Extruder Degassing

Achieve Superior Polymer Quality with EcoProcess Solutions

Efficiently remove volatiles and moisture to enhance mechanical properties and reduce defects in your extruded products.

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process overview

Extruder degassing (hot melt degassing/devolatilization) is critical for purifying polymer melt by removing residual moisture, entrained air, monomers, solvents, and reaction byproducts. Essential for hygroscopic polymers like PET and PA. Without removal, volatiles cause voids, bubbles, and inconsistent mechanical properties.

Process applied before the die via vacuum ports along extruder barrel. Twin-screw extruders (TSEs) are particularly effective due to intensive mixing and frequent surface renewal. Effective degassing improves homogeneity, odor, appearance, and mechanical properties.

 

Key Performance Metrics

Proven results that drive operational excellence

Vacuum level stability

1-200 mbar typical; demanding applications (undried PET, recycled plastics): 5-50 mbar 

Throughput

Optimized systems increase production by minimizing scrap and enhancing stability         

Defect rate reduction

Significant reduction in bubbles, voids, surface imperfections 

moisture content

Considerable reduction prevents hydrolytic degradation              

products & equipment

Comprehensive solutions for every requirement

Dry claw/ screw pumps

Oil-free, contact-free, minimizes contamination risk

vacuum sizing tanks

Downstream for accurate final product dimensions

vacuum boosters

Achieve deeper vacuum levels and higher pumping speeds                      

vent stuffers

Co-rotating twin-screw augers preventing melt escape under high vacuum

central vacuum systems

For large-scale operations

Drying Systems

 

Agitated Thin Film Dryers (ATFD)

Rotary Vacuum Paddle Dryers (RVPD)

Agitated Nutsche Filter Dryers (ANFD)

Complete Zero Liquid Discharge (ZLD) Systems

Supporting Vacuum Products

 

Dry Screw Vacuum Pumps

Centralized Vacuum Systems

SUSTAINABILITY & COST EFFICIENCY

Environmental & Economic Benefits

reduced scrap:

Preventing defects minimizes waste material 

energy savings:

Modern energy-efficient dry pumps reduce footprint 

circular economy:

Enables effective processing of post-consumer recycled (PCR) plastics - thorough degassing purifies contaminated material 

Real-world cost savings example

Steam ejector to dry pump replacement

 

€1,082,002

Previous Annual Cost

€132,266

New Annual Cost

8 months

Payback Period

Process Diagram

Raw Material Feed → Melting Zone → Mixing / Compounding Zone                                    

Re-compression Zone → Die → Cooling/Calibration (with vacuum sizing tanks)

Vacuum vent zone(s)

Screw de-compresses melt, vacuum ports remove volatiles, vent stuffer prevents escape
Proven results

case studies

Real-world success stories from industry leaders

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Case 1: PVC Pipe Extrusion Yield Improvement

 

Six Sigma optimization including stabilized degassing: Grade A yield increased from 75% to 95%

Case 2: Sheet Extrusion Downtime Reduction

 

Centralized vacuum system with multi-stage filtration: Cut downtime, extended oil life, improved yield

Case 3: Pharmaceutical Hot-Melt Extrusion

 

Vent port degassing produced clear, consistent extrudates vs. non-degassed irregularities. Reduced pressure/torque fluctuations.

industries we serve

Trusted solutions across critical manufacturing sectors

Plastics Recycling (PCR)

Compounding solution

Pipe & Tubing Extrusion 

Plastics Manufacturing

films, sheets, profiles 

Wire and Cable Coating 

 

Optimize Your Extrusion Process

Request a Free Line Audit Today! Contact EcoProcess for a comprehensive audit to identify opportunities for improved degassing efficiency, reduced defects, and enhanced product quality.

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Case Study

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