How to Optimize Barrel Temperature Profiling for Recycled Polymers

Tailoring barrel thermal settings for تولید کننده گرانول بازیافتی recycled polymers demands careful consideration due to their frequent contamination, chain scission, and variable feedstock quality

The first step is to understand the thermal history of the recycled material

Each reprocessing cycle tends to break polymer chains, decreasing molecular weight and changing how the material responds to heat

They frequently begin softening earlier and are far more prone to decomposition when exposed to excessive heat

Prioritize detailed physical and thermal profiling of the recycled batch

Apply melt flow testing and DSC scans to establish the optimal processing window for your material

This data will guide your temperature settings

Avoid using the same profiles you would for virgin material, as this can lead to thermal degradation, discoloration, or inconsistent flow

Design a progressive heat ramp from inlet to discharge

Keep the feed zone minimally heated—only enough to avoid clogging without initiating early softening

Gradually elevate temperature in the compression section to promote uniform fusion

Hold the final zone just under the polymer’s critical decomposition point

Monitor the melt temperature at the die or nozzle using a reliable sensor

Continuous monitoring is essential due to inherent inconsistencies in reclaimed streams

When melt exceeds target, lower rear barrel settings and decrease screw RPM to cut shear-induced heat

If the melt is too cool, increase the front zone temperatures slightly and consider increasing screw RPM to generate more shear, but only if the material can tolerate it

Reduce the time material spends in the barrel

These materials degrade faster under extended heat, so shorten cycles and eliminate idle holds

Clean the barrel and screw regularly to remove degraded material that can act as a nucleation point for further degradation

If feasible, mix in 5–15% virgin resin to stabilize processing

It smooths out inconsistencies and lessens reliance on extreme settings

Always test small batches before full production runs and document how each temperature setting affects output quality, color, and mechanical properties

Long-term tracking enables the creation of a precise, repeatable profile for your unique recycled material