6/20/23, 11:40 AM How Much L/D Do You Really Need?

| Plastics Technology

EXTRUSION KNOW HOW

Updated 9/18/2022 | Published 11/28/2011

How Much L/D Do You Really Need?

Just like selecting the extruder size and drive combination, the L/D should be carefully evaluated.
#screws

JIM FRANKLAND 
President, Frankland Plastics Consulting, LLC

In the early 1960s, extruders typically had a length/diameter ratio of 20:1, and a machine
with a 24:1 L/D was considered long. Since then, extruders have gotten longer, with the 30:1
to 36:1 L/D becoming the industry “standard.” Some extruders even exceed 40:1 L/D for
special purposes like double venting, compounding, or high-speed processing.

What benefits does the additional length provide? Mostly increased output and improved
homogenization.

Since the feed section stays approximately the same length, regardless of the L/D, the rest of
the screw is devoted to melting and pumping. The deeper the screw channels, or the higher
the specific output (lb/rpm), the more length you need to complete melting and develop the
pressure necessary to push the polymer out the die. As designers reached these limits,
extruders were built longer to handle the economic requirements to pump out more and
better product.

However, there are actual limits on increasing output as L/D is increased. Usually these
limits are due to the inability of the feed section to deliver more polymer. On smaller-
diameter screws, that limit often is determined by screw strength. On small screws you can
only go so deep in screw channels before the screw is overtorqued and fails. On larger
extruders, the efficiency of feeding decreases as the channels get deeper until there is no
further increase in output.

Two-stage screws benefit more with increasing L/D

For most applications, you’ll need a longer
two-stage screw to match the output of a
single-stage screw.
because about 4-6 D is consumed in the vent area,
which contributes very little to melting or
pressurization. For most applications, you’ll need a
30:1 two-stage screw to match the output of a 24:1
single-stage screw.

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6/20/23, 11:40 AM How Much L/D Do You Really Need? | Plastics Technology

There are actual limits on increasing output as L/D is increased.

Are there any disadvantages associated with longer extruders? Some polymers melt much
easier and faster than others. Also, some processes typically have low head pressures, while
others have much higher discharge pressures. Inherent viscosity differs a lot between
polymers, and some shear-thin significantly while others do not (i.e., are more
“Newtonian”). As a result screw performance is optimized at a variety of L/Ds rather than at
any one standard L/D.

A screw that is too long for the overall processing situation can actually limit output. The
limitation generally shows up as excessively high melt temperature that can cause polymer
breakdown, color shift, loss of additive effectiveness, and plate out, to name a few issues.
For a polymer that melts easily, the melting length should ideally be shorter, as excessively
long transitions can actually reduce melting rate. The same is true of pressure development,
as widely used melt pumps greatly reduce the need for long metering sections to handle the
discharge pressure.

A screw that is too long for the overall processing situation can actually limit output.

As a result, the tendency to buy longer and longer L/D extruders can actually penalize
overall performance. Custom extrusion houses may simply have to live with this reality
because they never know what they will be running next year, and a longer extruder has
more inherent flexibility than a shorter one. But if you have a dedicated process, there can
be self-imposed limits with an extruder that is too long.

Just like selecting the extruder size and drive combination, the L/D should be carefully
evaluated. Everyone wants the most usable output from their extruder, but if the material
comes out too hot or too degraded then the singular focus on rate is actually reducing the
extruder’s capability. Data such as diffusivity, power-law coefficients, melting points, head
pressure, viscosity, and crystallinity should be part of the evaluation process.

About the Author: Jim Frankland is a mechanical engineer who has been involved in all
types of extrusion processing for more than 50 years. He is now president of Frankland
Plastics Consulting, LLC. Contact jim.frankland@comcast.net or (724) 651-9196.

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6/20/23, 11:40 AM How Much L/D Do You Really Need? | Plastics Technology

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