As a core component in plastic extrusion production lines, melt pumps are widely applied across diverse scenarios. Their primary function is to achieve high-precision metering, stable conveying, and pressure control of molten materials through precise gear or screw engagement. Below is a detailed analysis of their specific applications and technical advantages:
I. Key Application Areas
1. Film and Sheet Extrusion
Scenarios: Biaxially oriented polypropylene (BOPP) films, cast films, optical films, etc.
Technical Impact:
Melt pumps restrict pressure fluctuations to within ±1%, reducing film thickness deviations from 5% (traditional processes) to below 1%. For instance, a BOPP production line integrating a melt pump achieved stable thickness deviations within ±1.5%, boosting the yield rate by 20%.
Pipe and Profile Extrusion
Scenarios: PE, PP, and PVC pipes, as well as wood-plastic composites (e.g., door frames, stair railings).
Technical Impact:
In wood-plastic production lines, melt pumps paired with twin-screw extruders resolve melt fracture caused by high wood flour loading, enhancing tensile strength by 15%.
For pipe manufacturing, melt pumps reduce extruder backpressure, lowering screw axial force by 30% and extending equipment lifespan by 40%.
Chemical Fiber Spinning
Scenarios: Melt spinning of polyester, nylon, polypropylene, etc.
Technical Impact:
A global enterprise adopting a five-gear melt pump reduced spinning breakage rates by 40% and decreased filament fineness variation from 2.5% to 0.8%.
High-temperature melt pumps (above 300°C) ensure stable polymer melt delivery, maintaining fiber fineness uniformity and supporting differentiated fiber production.
4. Engineering Plastic Modification
Scenarios: High-viscosity materials such as glass-fiber-reinforced plastics (filler content >40%) and thermoplastic elastomers.
Technical Impact:
Specially designed melt pumps, combined with forced feeding systems, prevent melt fracture and reduce material waste by 20%.
An automotive parts manufacturer adopting this solution improved tensile strength by 15%, meeting high-performance requirements.
5. Co-Extrusion and Multi-Layer Extrusion
Scenarios: Multi-layer composite pipes, packaging films, etc.
Technical Impact:
Melt pumps precisely control melt flow rates for each layer, ensuring stable interlayer thickness ratios and preventing interface delamination.
6. Recycled Material Pelletizing
Scenarios: Recycled HDPE, PET chemical recycling.
Technical Impact:
Melt pumps homogenize viscosity fluctuations caused by raw material variability, narrowing the melt index range of recycled HDPE from ±15% to ±3%.
In PET depolymerization reactions, they accurately control material residence time, increasing depolymerization rates from 85% to 98%.
Typical Application Cases
BOPP Film Production: After integrating a melt pump, the film thickness deviation decreased from 5% to below 1%, while production speed increased by 15%.
Chemical Fiber Spinning: A five-gear melt pump reduced spinning breakage rates by 40%, enabling the development of functional textiles.
Automotive Components: The tensile strength of glass-fiber-reinforced plastic products improved by 15%, with material waste reduced by 20%.
PET Chemical Recycling: The depolymerization rate rose from 85% to 98%, advancing the circular economy.
The melt pump has become an indispensable "heart component" in plastic extrusion production lines, with its applications spanning the entire industrial chain—from films and pipes to high-end chemical fibers and recycled materials. By stabilizing pressure, enhancing precision, reducing energy consumption, and extending equipment lifespan, it systematically addresses critical pain points in extrusion production, such as instability, inefficiency, and high energy use, driving the industry toward upgrades in high precision, low energy consumption, and sustainability.
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