PE+CaCO3 Filler Masterbatch Compounding Line
Xuedong Technology specializes in large-diameter PE pipes and fittings. The company faced two pressing issues. First, frequent fluctuations in PE resin prices were steadily eroding margins. Second, increasing product homogeneity in the market led to intense price competition and declining profitability.
To address raw material cost pressure and performance stability, HS Machinery designed a 75D parallel co-rotating twin-screw compounding line configured as a three-stage pelletizing system. The main configurations include:
- Main and auxiliary extrusion setup
The primary extruder is a 75mm co-rotating twin-screw unit. Because calcium carbonate and PE resin differ significantly in density and polarity, a specially designed screw configuration was used to generate strong shear and intermeshing action. This effectively breaks up CaCO₃ agglomerates and ensures uniform dispersion, reducing brittleness caused by poor filler distribution. Two single-screw auxiliary extruders are integrated downstream to support staged pressure building and stable output. - Filtration and degassing system
The line is equipped with one non-screen screen changer and one plate-type screen changer for impurity removal. A multi-section vacuum venting system further removes trapped gases during processing, helping produce dense pellets with minimal internal voids.
With this high-calcium PE compounding line, Xuedong Technology achieved stable large-scale production at 500 kg/h. The finished compound contains up to 50% CaCO₃ filler, directly replacing half of the PE resin content. This significantly reduced raw material costs, by more than 30%, while maintaining processing stability for pipe manufacturing.
- Raw material preparation and formulation
- Primary melting and extrusion
- Two-stage extrusion
- High-precision filtration and degassing
- Third-stage pelletizing and cooling
- Finished product handling and packaging