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Optimizing barrel temperature profiling for recycled polymers requires a nuanced approach because these materials often contain contaminants, degraded chains, and inconsistent compositions compared to virgin resins

Begin by evaluating how many times the polymer has been processed

Each reprocessing cycle tends to break polymer chains, decreasing molecular weight and changing how the material responds to heat

Consequently, these materials typically exhibit reduced melting points and heightened susceptibility to thermal breakdown

Prioritize detailed physical and thermal profiling of the recycled batch

Apply melt flow testing and DSC scans to establish the optimal processing window for your material

Your temperature zones must be calibrated based on this empirical evidence

Using standard profiles for new resin can cause charring, uneven viscosity, or flow instability

Design a progressive heat ramp from inlet to discharge

The feed zone should be kept relatively low, just above the material’s glass transition temperature, to prevent bridging or premature melting that can cause poor feeding

Gradually elevate temperature in the compression section to promote uniform fusion

Hold the final zone just under the polymer’s critical decomposition point

Track real-time melt viscosity via an accurate inline sensor

This real-time feedback is critical because recycled materials can vary batch to batch

When melt exceeds target, lower rear barrel settings and decrease screw RPM to cut shear-induced heat

If the melt is underheated, raise front zone temps modestly and boost RPM—only if degradation resistance permits

Reduce the time material spends in the barrel

Prolonged heat exposure accelerates breakdown—streamline cycles and eliminate extended dwell times

Scrape and flush the barrel and screw after each run to eliminate carbonized residues

Introducing a minor fraction of new resin can enhance flow and thermal stability

Blending helps normalize behavior تولید کننده گرانول بازیافتی and minimizes the need for drastic thermal tuning

Always test small batches before full production runs and document how each temperature setting affects output quality, color, and mechanical properties

Over time, you’ll build a reliable profile tailored to your specific recycled stream