This workshop provides a comprehensive foundation in Single Screw Fundamentals for Design and Optimum Processing. Participants will begin with an introduction to the basic single screw extruder and its functional parts, learning to convert screw geometry into useful mathematical calculations.

The curriculum connects extrusion performance directly to material science, examining molecular weight and distribution , basic polymer bonds , and primary degradation mechanisms. A core focus is placed on rheology and how polymer viscosity and shear thinning influence the process. The course explores the distinct functional zones of the screw, including:

• Solids Conveying: Analysis of the current model and its predictive limitations.
• Melting Zone: A look at the current melting model and the role of components like barrier screws.
• Metering Section: Focus on meter section calculations and the effect of die pressure on temperature.

The seminar delves into advanced screw rotation flow analysis , comparing literature models for pumping and temperature with experimental data. It also explains how changes in material can lead to gels and degradation products. Ultimately, attendees will learn the fundamentals for optimizing their single screw setup by leveraging key data—such as viscosity, rotation rate, die pressure, screw dimensions, and the shear thinning power law constant —to ensure the metering section is in control of the output.

This workshop is designed for engineers, scientists, and technicians involved in the design, processing, or optimization of single screw extrusion systems. It is ideal for professionals seeking to build a strong foundational knowledge of the extrusion process, moving beyond trial-and-error to a more scientific approach.

This includes:

• Process and Manufacturing Engineers responsible for achieving optimum processing and troubleshooting issues like gels and degradation products.
• Design Engineers who work with screw geometry and need to understand how design choices impact performance.
• Materials Scientists and R&D Professionals focused on how polymer properties—such as molecular weight, bonds, and rheology—affect extrusion performance.
• Technical Managers and Supervisors who oversee extrusion lines and want a deeper understanding of the process to improve efficiency and guide their teams.

• Are you struggling to optimize your single screw extruder for consistent, high-quality output?
• Do you face challenges like gels and degradation products when you introduce a new material?
• Is it difficult to predict how your extruder will perform without resorting to costly trial-and-error?
• Are you unsure how screw design, rotation speed, and die pressure truly affect your process and final product?
• Do you lack a fundamental understanding of the physics behind solids conveying, melting, and metering?

If these questions resonate with you, this workshop was designed to help you solve them.

Everyday Problems You’ll Address:

• How can I use fundamental engineering principles to control my extrusion process?
• What makes the metering section so critical, and how do I ensure it's in control of the final output?
• How do I properly use material data like viscosity and the shear thinning power law constant to predict and optimize flow?
• What is the real impact of screw rotation and die pressure on melt temperature and quality? Can I accurately diagnose process issues like gels and degradation by understanding the underlying science of the screw?

What You’ll Learn:

• The core mechanics of a single screw extruder, including the distinct functions of the solids conveying, transition (melting), and meter sections.
• How to apply fundamental principles of rheology to understand the powerful effect of polymer viscosity and shear thinning on your process.
• The difference between literature models and experimental data for screw rotation, pumping, and temperature analysis.
• A systematic approach to optimize your extruder setup using key data like screw dimensions, rotation rate, die pressure, and material viscosity.
• How to diagnose and troubleshoot common issues by understanding their root causes in the process, from solid bed breakup to the effects of material changes.

Why This Workshop Matters:

As demands for product quality, efficiency, and sustainability increase, simply “running” an extruder isn’t enough. A deep, fundamental understanding of the process is required to stay competitive and solve complex challenges.

This workshop moves beyond surface-level adjustments and gives you a solid foundation in the engineering principles that govern extrusion. You'll walk away ready to:

• Optimize your process with confidence.
• Diagnose issues with a scientific approach.
• Bring innovation and predictability to your manufacturing floor.

If you're ready to master the science behind the screw and take full control of your extrusion process, this workshop is for you.