Twin-Screw Extruder Elements
Screw elements are the portions of a twin-screw extruder that work directly on the material, performing functions such as conveying, plasticizing, shearing, mixing, devolatilizing, and pressure buildup. Their modular design allows for the flexible combination of pieces from different functions to meet the process, from stable conveyance to high-intensity dispersive mixing, while managing tough conditions such as high filler loading and heavy wear.
- Diameter range: Ø18 mm to Ø400 mm
- Do/Di Ratio: 1.22-1.80
- Length: 0.5–2.5D
An extruder screw layout must consider not only conveying efficiency and mixing quality, but also polymer properties, filler type, loading ratio, feeding method, devolatilization requirements, and process factors. As high-filler, glass-fiber-reinforced, flame-retardant, and biodegradable processes improve, a well-designed screw configuration becomes increasingly important for product quality and processing stability.
Lesun provides several types of screw elements for specific function needs, including conveying elements, kneading elements, mixing elements, and special-function elements that are tailored to each process requirement, are compatible with the world's leading twin-screw extruder platforms, and provide dependable extruder screw solutions across a wide range of materials.
Conveying Elements
Kneading Elements / Kneading Blocks
Mixing Elements
Special Screw Elements
High-performance screw elements designed for demanding mixing applications. Different material systems place varying demands on conveying, plasticizing, dispersion, and shear in high-filler modification, engineering plastics, functional masterbatch, and high-performance polymer processing, and standard elements may fail to meet the mixing target within a specific process window. Lesun develops specialized screw elements for complicated applications by optimizing element design, combination, and material systems to provide precise control over mixing efficiency, shear intensity, and energy input.
- High-dispersion mixing elements raise dispersion efficiency of fillers, pigments, and functional additives for more uniform melt quality
- High-shear mixing elements strengthen local shear and mixing for high-viscosity, high-performance material systems
- Low-shear gentle mixing elements reduce mechanical energy input and melt temperature rise for heat-sensitive materials and tight process windows
- Special kneading-structure elements balance conveying, plasticizing, and mixing by optimizing kneading-block stagger angle, disc thickness, and arrangement
- Diameter: Ø18–Ø400
- Do/Di Ratio: 1.22-1.80
- Length: 0.5–2.5D
- Pitch: Customized
- Material: N00/ D2/ W6/ H9/ H10/ H26/ Hastelloy/ Stainless
- Surface Hardness: HRC 58–64
- Max. Operating Temp: ≤450°C
- Wear Resistance: Standard / High / Ultra-high
- Corrosion Resistance: Standard / High / Ultra-high
- Application: Masterbatch / Compounding / Recycling / Film / Feed / Food / Pharmaceuticals
- Suitable for: Twin-Screw Extruder
Lesun develops custom screw elements to each customer's process requirements: distributive mixing, dispersive mixing, low-shear, and special-function elements:
- Distributive mixing elements improve material uniformity and component dispersion
- Dispersive mixing elements strengthen agglomerate breakdown
- Low-shear elements suited to heat-sensitive material processing
- Special-function elements developed for high-filler, glass-fiber-reinforced, battery-material, recycled-plastic, and foaming processes
Lesun works with proven German-standard, Japanese-standard, and US-standard alloy systems, including over 10 HIP alloy manufacturing options to meet a wide range of wear- and corrosion-resistance requirements.
| Product | Code | Material | Process |
| Element | N00 | Nitriding Steel | Surface Hardened |
| N00+ | Nitriding Steel | Surface Hardened | |
| D2 | Cold Work Tool Steel | Through Hardened | |
| D2+ | Cold Work Tool Steel | Through Hardened | |
| W6 | High Speed Tool Steel | Through Hardened | |
| H10 | PM Steel | HIP | |
| H26 | PM Steel | HIP | |
| H9 | PM Steel | HIP | |
| 10V | PM Steel | HIP | |
| S30 | Austenitic Stainless Steel | Solid-solution | |
| S50 | Martensitic Stainless Steel | Quenched and Tempered | |
| S60 | Precipitation-Hardening Stainless Steel | Solid-solution | |
| X | Hastelloy C-series Alloy | Solid-solution |
- A database of 12,000+ screw element types built to global twin-screw extruder standards
- Reliable batch production and delivery of large screw elements at Ø100 mm and above, supporting large-scale polyolefin pelletizing and continuous production projects
- Compatible with 30+ major twin-screw extruder platforms, including Coperion, KraussMaffei (Berstorff), Leistritz, and JSW
- Manufacturing from drawings, sample reverse-engineering, and custom development of special elements with material-selection schemes for high-wear and high-corrosion conditions, serving both OEM and end-user needs
- A screw element workshop equipped with CNC machining centers, dedicated screw-milling and precision-grinding equipment, and inspection instruments including hardness testers and runout gauges delivering batch manufacturing and stable delivery for large-format, high-volume projects, with fast response to special process requirements and shortened lead times
