Do-it-yourself extruder screw repair

Do-it-yourself extruder screw is one of the most popular requests today. And it's just that, because gradually this element becomes a truly necessary item in the molding of plastic. When it comes to extrusion, doing without an extruder screw is unrealistic. It is this element that allows you to quickly and with proper quality create a series of plastic products, rubber objects and mixtures, without being distracted by other manipulations.

The direct working process is the continuous movement of the raw material through the hole intended for molding. It is this process that results in a superior unit of product. And here the main role lies on such parts of the extruder as screws. By and large, to give a more complete understanding of the situation, you can compare the screws with a spiral moving meat through a meat grinder. It's the same for plastic.

It should be noted here that this element is very, very vulnerable. It is constantly subjected to a load, often excessive, and therefore fails. And buying a screw can have a very negative impact on the family budget. A do-it-yourself extruder screw is an acceptable option for saving money. The key point here is a thorough knowledge of the process.

To better understand the entire manufacturing process of this element, here is a list of the necessary tools:

So, the tools are laid out within reach, the place is prepared. As a raw material, you can take sheet steel, its thickness should be 3mm. But still, the first thing to consider is what and how the case will be created from. The body is a structure that resembles a segmented pipe, where each segment is bolted together.

Do not forget that the channels for loading and unloading raw materials must be present initially, and not hastily drilled. Otherwise, you will have nowhere to put the raw materials and, accordingly, the final output of the product will not be produced either. Do not forget about the liquidation hatch - in order to clean the unit from litter in time and prevent slaughter. The calculation of the extruder screw is made depending on the size of the direct unit.

In fact, all screws can be divided into two groups:

• The screw is solid, this element of the extruder is quite interesting. On the basis, direct and strong, the plate making capture is located. The plate is arranged in a helical manner, in which case the balance of the screw is very important. It is competent balancing that can protect the unit from deformation, displacement of vibrations and bends. Also, do not forget that the base of the screw must be wider than its shipping part.
• The second option is a tape screw. The design of this auger is quite simple - a pipe with a tape passed through the "ribs". Such an extruder screw is used when working with complex material. This design is fairly easy to clean.

Having finished with the preparatory work and having laid out the completed components, you can start assembling. The first screw is mounted in the manufactured case, the drive is attached to the extreme side of the structure. Here a gearbox is needed, in this case a two-stage one. It is the gearbox that is connected to the electric motor. Three seconds, and that's it, your auger is ready.

In order for a freshly made element to work as long as possible and better follow a few simple rules:

• frequent and abundant lubrication for the device will allow you to delay the moment of final breakdown for a long time;
• moderate loading - the weight of the loaded raw materials cannot be higher than the norm;
• careful prevention of drops in rotational speeds - it is the drops that wear out the unit especially strongly;
• timely shutdown and cleaning of the unit in case of clogging.

It is these simple and understandable commandments that will significantly extend the life of your extruder, which is undoubtedly important. After all, a do-it-yourself screw extruder will be cheaper in monetary terms, but, undoubtedly, more expensive in spiritual terms. Like any other thing created independently.

Usually, auger repair is carried out in the following cases:

– scheduled repairs;

– Foreign material entering the auger.

Our customers who have bought a new screw or a pair of screw often send the old screw for repair - this smart decision allows us to have one of the main parts of the extruder in stock.

Restoration and repair of screw pairs of extruders and granulators.

Our specialists have developed a process for the recovery of screw pairs of extrusion equipment, such as extruders, granulators and injection molding machines.

The refurbishment of key extruder components, such as the screw sleeve, greatly increases the productivity of the plant, and consequently reduces production costs. That in the current economic situation is a very weighty argument. The operating experience of restored screws allows us to talk about the complete restoration of their performance and resource at a price significantly lower than the cost of new parts.

The problem with which processors contact our company is the following:

• wear of the working part of the screw (screw pair):

In this case, our craftsmen perform turning, centering (checking and restoring alignment and the correct shape of the ridges), hardfacing of hardening material, honing of the sleeve, nitriding or carburizing of the sleeve. After that, the screw is sent for grinding, dimensional control, polishing and bench testing.

The restoration process is:
- Plasma surfacing of screw ridges with carbide materials
- Grinding and polishing of mating surfaces and internal parts of the auger ridges (according to the measurements of the sleeve. According to the sleeve cleaned or honed).
- Cleaning the ends of the auger. (addition if necessary).
- Check for runout, ovality, centering on the axis of rotation,

- Hardness control.
-Packing in a shipping box or oiling and wrapping in stretch film.

restoration of extruder screws

repair of extruder screws

Terms and cost of work:

The average recovery time for a screw pair for an extruder is 15-30 calendar days.

Individual cases and terms are always negotiated after an analysis of the failure and material of the auger.

The cost of work on the most common defects is from 30,000 rubles (depending on the complexity of the work performed, the length and diameter of the screw).

Examples of work done:

1. Extrusion line for PP yarn Starlinger – screw surfacing and repair;
2. ZkstruderQweenB(Taiwan) F60, F42 – screw surfacing;
3. Extruder VM-900 (Russia) F45 – screw surfacing;
4. Extruder URP-1500 F90 – screw surfacing;
5. Granulator 125/105RS(China) F125 – screw surfacing;
6. TPADemag500 tons - surfacing of the screw.

Application for repair of extruder screws

To repair your auger - contact us! And we will promptly perform a preliminary calculation of the cost.

Many keep an impressive livestock of animals in their backyard. In such cases, the problem of feed processing becomes acute - the appetites of the “wards” are considerable, and compound feed is prepared very often. To do this, you also need equipment, and industrial designs cost a lot. But there is still a way out - to assemble a grain extruder with your own hands.

This mechanism is designed to process raw materials (grain, straw, etc.) into "light" animal feed. The necessary conditions for obtaining such products are high pressure and high temperature.

This specificity of work leaves its mark on the entire structure. Among the main parts and assemblies are:

• frame (aka bed) that will hold the entire apparatus;
• receiving bunker;
• drive in the form of a belt;
• engine;
• reducer;
• screw;
• fiera;
• knife;
• cylinder;
• cuff;
• adjusting key;
• washers;
• control panel.

Of course, industrial designs are more complex and productive, but a home-made option will be enough for the owner of the farmstead. If you have a fairly powerful electric motor at hand, you can get up to 40 kg of high-quality mixture per hour.

Having learned what the extruder is intended for and how it can help in the preparation of the feed base, let's take a closer look at the processing process itself.

Most extruders (both factory and homemade) are distinguished by their versatility. In addition to grain mass, the following are suitable as raw materials for processing:

• rye and soybeans;
• meal and cake obtained from these crops;
• fish and meat meal.

Processing starts with the fact that the raw material that has entered the bunker is fed to the injection screw, the heating washers of which soften the grain. The auger, rotating, moves the products to the fiera. It is there that the heat treatment and the main crimping take place.

The last stage is the passage through the disk, controlled by the handle (by changing the position, you can set the desired fraction value). A small roller with a knife is hooked to it by a spring, which cuts the resulting "sausages". They come out through holes in the form of a thin (up to 3 cm) dense tourniquet. Note that this is typical for large, industrial units. For self-made ones, the exit is adjusted directly from the fire.

The extruder, designed for the preparation of feed, compares favorably with the fact that even stale and slightly aged grain can be used - with such heat treatment, the mold is “neutralized”.

You can assemble such a device at home. This will require suitable parts and locksmith skills (although familiarity with turners is also desirable). Let's start with the preparation of "iron".

First of all, they select electric motor. Here you need a 4 kW (1400 rpm) motor - this is the best option for working with a 220 V household electrical network. A less powerful "engine" will not cope with such loads.

Often, for such purposes, they take old motors that have not been used for years, falling with dust in the corner. In this case, the unit will have to be thoroughly inspected - the body is disassembled, the condition of the rotor, winding and bearing is checked.

Elementary diagnostics will not interfere either. Simple spin test: try spinning the rotor by hand (only with the motor not connected). If with effort, but still gone - no problem. In turn, tight running can be the result of clogging or unsuitable grease in the bearings (or using the wrong one).

After making sure that the motor is working, put the casing back in place and try to turn it on. Listen - the rumble should be even, without "wedging" that cuts the ear. Their presence indicates bearing play or a broken cage.

Dealt with the engine. In addition to the "heart", you will need the following components:

• iron corner (25 and 35 mm);
• auger shaft;
• steel wire (diameter 10 mm);
• bars (8 mm);
• pipe (for the body);
• blank for fiera;
• threaded transition;
• coupling with a lock nut on an exit;
• box with two bearings (63x18 in diameter);

• two pulleys (gear ratio ¼);
• galvanized iron under the bunker;
• capacitors (4 workers at 8 uF and 2 starters at 280 uF each);
• plug and switch.

Mandatory "props" - an angle grinder, a welding machine and a yew. In addition to them, you will also have to use a lathe.

The algorithm of actions at the beginning of the assembly will be as follows:

• The frame is ready first. Corners are cut to size, exposed and boiled. In our case, the base of the “bed” has dimensions of 40x80 cm. The upper platform for the body is 16x40.
• Then legs (40 cm) are put on the frame. Having welded them to the base, they proceed to the connection with the "top". In 5 centimeters, paired jumpers are placed under it.
• To mount the engine, you will have to cook another frame from the same corner. Elongated slots are made in its racks, thanks to which the belt tension will be adjusted.It is finally fixed only after both shafts are exposed.

You can make a frame yourself, and then more complex work begins (including turning). Difficulties relate mainly to the production auger:

• On one of the edges of the shaft (42 cm long and 27 mm in diameter), a 2 cm cone is machined on a lathe with angles of 45 °. He plays the role of the tip.

• On the base of the shaft, tightly clamped in a yew, a “ten” wire is wound. These will be the screws. It will have to be set at the right angle, welded and carefully trim the ridges with a “grinder”. Without an assistant, this is almost impossible.
• The first one comes out of a roller that has not been machined. From the first to the second screw should be about 25 mm (if measured in the center of the ridge) - this is where the raw material gets. The gap between the second and third will be the same.
• Five central turns are placed with an interval of 20 mm;
• At 2–2.5 cm from them, two pieces of wire are tightly “riveted” at once - a blank of a heating washer. Having trimmed its surface, slightly oblique shallow cuts are made with a “grinder” (along the entire circumference, in increments of 1 cm).
• From the edge of the washer, an auger of the external part will protrude, after which three more go with a gap of 20 mm. This job can take a whole day.

WITH cylinder will also have to move.

Putting the bars just like that, "by eye" will not work. To avoid distortion, look for a pipe - "magpie" (it has an outer diameter of 48 mm). Clamps are placed on both ends of it, which will clamp the bars. But there is one more nuance. Even before “welding”, several bars will have to be cut so that a loading window (3x2 cm) is obtained, which will be 3 cm from one of the edges.

When the cylinder has cooled, it is cleaned of rust. Then insert the finished screw. There should be no more than 1 mm between the walls and screws. The tapered end of the shaft will come out completely. It is there that a thread of a suitable diameter (here - “by 50”) 2 cm long will be welded.

A separate topic is manufacturing fiery. This is complex turning work. The fact is that at one end it should be put on the conical edge of the shaft (you will have to make a similar recess in the center). Do not forget about the external thread, with which the entire part will be wound onto the cylinder. And here are its parameters:

• length - 80 mm;
• diameter of the "joint" - 49 mm;
• inner hole - 15 mm.

Do frame already easier - a piece of pipe of the desired diameter is cut off, after which it is cut along. The cylinder is placed inside for fitting. You may need to level the cavity with a hammer. If everything fits, the cylinder is covered with the second half of the casing and seams are made at the place of the pipe cut. On the sides, they gently grab it, wrapping the paronite. A suitable tube 3 cm long is placed on top of the prepared window (it is also welded “in place”).

For a small farm, an ordinary backfill will suffice. bunker from galvanized iron. It is based on a riveted square (16x16 cm). Counting from its top 14 cm, make a uniform bend at the bottom of the front wall. Then the back wall is adjusted and a hole is made, which should go into the window on the body.

It is connected to the upper frame by “legs” from a 25 mm corner, welded at an angle. The bunker is riveted to them on both sides, having previously drilled holes.

Final assembly connected with electrical equipment:

• All working compensators are placed in one block and soldered in series. With launchers the same story.
• Then both wires are removed from the first worker.
• On the middle and lower bolts of the motor “block”, the free ends from the fork should already be fixed. One of the free wires from the capacitor is hooked to the upper bolt, and the second is brought out to the starting "condo".
• The wire from the starting switch is soldered to the first working "condo" (the second one is already connected to them).

Everything is ready for launch. Starting capacitors turn on for a couple of seconds, at the very beginning of operation, otherwise they may explode.

The final chord is the installation and “hanging out” of the pulleys, which must be strictly vertical and without the slightest distortion relative to each other. If everything fits together, you can test and start working. The first "runs" are made on soft raw materials like cake.

We gave an example of how you can assemble an extruder at home, and this “manual” is enough to understand what it is and whether it is worth taking on the manufacture yourself.

The arguments in favor of this decision are as follows:

• cheapness;
• the ability to "fit" the unit to your needs by choosing the appropriate size;
• ease of maintenance;
• a simple electrical circuit without a lot of pads and plugs;
• savings on the purchase of feed (home stocks are used);
• good productivity.

But there are also disadvantages:

• the complexity of the assembly, which requires tools and skills;
• accelerated heating of the cylinder, from which almost all “home-made products” suffer;
• unprotected wiring.

Let everyone draw their own conclusions based on their own considerations. We can only state that the extruder will be a great help to a small farmstead with a "handy" owner. But a farmer on a grand scale will need a stable (and expensive) factory product.

Now you know how an extruder is useful, and what its manufacture is connected with. We hope you will correctly calculate the design by assembling a durable device. Good luck in business!

An easy-to-use feed extruder makes it possible to independently produce compound feed for animals. This device is considered an indispensable assistant both in a large-scale agricultural sector and in a small farm for growing animals and birds. In specialized stores, such equipment costs decent money. To save money, the unit can be assembled with your own hands, the drawings and recommendations of specialists will serve as an auxiliary informant in this matter.

An extruder is used to process grain crops into compound feed, which is much easier to digest in the stomach of animals. Processing is carried out using a press under a pressure of 60 atmospheres and at high temperature. The result is a product that is shaped like corn sticks 20-30 mm, but with a dense structure.

Feed preparation devices exist with a different power indicator, the volume of the outgoing product depends on it. For a small farm, a device with a capacity of 25-45 kg / h is perfect - the price of such a device starts at 47 thousand rubles. But a large farm will require more powerful models capable of producing up to 1.5 tons per hour and they cost from 160 thousand rubles.

Due to high prices, equipment for processing products into compound feed, even second-hand, is available to a narrow circle of consumers. But if you make a feed extruder with your own hands, you can save a lot. Only in this case, you need to study in detail the device of the unit, the principle of operation, and also have all the necessary spare parts available.

Diagram of a large extruder

The design of the device includes the following elements:

• frame - serves as the basis, all details are fixed on it;
• drive unit;
• belt;
• loading capacity;
• cuff;
• dosing screw with a separate drive;
• reducer;
• receiving tank;
• motor;
• blowing screw conveyor;
• Control block;
• carved blade;
• washer;
• adjustment key.

In a homemade extruder, the main function is performed by the pressing mechanism. The element includes an injection screw assembly mounted in a cylinder. The blade block gives the product the shape of oblong sticks.

The functions of the electrical appliance are not limited to pressing the feed. With its help, you can grind grain, carry out heat treatment and disinfection of feed, mix different components into a single mass.

The design of the injection screw includes:

• outer part;
• internal;
• heating washers;
• outgoing screw.

Each assembly is mounted on a stud with a left-hand threaded part and covered with a metal case.Thanks to the keys, the revolutions come from the main shaft to the combined auger. All components are firmly fixed on the frame.

Detailed design of the extruder (download)

The body element is equipped with a hole, a receiving part is mounted to it. The inner area is equipped with longitudinal grooves, due to which all feed components are mixed along the longitudinal side of the axis.

A granule regulator is installed on the outlet part, its design includes:

• matrix block;
• exit body;
• a blade pressed against the die block by a spring element.

The revolutions of the shaft with the blade are carried out by means of an occasion. You can monitor the temperature regime using a thermocouple mounted on the frame. The grain extruder operates from electrical voltage. But there are already modifications that work on fuel.

If you have the necessary material, parts and tools, you can make an extruder with your own hands. Let's consider how to get a small performance model.

• electric motor with a power of 2.2 kW at 3,000 rpm;
• gears from a tractor box - parts from YuMZ will serve as an excellent option;
• spring 8 mm;
• rod with a cross section of 5 cm;
• welding equipment.

Step-by-step work on the manufacture of a feed extruder with your own hands:

1. To obtain a cylinder, you will need to weld the tractor gears together. As a result, a spare part with a section of 625 mm should come out. Next, a spring with a diameter of 8 mm is mounted on the hydraulic rod. Weld all the details, with an uneven seam, treat the area with a grinder.

1. Using turning equipment, machine 2 axle boxes, which will be intended for the auger and gearbox. Weld the auger, shaft member and bushings into one piece, remembering to insert the bearing between the last pieces.

1. The head of the equipment is mounted on the screw, it will act as a regulator of the die, to which the nozzles are welded.

1. The auger is covered with a housing, all parts are assembled and fixed to the frame, an electric motor, belts and a starting part are also mounted. A loading tank is installed on top.

In general terms, a home-made extruder in terms of external and functional characteristics is similar to a household electric meat grinder.

VIDEO: Making a screw granulator with your own hands (part 1)

The self-assembled grain granulator before large-scale production needs preliminary testing and verification work. Equipment must be tested in a safe environment.

Homemade extruder for the production of animal feed

1. The first thing to check is the quality of all connections, as well as fasteners and the maximum level of lifting to the stop.
2. Then the device is fixed on a flat, stable surface. If the coating is loose, the appliance may not function properly.
3. Connect to a power source, start up and leave for a few minutes to fully warm up the system. To prevent the elements from rotating in vain, it is possible to pass a light product through the mechanism in the form of flour or cake from sunflower seeds for verification. By the correctness of the form, it is determined whether the device has warmed up enough.

When the shape of the "sausage" becomes even and dense, then the unit is ready to work with grain

1. After the compound feed comes out in the desired shape, you can fill in the grain product. The supply of grain must be regular without stopping, the mechanism must not be allowed to function idle. You should also fill in the raw materials in uniform portions so as not to load the system and not create a congestion.
2. At the outlet, you need to adjust the feed fraction by periodically tightening the bolt and reducing the opening of the spinneret plate.
3. At the end of the production process, it is necessary to thoroughly clean the internal components from product residues. To do this, it is not required to disassemble the device, it is enough to fill the shell from the seeds into the equipment. This raw material is able to collect grain product particles well due to the oils it contains.
4. Reduce the level of rotation to gradually cool the components of the mechanism. If you need to disassemble the device, you should wear heat-protective gloves, there is a risk of getting burned.

A do-it-yourself device is capable of producing up to 40 kg / h of feed. The level of performance depends entirely on the degree of power of the motor, which is in the design of the equipment. For personal use, such processing efficiency will be enough.

Mechanized processing of raw materials allows you to fully provide livestock with mixed fodder, while reducing the cost of buying factory mixed fodder. In the process of preparing feed pellets, you can use a variety of grain products with additives, enriching the diet with various world and macro elements, which are so lacking in conventional feed.

VIDEO: Making a screw granulator with your own hands (part 2)