Frequently Asked Questions (FAQ)

1. What is a co-rotating twin-screw extruder?

A co-rotating twin-screw extruder is an advanced polymer processing machine using two intermeshing screws rotating in the same direction inside a modular barrel system. The technology provides excellent mixing, homogenization, dispersion, degassing and process control, making it the preferred solution for demanding applications such as polymer compounding, masterbatch production, engineering plastics, bio-polymers and mechanical recycling.

2. What are the main advantages of a twin-screw extruder compared with a single-screw extruder?

A twin-screw extruder provides significantly higher flexibility and process control compared with conventional single-screw systems.

Key advantages include:

• Superior distributive and dispersive mixing
• Better filler and fibre dispersion
• Higher flexibility for different materials
• Efficient devolatilization and degassing
• Faster colour and formulation changes
• Improved process stability
• Ability to process complex polymer formulations

These advantages make twin-screw extrusion ideal for advanced polymer compounding applications.

3. What materials can be processed with a co-rotating twin-screw extruder?

Co-rotating twin-screw extrusion systems can process a wide range of polymers and compounds, including:

• Engineering plastics
• Masterbatch formulations
• Thermoplastic elastomers (TPE)
• TPU, TPO and TPV materials
• Polyolefins such as PE and PP
• Filled polymers
• Glass fibre reinforced compounds
• Flame-retardant materials
• Bio-based polymers
• Recycled plastics
• Natural fibre composites (WPC)

The modular screw design allows the process configuration to be optimized for each material.

4. What is polymer compounding?

Polymer compounding is the process of modifying base polymers by adding fillers, fibres, pigments, additives or other materials to achieve specific performance characteristics.

Compounding can improve:

• Mechanical strength
• Thermal resistance
• UV stability
• Flame retardancy
• Electrical properties
• Processability
• Sustainability

Co-rotating twin-screw extruders are widely used for high-performance polymer compounding because of their excellent mixing capability and process flexibility.

5. Why is self-wiping screw technology important?

Self-wiping screw geometry is one of the most important advantages of modern co-rotating twin-screw extrusion technology.

The intermeshing screws continuously clean each other during operation, reducing stagnant areas where polymer degradation or contamination could occur.

Benefits include:

• Reduced material degradation
• Faster product changeovers
• Improved purity
• Lower cleaning requirements
• Higher production uptime
• Consistent product quality

6. Can twin-screw extrusion be used for mechanical plastic recycling?

Yes. Advanced co-rotating twin-screw extruders are highly suitable for mechanical plastics recycling.

The technology provides:

• Efficient melting and homogenization
• Excellent degassing capability
• Moisture and volatile removal
• Stable melt quality
• Processing of PCR and PIR materials
• Production of high-quality recycled compounds

ICMA San Giorgio systems are designed for demanding recycling applications, supporting circular economy manufacturing.

7. What is Direct Extrusion (In-Line Compounding)?

Direct Extrusion, also known as In-Line Compounding, combines polymer compounding and final product manufacturing into one continuous production process.

Instead of producing pellets first and processing them again later, the polymer melt can directly move from the twin-screw extruder to downstream equipment for products such as:

• Sheets
• Films
• Foils
• Profiles
• Other finished components

Advantages include:

• Lower energy consumption
• Reduced thermal history
• Improved material properties
• Lower production costs
• Increased manufacturing efficiency

8. Can PU Consulting AB support development from laboratory trials to industrial production?

Yes. PU Consulting AB supports customers throughout the complete polymer development and production journey.

Together with ICMA San Giorgio, customers can access:

• Laboratory extrusion trials
• Pilot-scale testing
• Process optimization
• Material evaluation
• Scale-up studies
• Industrial production solutions

This approach reduces technical risk and helps accelerate the transition from material concept to commercial production.

9. Why should manufacturers perform an End-to-End Engineering Assessment™?

An End-to-End Engineering Assessment™ identifies improvement opportunities throughout the complete manufacturing value chain.

The assessment can include:

• Raw materials
• Polymer formulations
• Production processes
• Extrusion equipment
• Automation
• Quality systems
• Packaging
• Logistics
• Recycling opportunities

By analysing the complete system, manufacturers can identify measurable improvements in quality, productivity, profitability and sustainability.

10. Why choose PU Consulting AB and ICMA San Giorgio for extrusion projects?

PU Consulting AB combines deep polymer expertise, material analysis and process engineering with the advanced extrusion technology of ICMA San Giorgio.

Together we support manufacturers with:

• Polymer compounding solutions
• Twin-screw extrusion technology
• Laboratory and pilot trials
• Industrial production systems
• Mechanical recycling solutions
• Process optimization

Our goal is to help customers transform advanced materials and innovative ideas into successful industrial products — From Molecules to Market Leadership™.