The performance of a given plasticating unit is defined by the feed screw’s ability to melt and convey the desired rate and quality of polymer to the die or mold. As the screw flights, channel geometry, and surface treatment wear, performance and quality degrades while energy consumption soars. The overall screw design and material(s) processed has a major impact on the wear-life of the plasticating unit, so it is vital to monitor screw wear and performance, regardless of application. Minor wear will have little effect on the overall performance – as machine parameters can be adjusted to maintain productivity. As the radial clearance gap between the screw and barrel increases, energy costs and cycle times rise while rate and quality plummet.

To avoid costly downtime it is important for every company to have a robust maintenance program in place. When screw wear isn’t monitored, the overall wear on the screw can become so severe it is no longer economical to rebuild – leaving you with crippling downtime that can ultimately cost more than the components you attempted to salvage.