Extruder Screen: The Ultimate FAQ Guide

If you have any question about the extruder screen, you will find the answer right here.

From designs, material type, parts, benefits to uses – you will find all information you need about extruder screen in this guide.

Keep reading to learn more.

What is an Extruder Screen?

 Extruder Screen

 Extruder Screen

This is a wire filtration system with single or multiple layers of wires which you weld together.

The melted materials will go through a wire mesh to eliminate contaminants.

Depending on your decontamination requirements, you can use varying layers of configuration and micron ratings.

Besides, you will change extruder screens frequently since you cannot clean or reuse them.

How do you Make an Extruder Screen?

You can make extruder screens with varying specifications.

Meshes that make the extruder screens will have the exact opening relating to your application process.

Also, the size and shape of the extruder screen will depend on your machine.

Here is how to make an extruder screen:

  • Begin by choosing a wire mesh with the appropriate micron rating for the application.
  • Proceed by joining the layers of materials together using a spot welding process.
  • After spot welding, proceed to a punching process that makes use of compound tooling.
  • Thereafter, separate the final extruder screen away from the waste or skeleton substance.
  • The next step involves cleaning the extruder screen.
  • Finally, shrink wrap the clean extruder screen ready for shipping.

What are the Parts of an Extruder Screen?

These parts include:

Breaker Plate

This part has perforations and you can find them at the end of the extruder head.

It will provide support to the screen and help in preventing contaminants and other foreign particles from the die.

Also, one should measure the pressure at two locations during the extrusion process.

This is before and after the location of the breaker plate.

One will place the extruder screen against the breaker plate to assist in capturing contaminants.

Extruder Screw

This part will apply force on the material undergoing the extrusion process through the die.

It can come as a single or multiple extruder screw.

Screen Wire Mesh

The mesh of the extruder screen has to handle the materials you will be filtering.

Besides, no one wants the extruder screen to corrode or rust during the filtration process.

If the polymer you are processing can corrode mild steel, use stainless steel material.

Also, it will avoid the change for contamination through oxidation of the steel material.

The size of the opening and the weave type will also influence the quality of an extruder screen.

Depending on your outcome, the micron rating or mesh number will vary a lot.

Square meshes will offer a suitable flow capacity while filter weaves will offer a fine filtration process.

Square mesh counts and micron rating will vary from 18 mesh or 1000 microns to 500 mesh or 25 microns.

Most extruder screens have a round or kidney-shaped configuration.

One will use round extruder screens one at a time.

Also, you will stop the filtration process to change the extruder screen.

Kidney-shaped extruder screens are suitable for several screen-changing wheels.

These wheels will automatically change to the next extruder screen when it notices a pressure drop or clogging.

The advantage of this process will allow the system to run with no interruptions.

Also, the operator can change the clogs in the screen as the melt flow proceeds with the new screens.

The size of an extruder screen will vary widely depending on each style.

Round screens can be less than 1 inch or exceed 16 inches in diameter depending on the material and volume.

Kidney-shaped screens can vary between 2.5” by 3” to more than 3.5” by 6.5”.

Also, it is possible to manufacture an extruder screen with one layer or several layers.

A single layer is suitable when processing a virgin substance with fewer contaminants.

Multi-layers are suitable when processing reground or recycled materials with most contaminants.

It offers more protection layers with which the melted polymer will come into contact first.

This will protect the finer filtration single or multi-layer from damage from debris, pressure, or when the plastic is swirling.

Also, there is a coarse layer of faves in the breaker plate.

This will protect and support the fine layer mesh from pushing into the holes of the breaker plate.

What is the Price of an Extruder Screen?

The price of an extruder screen will depend on several factors like:

  • Shape.
  • Size.
  • Alloy.
  • The number of layers.
  • Unique processing requirements.
  • The number of extruder screens you purchase.
  • Cost of individual extruder screen specifications you select.

Can you Change an Extruder Screen?

Good extruder screens are usually of high quality and you can use, change, and discard them at frequent intervals.

The replacement period depends on the filtration process of your application.

Also, the amount of dirt in the melt, or the number of impurities you need to filter out influences the replacement period.

When filtering out clean melt substances, they can last for many days or weeks with no changes or replacements.

Besides, you need to replace extruder screens that filter dirty materials severally every hour.

Extrusion Screen Pack

Extrusion Screen Pack

What Types of Extruder Screens are Available?

There are several types of extruder screens and they include:

  • Disc extruder screens.
  • Belt extruder screens.
  • Cylindrical extruder screens.
  • Single or multi-layer extruder screens.
  • Pack extruder screens with spot welding and with or without an aluminum frame.
  • Circular, square, rectangular, kidney-shaped, cone, or oval extruder screen.
  • Nickel alloy, brass wire mesh, galvanized wire mesh, or stainless steel wire mesh extruder screens.

What are Extruder Screens for the Contact of Food Polymer Filtration?

These are extruder screens suitable for use in the food and beverage industries.

Food grade materials have to conform to several regulatory requirements.

This means the filtration process and the results should be stringent.

Ultrasonically cleaning an extruder screen is one way of ensuring the filter has no dirt, oil, or grease.

Besides, you can ultrasonically clean carbon steel and stainless steel alloy.

Also, they conform to ISO 9001 certification meaning the manufacturing meets the highest standards of quality.

What are Some Extruder Screens Product Options?

These include:

Auto Screen Belts

This has a reverse dutch weave belt and slits that match with the rubbed edges.

Cylindrical Extruder Screen

They come in varying sizes and offer a high and low-pressure drop.

Frame Packs

These come in varying weaves, finishes, and materials.

Spot Weld Packs

Spot weld extruder screen offer a simple insertion of replacement screens within the screen changer by removing pack assemblies.

Pleated Spin Packs

They offer stainless steel or aluminum binders.

These will form a seal on the outside diameter of the extruder screen pack and the breaker plate.

Custom Extruder Screen

It is possible to customize an extruder screen for a specific application, whether original or a replacement.

What are the Applications of Extruder Screens?

There are varying uses of extruder screens in various fields including:

  • Recycling
  • Extrusion
  • Sheet extrusion
  • Melt pump filters
  • Blow film
  • Compounding
  • Profile extrusion
  • Post-consumer recycling
  • Continuous melt filters
  • Industrial scrap recycling
  • Carpet recycling
  • Synthetic fiber production
  • Food grade recycling

What is a Disc Extruder Screen?

This is an extruder screen whose construction comprise of is stainless steel, brass, plain steel, or galvanized wire mesh.

They offer an extremely thin and fine extrusion in industrial plants.

One can make them from sintered fiber web, a woven wire mesh, or a sintered cloth of a wire sheet.

Also, the most popular material is a woven wire mesh filter.

The features of this extruder screen include:

  • Resistant to corrosion and high temperatures.
  • Resistant to tear and wear.
  • Offers good molding.
  • Also, it has a reliable filtration efficiency.
  • It is neat with no bugs.
  • The compressive strength is high.

The main applications include:

  • Filtration of liquids and gases.
  • Separation of other mediums.
  • Accurate stress filtration.
  • Fuel filtration.
  • Vacuum filtration.
  • Chemical industries.
  • Medical industries.
  • Mettalurgy.

What is a Multilayer Extruder Screen?

These are extruder screens that have several layers of meshes that you weld together.

It has the finest screen wire in the middle of the pack while the larger mesh sizes are on the outer sides.

Also, the arrangement is symmetrical hence preventing one from installing a multi-layer extruder screen backward.

They are suitable in the extrusion process of plastics, fibers, and polymers.

It is possible to customize the number and the arrangement of the welding spots according to your application needs. Also, one can produce multi-layer extruder screens with welds.

For instance, you can weld a stainless steel wire mesh and a plain steel wire mesh together.

Multi-layer extruder screens come in different shapes and sizes.

One will properly assemble and spot weld them to produce multi-layer packs.

 Multilayer Extruder Screen

 Multilayer Extruder Screen

Some features of a multi-layer extruder screen include:

  • They are sturdy, strong, and offer convenience when you are processing substances.
  • Also, one can assemble them in the right sequence to eliminate errors when the operator is installing them.
  • Also, it will make the extrusion clear and clean.
  • It comes with two or more layers, depending on your application needs.
  • The material construction is stainless steel, aluminum alloy, nickel alloys, woven wire cloth, copper wire cloth, etc.
  • It comes in several shapes like round, oval, elliptical, rectangle, etc.
  • The diameter of the pack can range between 20 mm and 900 mm.
  • Also, the frame style can be with or with no frame and spot welding.

What are Some Extruder Screen Shapes Available?

There are several shapes that an extruder screen comes in, which include:

Circle Extruder Screens

They have a circular shape, are durable, resistant to corrosion, and a robust structure.

It can come as a single or a multi-layer extruder screen.

The benefits include:

  1. The cut is uniform thus no uneven edges.
  2. It offers high durability.
  3. They are stable when under tension.
  4. Also, they have a smooth surface screening lacking sharp edges, acute angles, or burrs.
  5. They provide a cleaner and clearer extrusion.
  6. It will keep off contaminants from the final extrusion substance.
  7. They are suitable for the chemical, pharmaceutical, and rubber industries.

Cylindrical Extruder Screens

They have the shape of a tube and come as a single or multi-layer extruder screen.

It is durable and strong thus suitable for extrusion of polyesters, polymers, plastic blown, paint, polyamide, varnishes, etc.

One can use them to filter sand or other small particles from water in irrigation systems or industrial plants.

Material construction is stainless steel, iron wire, or galvanized wire.

They can be long or short depending on your application requirement.

The frame can be from aluminum alloy or a spot welded edge.

These extruder screen types are suitable for film coating, filtration, and lamination in petroleum plants, rubber, plastic, and pharmaceutical industries.

Some advantages include:

  1. They offer a high flow rate at a low-pressure drop.
  2. Also, they have a wide operational temperature capacity.
  3. Besides, they have high strength and a high dirt holding capability.
  4. They are resistant to acids, corrosion, heat, alkali, wear and tear.

Kidney-Shape Extruder Screens

Their shape is kidney-like and you can make them from various materials.

One can use a single-layer kidney-shaped extruder screen in blown film applications that use low pressures.

Multi-layer kidney-shape extruder screens are sturdier and you can use them severally in glass, plastic, and fiber industries.

The material construction is stainless steel, black wire cloth, alloy wire, and aluminum meshes.

Processing can be spot welding, plain weave, dutch weave, etc. It offers an accurate filtration process, is reusable, and long-lasting.

The main applications are extrusion and the reclamation of glass or plastics.

Also, one can use it in oil industries, pharmaceuticals, film coating, etc.

Extruder Screen Shapes

 Extruder Screen Shapes

Rectangular Oval-Shaped Extruder Screens

They have a precise size and the material construction is a stainless steel wire with high resistance to rust and corrosion.

Also, you can make them from copper, aluminum, or low carbon steel depending on your application requirements.

They are suitable for fine filtration in color masterbatch, filler industries, non-woven materials, and fibers extruder industries.

The processing can be woven, perforated, or sintered and come as a single or in multiple layers.

They are easy to install, have high tensile strength, and are durable.

Besides, they offer a clean and fine extrusion of polymers and molten substances.

Also, they are good for metallurgy, plastic, leather, and petroleum industries.

Ring-Shaped Extruder Screens

The material construction is aluminum, copper, or stainless steel.

They are circular but with a circular gap at the center to form a ring shape.

Besides, they are lightweight, offer accurate filtration, are easy to operate, and offer resistance to high temperatures.

Some applications include medical industries, metallurgy, and oil industries.

They offer clean extrusion to chemical fibers, ceramics, adhesives, or melt plastics.

What is the Edge Material for an Extruder Screen?

The edge material can be metallic, spot welding, or rubber in nature.

What are the Types of Mesh you can find on Extruder Screens?

The common mesh types of extruder screen include:

  • Plain weave mesh
  • Dutch weave mesh
  • Sintered mesh
  • Perforated mesh
  • Etched mesh
  • Expanded metal mesh
  • Pleated mesh
  • Wedge mesh

What are some Processing Methods for Extruder Screens?

There are several processing methods like:

  • A single-layer extruder screen.
  • Single extruder screen layer with a frame.
  • Multi-layer pack of extruder screen.
  • A multi-layer extruder screen with a frame.
  • Multi-layer extruder screen with spot welding.
  • A rubber frame extruder screen
  • Tri-clamp screen gaskets.

What Materials Make an Extruder Screen?

Here are the common materials used in making an extruder screen:

 Stainless Steel Extruder Screen

 Stainless Steel Extruder Screen

Can you Clean and Reuse an Extruder Screen?

It is not possible to clean and reuse an extruder screen. This is because the flow of products can make the mesh warp thereby lowering their efficiency.

Which Qualities will Ensure an Extruder Screen is Efficient?

Some of the qualities to look for in an efficient extruder screen consist of:

  • Durability of the extruder screen.
  • Resistance to elements like corrosion, rust, and high temperatures.
  • Number of screen mesh per square inch.
  • Weave type like plain weave, dutch weave, twilled weave, etc.
  • Diameter of the extruder screen.
  • Percentage of the opening of the mesh.

What are the benefits of extruder screens?

Here are the key advantages of extruder screens:

  • Corrosion and anti-abrasive resistance.
  • An optimum cost-performance ratio.
  • Good quality control during the filtration process.
  • Durability with a robust structure.
  • It can come in different shapes and sizes.
  • Material construction can vary considerably.

As you can see, there are many factors you should consider when choosing extruder screen.

The best part, this guide has highlighted all the fundamental aspects you need to know.

In case you have any question or inquiry, contact FilSon Filters now.

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