Transcyko CORP Counter-Rotating Parallel Twin Screw Extruder Gearboxes
CORP Counter rotating twin screw extruder gearboxes are the rubber and plastics extruder industry choice for mixing rubber and plastic compounds where even consistency is required. Transcyko CORP parallel twin screw extruder gearboxes give you the reliable torque you need with convenient frame sizes and ratios to make a perfect match for your OEM rubber and plastic extruders.
Counter rotating extruder gearboxes
In a counter rotating extruder gearbox the output screws rotate in opposite directions, enabling very efficient mixing and compounding of plastic and rubber materials. Counter rotating twin screw extruders are ideal for high torque, high shear mixing of materials with high viscosity that resist smooth mixing using single screw extruders or parallel co-rotating twin screw extruders.
- CORP counter-rotating twin-screw extruders for high torque density 16-18 Nm/cm³ for each shaft
- Highly efficient mixing and compounding of plastics & rubber
- Ideal for smooth mixing of high viscosity materials
Counter rotating twin screw extruders are the alternative to co-rotating twin screw extruders when you don’t just want very high shearing and mixing forces, but also want to improve the homogenous mixing characteristics of the resulting compound. The counter rotating parallel configuration forces the compound between the mixing screws. Consistency of the mix can be further adjusted by output speed and choice of either straight or conical screws.
| Size / Model | Nominal Ratio (i) | Input Speed n1 [min−1] | Output Speed n2 [min−1] | Rated Torque per Shaft Mt [Nm] (Fs = 1.2) | Rated Total Torque Mt [Nm] (Fs = 1.2) |
|---|---|---|---|---|---|
| CORP 55/65* | 20–80 | 1500–2500 | 20–60 | 3050 | 6010 |
| CORP 61/75* | 20–80 | 1500–2500 | 20–60 | 4790 | 9580 |
| CORP 64/75* | 20–80 | 1500–2500 | 20–60 | 4790 | 9580 |
| CORP 73/90* | 20–80 | 1500–2500 | 20–60 | 6610 | 13220 |
| CORP 75/90* | 20–80 | 1500–2500 | 20–60 | 7450 | 14900 |
| CORP 75.35/90* | 20–80 | 1500–2500 | 20–60 | 7450 | 14900 |
| CORP 77/93* | 20–80 | 1500–2500 | 20–60 | 7450 | 14900 |
| CORP 90/110* | 20–80 | 1500–2500 | 20–60 | 13500 | 27000 |
| CORP 92.5/114* | 20–80 | 1500–2500 | 20–60 | 13500 | 27000 |
| CORP 110/130* | 20–80 | 1500–2500 | 20–60 | 24080 | 48160 |
Choosing parallel or conical counter rotating twin screw extruders
The choice of parallel or conical counter rotating twin screw extruder is highly dependent on the chosen application. Choice of parallel or conical screws has a significant impact on barrel geometry, screw centreline, and machine assembly, so it cannot be left to the end of the design phase. Counter rotating twin screw extruders are more complex and have significantly more challenging engineering requirements than single screw extruders, requiring multi-stage gearing and balanced torque distribution.
If you are looking for a counter rotating twin screw extruder solution for your rubber or plastics production line, please contact us to discuss your exact requirements. Our in-house engineers have a wealth of experience in gearbox design and manufacturing that enables us to rapidly assess and advise on your specific machinery requirements and offer the best, most cost-effective solution.
Choice of size and type of twin screw extruder gearbox is product related
Counter-rotating parallel twin screw extruder gearboxes are used in the plastics industry for consistent masterbatch production, compounding and plastic extrusion, offering added benefits to industries that require extremely smooth and reliable consistency, like PVC windows and profiles. They are also used in composite manufacturing as well as rubber production.
Single stage gearboxes can be used for low power, high mixing quality applications, and add simplicity to the design and engineering for high reliability and extended service intervals. Most extrusion tasks, however, require the higher torque that can only be achieved efficiently by multi-stage gearing solutions. Desired throughput and torque dictate the gear stages and scale of gearbox required.
High manufacturing quality is essential for extruder gearboxes
Manufacturing quality of all twin screw extruder gearboxes has a significant impact on longevity, and this is very apparent in the requirement to use appropriately rated thrust bearings on the output shafts to withstand very high axial loads created by the pressure that is generated in the extruder barrel during processing. Premature bearing wear reduces mixing quality and efficiency as well as leading to potentially costly maintenance downtime, and is one of the most common failures of rubber extruder gearboxes.
Precision DIN4 gear grinding for twin screw extruder gearboxes
Very high precision gear grinding (to DIN4) is required to enable twin screw extruder gearboxes to comfortably withstand high torque loads without excessive wear or the risk of premature failure. Transcyko uses state of the art gear grinding technology to achieve DIN4 German DIN 3962 standard (JIS 0) gear grinding precision for our CORP coounter-rotating twin-screw extruder gearboxes.
Ease of servicing and maintenance including replacement parts
Ideally your choice of twin screw extruder gearbox should be with a supplier who gives you complete confidence in component quality, ease of servicing and replacement of standard wear components, as these will impact customer impressions of the quality of your entire extruder line.
Effective, high efficiency cooling systems are required
Heat management and heat dissipation is an essential feature of counter-rotating twin screw rubber extruder gearboxes, due to higher pressures and axial loads on the gear box than are found in less intensive mixing processes. Effective cooling system design is one of the most important requirements for a twin screw rubber extruder gearbox. Cooling and lubrication also have an important function, along with gear grinding precision, in reducing noise and vibration, and the premature wear that can result.
Transcyko makes gearboxes for all types of extruders
Transcyko manufactures single screw and twin screw rubber extruder gearboxes for a very wide range of plastic and rubber manufacturing. We use only high quality materials and state of the art production processes focused on long term reliability and delivering the power required for consistent, accurate, mixing. We offer application specific engineering solutions to our extruder customers to ensure the best possible performance.
The process applications of your rubber extruder will determine which type of extruder gearbox you require and this is an essential part of the design stage. Please contact our engineers if you have any queries or seek clarification, customization options or modifications to suit your specific requirements, they will be happy to help you find the perfect gearbox solution for your rubber extruder design.