Technical Problem Solving

Introduction to Twin Screw Configuration and Design

Language: English
Length: 90 min
Recorded on: 09 Jul 25

Package Includes

6 months access to Course Recording, Presentation Slides, Q&A Transcript

Course Description

Overcome your polymer compounding challenges (melt disturbance, uneven material thickness, surging…) by unravelling the underlying science behind twin screw extruder configuration and design.

In this course industry expert Luis Roca will explain how different element designs function to ensure proper distribution & dispersion of ingredients & materials. He will also lay focus on unit operations like polymer melting, mixing, devolatilization... to help you achieve high quality & productivity.

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Luis Roca
Luis Roca
AIMPLAS
0 courses

Luis Roca is the Head of the Compounding Department at AIMPLAS. He is an experienced polymer researcher specializing in compounding.

Throughout his career, Luis has worked as an R&D project developer, either as the lead or supporting researcher, collaborating with plastic companies to modify or enhance polymer properties across regional, national, and European projects. He has contributed to various projects involving nanomaterials, biopolymers, flame retardancy, natural fibers, electrical conductivity, and recycling.

With over 15 years of experience in processing a wide range of polymers—including commodity plastics, starch-based biopolymers, technical polymers, and high-performance materials—Luis has also delivered more than 3,000 hours of training courses to companies in areas such as compounding, additives, fillers, and injection molding. Additionally, he has presented at numerous seminars organized by AIMPLAS and at various conferences related to plastic modification and recycling.

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Participants of this course includes

Why should you view this course?

You will agree that a twin-screw extruder design plays a significant role in ensuring that all the ingredients are distributed evenly, dispersed well, and the compound is processed at the correct melt temperature.

However, getting all these factors right can fail miserably if your twin screw configuration and design are not up to the mark. So, why rely on hit & trial, when the solution is right in front of you! Attend this course to:

  1. Get a detailed view of screw design & configuration with a better understanding of extrusion science and compounding process parameters.

  2. Easily adapt your extruder to suit new material by better understanding how different element designs function to promote unit operations such as solids conveying, polymer melting, mixing, devolatilization, pumping…

  3. Address challenges & troubleshoot compounding instabilities (melt disturbance, surging…) by implementing the tips & tricks shared by the expert.

Who should join this course?

  • R&D Chemists, Compounders, Engineers, and Technicians working with twin screw extruders and new materials, looking to accelerate their learning curve & solve complex compounding challenges.

  • Complete the course and (unlock your personalized certificate) – your badge of accomplishment awaits!

  • This course is suitable for beginner level proficiency
    Beginner
Questions you will be able to answer after this course:

  1. What is the difference between co-rotating and counter-rotating twin screw extruders?

  2. How do I choose the right screw configuration for my application?

  3. Which screw elements affect residence time and dispersion?

  4. How do I avoid over-shearing or degrading sensitive materials?

  5. What screw setup is ideal for compounding filled polymers or masterbatches?

Course Outline

Extrusion of plastics – Overview

Operations of a compounding line

  • Components in detail (feed hopper, continuous barrel, long tapered screw, die)

The compounding extruder as a series of unit operations

  • Feeding
  • Melting
  • Downstream feeding
  • Mixing
  • Venting
  • Pumping

Configurability of the twin-screw extruder

  • Clam Shell Barrels
  • Segmented Barrels
  • Closed Barrels
  • Open Barrels
  • Side feed Barrels
  • Assembled Barrels

Function of screw elements

  • Conveying
  • Melting
  • Mixing
    - Distributive
    - Dispersive
    - Liquid

Examples of Screw Designs

  • Filled polymer
  • Glass filled polymer
  • Liquid addition compounding
  • Pelletizing powder
  • Incorporating nanoparticles
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