Twin-screw Extrusion Casting Pilot Line

 

The FDSL-25/22 is a modular, split-type laboratory continuous film forming system. It consists of two independent units connected by a melt pipeline and a coat-hanger casting die:

• Right unit - the 25 mm co-rotating twin-screw extruder host;
• Left unit - the separate casting, cooling, traction and winding unit.
• The whole machine occupies a modest floor area that fits a standard laboratory, runs at low noise, and makes material changes and cleaning fast - which directly cuts the loss of expensive raw materials such as PEEK, lithium battery separator powder and high-end additives.

Feeding → Melting & high-intensity mixing → Vacuum degassing → Melt filtration → Coat-hanger die → Mirror cooling roll (quench & shape) → Edge trimming → Servo traction → Constant-tension winding

 

Powder/pellet feeders meter the material into the twin screws, where it melts and disperses under high-intensity co-rotating shear. A vacuum port strips off low-molecular-weight volatiles. The filtered melt flows through the coat-hanger die onto a mirror chrome cooling roll, which rapidly quenches and flattens the film. Pneumatic edge trimming removes the thick edges, servo-driven traction sets the draw ratio, and a constant-tension winder collects a flat, deformation-free roll.

25 mm Co-Rotating Twin-Screw Extruder Host

Screw diameter 25 mm, L/D = 28:1, co-rotating parallel twin screws.

Modular kneading and conveying blocks can be reconfigured to tune shear for filling modification, toughening blends and reactive extrusion.

Segmented barrel; split barrel optional for easy cleaning and zero cross-contamination. Alloy-lined, wear- and corrosion-resistant for highly filled powders (calcium carbonate, glass fiber, carbon black).

Multi-zone independent PID heating + water cooling, ±1 °C accuracy, room temperature to 350 °C - covers PLA, PEEK, PPS and UHMWPE.

Metering Feeding System

Volumetric feeder standard.

Supports multi-component simultaneous feeding; liquid forced-feeding system available for liquid additives.

Coat-Hanger Casting Die

Effective die width 200 mm; max effective film width 150 mm.

Manually fine-tunable die lip gap, with independent die temperature control.

Metering System (Optional)

The optional melt metering pump can stabilize melt pressure and flow rate, reduce extrusion fluctuation, and ensure consistent film thickness and uniform product quality in continuous experiments.

Mirror Cooling Casting Roll

Roll face width 220 mm, chrome-plated mirror roll, surface roughness Ra 0.01 µm.

Constant-temperature circulating cooling water rapidly quenches and shapes the melt for a flat, smooth film with few crystal points.

Air knife optional to assist film adhesion and reduce film flutter.

Traction & Edge Trimming

Independent servo-driven traction rolls with full-line speed linkage and synchronization.

Line speed 0–10 m/min for accurate control of the film draw ratio.

Pneumatic edge trimming removes thick edges on both sides for regular, clean samples.

Electrical Control

PLC + touchscreen control with formula storage and data recording, so every recipe and process setting is saved and reproducible.

Universities & research institutes - polymer teaching, project research, thesis sample preparation, rheology and forming-mechanism research.

Biodegradable material manufacturers - formulation and process development for packaging films and degradable mulch films.

New energy enterprises - lithium battery separators, EVA photovoltaic encapsulant films, energy-storage functional films.

Functional film manufacturers - optical films, barrier films, conductive films, waterproof & breathable films.

Masterbatch & additive suppliers - filler dispersion evaluation, additive screening and formula comparison.

Third-party testing institutions - standard film samples for performance testing and standard-method verification.

 

Model	FDSL-25/22
Screw Diameter	25 mm
Screw L/D Ratio	28
Screw Speed	0–120 rpm
Processing Temperature	Room temperature ~ 350 °C
Temperature Control Accuracy	±1 °C (multi-zone independent PID)
Effective Die Width	200 mm
Max. Effective Film Width	≤ 150 mm
Film Thickness	0.02 ~ 0.1 mm
Cooling Cast Roll Width	220 mm
Line Speed	0–10 m/min, servo linkage
Melt Pressure Range	0–50 MPa, accuracy 0.5 % FS
Main Drive	Servo motor
Whole-Machine Control	PLC + touch screen, formula storage & data recording
Power Supply	3-phase 380 VAC ±10 %, 50 Hz

 

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