Compounding and Extrusion Instruments

Compounding and extrusion tools for materials processing

Twin-screw extrusion is a standard technique for polymer mixing and compounding, but has also expanded into other applications, such as novel materials development. Extruders offer a high level of process flexibility, control of process parameters, and can produce a wide range of products. Being a continuous mixing process, where a base matrix and multiple additives are transformed into a new compound, twin-screw extrusion has the potential to benefit multiple areas beyond traditional polymer processing.

 

Thermo Scientific extruders and compounders are designed to offer flexibility, efficiency, and reliable scale-up for a wide range of process requirements.

Twin-screw extruders

Lab-scale extruders only require a small amount of material to conduct experiments, allowing you to perform numerous trials efficiently and cost effectively, while also saving precious laboratory space.

 

With a Thermo Scientific lab-scale twin-screw extruder, easy upscaling from 11, to 16, to 24 mm screw diameters is ensured by design.

Torque rheometers

Comprehensive characterization is often essential during the development of new, innovative materials. Thermo Scientific HAAKE PolyLab Torque Rheometers are measuring mixer and extruder systems designed to meet today’s (and tomorrow’s) quality control and R&D needs. This modular system starts with a torque rheometer drive that can be connected to an interchangeable mixer, single-screw extruder, or conical/parallel twin-screw extruders. Analyze material properties, simulate production processes, and perform capillary rheology to determine flow characteristics under real process conditions.

Pharmaceutical extruders

When developing new drugs, shorter time-to-market, reduced waste of expensive APIs, and minimized development costs provide a distinct competitive advantage for pharmaceutical manufacturers. Thermo Scientific pharmaceutical extruders and related analytical instrumentation shorten the path from feasibility studies to manufacturing and help overcome drug formulation challenges.

Online rheometers

The Thermo Scientific Process Control Rheometer Series (PCR) is ideal for continuous, real-time measurement of viscosity and melt flow index, ensuring high quality during the production or recycling of polymers and other related materials.

Micro compounder and injection molding instruments

Thermo Scientific micro-compounders are conical twin-screw extruders, well-suited for polymer, pharmaceutical, bioscience, and nanotechnology R&D. All models use as little as five grams (or seven milliliters) of material for compounding. This is especially beneficial if you compound expensive or small-scale materials. The optional force-feeder attachment even allows you to continuously extrude very small material volumes.

 

HAAKE MiniCTW Micro-Conical
Twin-Screw Compounder		 HAAKE MiniLab 3 Micro-Compounder HAAKE MiniJet Pro Piston Injection Molding System

Offers high-precision control of compounding and extrusion for a wide range of materials used in new product development. 

  • Ideal for viscous material melts
  • Full control of the residence time of the extrusion process
  • Removable top barrel for quick, easy cleaning
  • Controllable torque speed allows you to monitor reactions

 

 

 

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Ideal for R&D, this instrument lets you measure structural changes during compounding and assess rheological properties of test materials.

  • Measures relative viscosity during compounding
  • Uses as little as 5 g or 7 mL of material
  • Fits in a fume hood to limit exposure to hazardous materials
  • Use as a standalone unit or as a computer-controlled system

 

 

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Produce test specimens with 2–12 mL of material. Designed for mechanical and optical testing, rheology, as well as pharmaceutical testing. 

  • Test specimens can be produced from powders, pellets, or direct melt transfer
  • Various specimen geometries can be produced with easy to exchange molds
  • Features a control and design concept that provides straightforward handling with consistent, reproducible results

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Compounding and extrusion instrument selection guide

  Barrel diameter (mm) Barrel 
length
L/D		 Da/Di       

Achievable output

(kg/h)*

 Temp. (°C) Screw design Max. screw speed (rpm) Temp. zones ** Drive power (kW)
HAAKE MiniCTW Conical     0.01–0.1 300 Conical co- and counter rotating 360 2*** 0.4
Pharma mini HME Conical     0.01–0.1 280 Conical co- and counter rotating 360 2*** 0.4
MiniLab 3 Conical     0.01–0.1 350 (420) Conical co- and counter rotating 360 2*** 0.4
Laboratory scale
Pharma 11 11 40 1.72 0.02–2.5 280 Parallel co-rotating 1000 8 1.5
Process 11 11 40 1.72 0.02–2.5 350 (450) Parallel co-rotating 1000 8 1.5
Process 16 16 40 1.73 0.4–20 350 (450) Parallel co-rotating 1000 8 3.7
Rheomex PTW 16 OS 16 25 (40) 1.73 0.2–10 400 (450) Parallel co-rotating 1100 7 (10) 7 (16)****
Rheomex PTW 24 OS 24 28 (40) 1.77 0.5–50 400 (450) Parallel co-rotating 1100 (560) 7 (10) 16 (7)****
Rheomex CTW 100 OS Conical     0.2–5 450 Conical counter rotating 250 3 7 (16)****
Pilot processing and production
TSE 24 MC 24 28 (40) 1.77 0.5–50 400 (450) Parallel co-rotating 500 (1000) 7 (10) 5.5(11)
Pharma 16 16 40 1.73 0.2–5 300 Parallel co-rotating 1000 8 2.5
Pharma 24 24 40 1.77 0.5–20 300 Parallel co-rotating 1000 8 11

L/D = Ratio of flighted screw length to outer diameter

PC = External computer control

TS = Integrated touchscreen control

 

* = Material dependent

** = Barrel length dependent

*** = Common set point

****= Driven by PolyLab drive unit

 

( ) = Optional

For Research Use Only. Not for use in diagnostic procedures.