optimized the profitability of existing lines. Process
optimization strives to maximize the rate of the line and
reduce downtime and off specification product, all while
minimizing the amount of resin in the product. The three
major components that are key to this optimization
include: i) resin selection, ii) equipment selection, and iii)
operational settings such as the barrel temperature profile.
The resin selected must obviously provide the proper
physical properties required by the final part, and facilitate
processing at high rates. Equipment must be selected such
that the long-term cost of ownership is minimized, allows
for future rate increases, and minimizes the consumption
of resin in the part [1]. Barrel zone temperatures must be
set so that solids conveying is stable [2], melting rates are
acceptable, and the discharge temperature is acceptable
for the downstream processes.
The goal of this paper is to provide the procedures for
optimizing the barrel zone temperatures. Experimental
data are provided for polypropylene (PP) and high density
polyethylene (HDPE) resins.
Materials
Polypropylene (PP) and high density polyethylene
(HDPE) resins were used for these extrusion studies. Both
resins were manufactured by The Dow Chemical
Company. The PP resin was a homopolymer with a solid
density of 0.900 g/cm3 and a melt flow rate of 8.8 dg/min
(230oC, 2.16 kg). The HDPE resin had a solid density of
0.958 g/cm3 and a melt flow index of 5.9 dg/min (190oC,
21.6 kg). The melting peak temperature was 142 and
133oC for the PP and HDPE resins, respectively.
Background
Several processes exist for the optimization of barrel
zone temperatures, and they all start by optimizing the
temperature in the solids conveying zone [3]. The starting
temperature for the solids conveying zone can either be
the recommended feed zone temperature from the resin
manufacturer, the current operating temperature, or the
melting (or devitrification) temperature plus about 25oC.
The barrel zones over the metering section should be set
to a temperature near the expected discharge temperature
of the extrudate. The barrel zones over the melting section
should be set at an intermediate temperature. Since all
extruders are unique with different diameters, lengths,
heater positions, and thermocouple positions, the optimal
barrel zone temperatures for each extruder will be slightly
different for a specific resin.
Next the solids conveying zone temperature is
increased (or decreased) in 10oC increments until a
maximum rate is obtained. Once the maximum rate at the
optimal solids conveying barrel temperature is determined,
the discharge temperature can be adjusted by increasing or
decreasing the temperature of the barrel zones in the
metering section of the screw. The melting rate can be
increased by increasing the barrel temperature in the
transition section.
The method described above is simple and can be
quickly performed on commercial extruders. A more
elaborate method uses a designed experiment where
numerous factors are selected at two or more levels as
outlined by Himmelblau [4] and described by Wagner and
Perdikoulias [5]. This method is not the focus of the study
here.
Extrusion Equipment
The extruder used in this study was a fully
instrumented 63.5 mm diameter, 21 length-to-diameter
(L/D) single-screw extruder. The extruder was equipped
with three barrel temperature and cooling zones. The first
2.5 diameters of the screw were inside a water-cooled feed
casing. Twelve pressure transducers were positioned in the
ANTEC 2008 / 1410
 barrel wall to measure the axial pressure profile of the
process. The resin flowed through a short transfer line and
then to a die system.
The screw used in this study was a conventional,
single-flighted screw with a square-pitch lead length. The
screw was used in numerous other studies [6-8], and it was
designed with three sections: 1) a 6 diameter long feed
channel with a constant depth of 8.89 mm, 2) an 8
diameter long transition section, and 3) a 7 diameter long
metering section with a constant depth of 3.18 mm. The
specific drag flow rate, the rate due to just rotation, was
calculated at 0.71 kg/(h rpm).
Results
The extrusion process in this work was optimized first
for rate (or specific rate) and then for discharge
temperature. At a maximum specific rate, the pressure in
the channels will be relatively high and the process should
operate very stably. Each of the experiments was
conducted at a screw speed of 50 rpm. The initial extruder
barrel temperatures were selected based upon common
practice and they are shown in Table 1. To demonstrate
the effect of temperature on solids conveying, the Zone 1
temperature was increased in 10oC increments and the
Zone 3 temperature was held constant at 220oC. For each
condition, Zone 2 was set at the mid-point value between
the Zone 1 and Zone 3 temperatures. This process was
repeated across a range of temperatures until a maximum
extrusion rate was identified. At each new condition,
process data were collected including: discharge
temperature, rate, motor current (load), and pressures
along the axial length of the barrel. The discharge
temperature was measured by inserting a hand-held
thermocouple into the extrudate. The rate was measured
by weighing the extrudate from a specific period of time.
All other processing data were collected using
instrumentation installed on the extruder and a data
acquisition system.
For the PP resin, the Zone 1 temperature was
increased from 200 to 278oC as shown in Table 2. The
Zone 1 temperature of 278oC was selected because it was
the highest possible temperature that could be attained by
Zone 1 of this extruder. To attain temperatures greater
than 260oC with the PP resin, it was necessary to turn off
the cooling water flow to the feed casing because the
conductive cooling effect along the barrel was greater than
the heating capacity of the Zone 1 heater. Data were
collected at 260oC with and without feed casing cooling to
determine if turning off the cooling had an effect on the
experiment. Operating without cooling on the feed casing
did not affect the extrusion performance, but allowed Zone
1 to operate at higher temperatures.
1411 / ANTEC 2008
The maximum rate attainable with this screw at a
screw speed of 50 rpm was 33.4 kg/h at a Zone 1
temperature of 240oC, as shown by Figure 1 and Table 2.
From the initial Zone 1 temperature of 200oC, this change
represents about a 7% increase in the rate by adjusting the
temperature profile of the extruder. This increase in rate is
attributed to an ideal operating temperature for the feed
section where the maximum forwarding forces are exerted
on the solid bed [9, 10] and to a smaller temperature
change in Zone 2 in melting section. Figure 1 illustrates
that operating Zone 1 at temperatures higher than 240oC
resulted in a decrease in the rate; i.e., the forwarding
forces were decreased. The discharge temperature
increased from 222oC for a Zone 1 temperature of 200oC
to 236oC at a Zone 1 temperature of 278oC, as displayed
in Figure 2. It is also worth noting that the motor current
decreased as the Zone 1 temperature increased. This
change is attributed to a combination of the rheology of
the PP resin, the relatively low increase in rate, and the
increase in the discharge temperature with increasing Zone
1 temperature. The extrusion process was very stable
using a Zone 1 temperature of 240oC.
The axial pressure profile was affected by changing
the temperatures in the Zone 1 and 2 barrel sections, as
shown by Figure 3. In this figure, the pressure profile for
the extruder shifted to higher pressures as the Zone 1
temperature was increased from 200 to 240oC. Moreover,
the discharge pressure increased by about 2 MPa during
the optimization. The shift to higher axial pressures and
higher discharge pressure with an increase in the Zone 1
barrel temperature was a result of the increased
forwarding forces in the melting section and the higher
rates. From this figure, it is clear that the change in the
Zone 1 and 2 barrel temperatures has caused a significant
change in the process.
As mentioned earlier, the discharge temperature
increased with increasing Zone 1 temperature, as shown
by Figure 2 and Table 2. Based on the initial Zone 1
temperature of 200oC, the discharge temperature increased
by 5oC during the optimization; i.e., discharge temperature
was 227oC for a Zone 1 temperature of 240oC. This
discharge temperature increase has the potential to
negatively impact the downstream processing of the
extrudate. Once the preliminary work was completed to
identify the Zone 1 temperature at which the maximum
extrusion rate occurs, the process was adjusted to correct
for discharge temperature. This discharge temperature
correction was achieved by decreasing the temperature of
Zone 3. Figure 4 shows the effect of the Zone 3
temperature on the rate and discharge temperature. By
adjusting the Zone 3 temperature, the discharge
temperature decreased to a value near that of the original
operating conditions. Figure 4 also shows that decreasing
the Zone 3 temperature also resulted in a decrease in rate.
By making the adjustment for discharge temperature, the
rate decreased from 33.4 kg/h to 32.5 kg/h. In practice, the
discharge temperature can be adjusted to higher or lower
values using the barrel temperature zone in the metering
section.
A similar approach was used to optimize this extruder
for the HDPE resin. The effect of the Zone 1 temperature
on the rate is shown by Figures 5 and 6 and Table 3. In
Figure 5, the rate was initially at 26.1 kg/h for a Zone 1
temperature of 170oC. As the Zone 1 temperature was
increased, the rate increased to a maximum of 32 kg/h at a
Zone 1 temperature of about 230oC. This represents a rate
increase of about 21%. As the Zone 1 temperature
increased, the motor current also increased. This result
was different than that observed for the PP resin. For the
PP resin, the motor current decreased with increasing
Zone 1 temperature. For the HDPE resin, the increase in
motor current was a result of the higher rates and
increased discharge pressures. The extrusion process was
very stable using a Zone 1 temperature of 230oC.
The axial pressure profiles for the HDPE resin at
Zone 1 temperatures of 170 and 230oC are shown in
Figure 7. Like the PP resin, the axial pressures for the
HDPE resin increased when the Zone 1 temperature
increased from the initial temperature to the optimized
temperature. As shown by Figures 3 and 7, the increase in
the axial pressure profile during optimization for the
HDPE resin was significantly greater than that of the PP
resin. Moreover, the magnitude of the shift in discharge
pressure with the HDPE resin was proportional to the
increase in rate achieved through optimization. The large
shift in pressure observed is evident in the increase in
motor current during optimization for the HDPE resin.
The discharge temperature for the HDPE resin
increased with increasing Zone 1 temperature, as shown
by Figure 6. This effect was essentially identical to that for
the PP resin. For example, the discharge temperature
increased from 257 to 260oC when the Zone 1 temperature
was increased from 170 to 240oC. Although this discharge
temperature increase is relatively small, it might impact
the operation of the downstream equipment and processes.
To demonstrate that discharge temperature can be adjusted
at the higher rates, the Zone 3 temperature was decreased.
Figure 8 shows that decreasing the Zone 3 temperature
had a significant effect on the discharge temperature for
the HDPE resin. The discharge temperature was decreased
from about 260oC at a Zone 3 barrel temperature of 220oC
to 235oC at Zone 3 barrel temperature of 190oC. As the
Zone 3 temperature was decreased the rate decreased from
31.7 kg/h to 30.2 kg/h.
Discussion
An experimental approach was used to optimize the
performance of an extruder for PP and HDPE resins. For
these resins, screw, and fixed screw speed of 50 rpm,
barrel temperatures in the solids conveying zone were
identified that provide a maximum rate. The smaller
changes in the barrel temperature in the melting zone also
contributed to the higher rates as shown by the increased
barrel pressures. Moreover, the barrel temperatures in the
metering section were easily changed to control the
discharge temperature of the extrudate. Although this
technique is not new, the data provided here demonstrates
the process described in previous works.
For the small diameter extruder used for this study,
the optimal barrel temperature in the solids conveying
zone was determined to be 240 and 230oC for the PP and
HDPE resins, respectively. At these barrel temperatures,
the rates for the resins were increased by 7 and 21% based
on the starting temperature profile. The rates were
increased in part by the higher solids conveying forces [9]
imparted at the optimal Zone 1 barrel temperature and the
changes in the barrel temperature in the melting section.
These forces were obviously increased as shown by the
axial pressure profiles.
In extreme cases [2], improper temperatures in the
solids conveying zone (screw temperature, feed casing
temperature, and barrel temperature) can cause the
extruder to operate at rates that are about 60% of the
maximum value. Operations at these conditions can lead
to extreme flow surging, reducing the profitability of the
line.
The discharge temperature of the extrudate can be
adjusted by changing the barrel temperatures in the
metering section of the screw. The effectiveness of this
approach, however, is highly dependent on the diameter of
the extruder. For the 63.5 mm diameter extruder used
here, the discharge temperature was easily changed using
the Zone 3 barrel temperature. For larger diameter
extruders, however, the ability to transfer energy out
through the barrel will increase linearly with diameter, D,
while the rate will increase to nearly D3. Thus, larger
diameter extruders will have a smaller change in the
extrudate temperature for the same change in the barrel
temperature setting.
Although not discussed here, the melting rate of the
extruder can be increased by increasing the temperature of
the barrel in the melting zone [10-12]. Increasing the
barrel temperature in the melting section is often effective
in mitigating solids in the discharge, especially for screws
with barrier flight designs [13].
ANTEC 2008 / 1412
 Table 2. Extrusion results for the PP resin.
Conclusions Zone 1 Rate, Discharge
Temperature, oC kg/h Temperature, oC
Procedures for optimizing the barrel temperature 200 31.2 222
profile for a plasticating, single-screw extruder are 210 32.1 224
outlined and presented with experimental data. Although 220 32.7 225
the method has been used for many years, the
230 33.1 229
experimental data provides additional insights into the
240 33.4 227
process.
250 33.1 231
260 33.1 234
References 270 33.0 236
278 32.8 236
1. D. Smith, M.A. Spalding, and R.J. Gould, SPE-
ANTEC Tech. Papers, 52, 814 (2006).
Table 3. Extrusion results for the HDPE resin.
2. M.A. Spalding, J.R. Powers, P.A. Wagner, and K.S.
Hyun, SPE-ANTEC Tech. Papers, 46, 254 (2000). Zone 1 Rate, Discharge
3. H.F. Giles, J.R. Wagner, and E.M. Mount, “Extrusion Temperature, oC kg/h Temperature, oC
– The Definitive Processing Guide and Handbook,” 170 26.1 257
William Andrew Publishing, Norwich, NY, 2005. 180 27.6 257
4. D.M. Himmelblau, “Process Analysis by Statistical 190 30.2 255
Methods,” John Wiley & Sons, Inc., New York, 1970. 200 30.8 257
5. J.R. Wagner and J. Perdikoulias, SPE-ANTEC Tech. 210 30.6 258
Papers, 51, 311 (2005). 220 30.8 259
6. M.A. Spalding, J. Dooley, K.S. Hyun, and S.R. 230 31.7 260
Strand, SPE-ANTEC Tech. Papers, 39, 1533 (1993). 240 31.7 260
7. T.A. Hogan, M.A. Spalding, K.S. Cho, and C.I. 250 31.7 261
Chung, SPE-ANTEC Tech. Papers, 48, 384 (2002). 260 31.7 262
8. A. Altinkaynak, M. Gupta, M.A. Spalding, and S.L.
270 31.5 262
Crabtree, SPE-ANTEC Tech. Papers, 52, 809 (2006).
9. K.S. Hyun, and M.A. Spalding, SPE-ANTEC Tech.
35 25
Papers, 43, 211 (1997).
Motor Current
10. E.E. Stangland, J. Dooley, M.A. Spalding, E.K. Kim, 34 20

Motor Current, %
and K.S. Hyun, SPE-ANTEC Tech. Papers, 48, 302
Rate, kg/h

(2002). 33 15
11. M.A. Spalding, K.S. Hyun, and B.R. Cohen, SPE-
ANTEC Tech. Papers, 43, 202 (1997). 32 10
12. A. Altınkaynak, M. Gupta, M.A., Spalding, and S.L. Rate
31 5
Crabtree, SPE-ANTEC Tech. Papers, 53, 395 (2007).
13. E. Steward, SPE-ANTEC Tech. Papers, 48, 69 (2002) 30 0
180 200 220 240 260 280 300
Table 1. Initial extrusion conditions for the PP and HDPE
Zone 1 Temperature, oC
resins used in this work. Extrusion conditions were
Figure 1. Extrusion rate and motor current results for the
selected based upon common industry practice.
PP resin. By increasing the Zone 1 temperature, an
PP HDPE
optimum rate of 33.4 kg/h was attained at a screw speed of
Zone 1 Temperature, oC 200 170 50 rpm. Motor current decreased with increasing Zone 1
Zone 2 Temperature, oC 210 195 temperature. The Zone 3 temperature was held constant at
Zone 3 Temperature, oC 220 220 220oC.
Die Temperature, oC 220 220
Screw Speed, rpm 50 50
Feed Casing Cooling On On

1413 / ANTEC 2008

 35 250 35 40

Discharge Temperature, o C
Discharge Temperature Motor Current
34 230 33 35

Motor Current, %
Rate, kg/h

Rate, kg/h
33 210 31 30

32 190
29 25
Rate
31 170
27 Rate 20
30 150
25 15
180 200 220 240 260 280 300
150 200 250 300
Zone 1 Temperature, o C
Zone 1 Temperature, oC
Figure 2. Extrusion rate and discharge temperature results
for the PP resin. Discharge temperature increased when Figure 5. Extrusion rate and motor current results for the
the Zone 1 temperature was increased. The Zone 3 HDPE resin. The highest rate was achieved at a Zone 1
temperature was held constant at 220oC. temperature of 230oC. Motor current increased when the
Zone 1 temperature was increased. The Zone 3
10 temperature was held constant at 220oC.
Z1=240oC
8 35 300
Pressure, MPa

Discharge Temperature, oC
6 33 290
Rate
Rate, kg/h 31 280
4
Z1=200oC 29 270
2
27 260
0 Discharge Temperature
25 250
0 4 8 12 16 20 24 150 200 250 300
Axial Position, diameters Zone 1 Temperature, C
o

Figure 3. Axial pressure profiles for the PP resin at Zone 1 Figure 6. Extrusion rate and discharge temperature results
(Z1) temperatures of 200 and 240oC. The Zone 3 for the HDPE resin. Discharge temperature increased
temperature was held constant at 220oC. when the Zone 1 temperature was increased. The Zone 3
temperature was held constant at 220oC.
35 250
Discharge Temperature, o C

Discharge Temperature 30
34 230 Z1=230oC
25
Rate, kg/h

33 210
Pressure, MPa

Rate 20
32 190
15
31 170
10
30 150 Z1=170oC
180 190 200 210 220 5
o
Zone 3 Temperature, C 0
Figure 4. Extrusion rate and discharge temperature results 0 4 8 12 16 20 24
for the PP resin. Discharge temperature decreased when Axial Position, diameters
the Zone 3 temperature was decreased. Rate also
Figure 7. Axial pressure profiles for the HDPE resin at
decreased slightly. The Zone 1 temperature was held
Zone 1 (Z1) temperatures of 170 and 230oC. The Zone 3
constant at 240oC.
temperature was held constant at 220oC.

ANTEC 2008 / 1414

 35 270

Discharge Temperature, oC
33 260
Key Words: Extrusion Optimization, Temperature
Profile, PP, HDPE
Rate, kg/h

31 Rate 250

29 240

27
Discharge Temperature 230

25 220
180 190 200 210 220
o
Zone 3 Temperature, C
Figure 8. Extrusion rate and discharge temperature results
for the HDPE resin. Discharge temperature decreased
when the Zone 3 temperature was decreased. Rate also
decreased slightly. The Zone 1 temperature was held
constant at 230oC.

1415 / ANTEC 2008

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