Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists

Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists.

We manufacture feed screws of the highest quality, and provide service and a product that is second to none.

We service the plastics and rubber industries to processors and OEMs worldwide, countries such as USA , UK ,EUROPE, RUSSIA,MIDDLE EAST,AFRICA,ASIAN Countries etc…..

Our Technical and Engineering Department offers more than 15 years of experience in the field of plastic machinery and screw design.

We have developed our own line of screw designs which can be tailored to suit your application.

We stand behind the parts we produce and provide long term support for our products. Ever since it & we believe in the quality first, honesty to customers, prompt services to

customer’s satisfaction.

INDRODUCTION

www.kaivanyaextrusion.com

Our comprehensive production facilities enable us to perform the entire manufacturing process in-house. As for new screw or old rebuild screw , we utilize traditional methods to achieve the highest international standards.

Feed screw cutting machines over 6m (20 ft.) long x 20 cm (8 in.) diameter Milling and turning Welding of hard facings Heat treatments (Ion & Gas nitriding, Vaccum hardening) Chrome plating max. length 6 m (20 ft.) Deep hole boring/trepanning Honing 200 ton press

Complete Production Facilities


To assist in ameliorating the designs off different Screws & Barrels for running different plastics polymers.

To assist in increasing your extruder’s out put as well as prolonging its service life.

To assist in increasing your extruders according to your specific melt quality. Better processing of film and reduce scrap and also cost saving of resins. Speedy returns on your initial high investments by our products. Kaivanya extrusion use strong R&D skill work closely with our customers to

ensure quality products that produce high end output at a very economical price.

KAIVANYA SERVICES


Equipments


Plasma Nitriding furnace Microscopic Structure Hardness Teter Quality Control

Thread Milling

KAIVANYA EXTRUSTION TECHNIK

PRESENTATION ON

EXTRUSION Single & Twin Screw & BARREL(Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)


Extrusion moulding is a manufacturing process used to make pipes,filim,hoses,drinking straws, curtain tracks, rod and fiber,yarn,cable & wire,sheet,rope,sutli,&other product.

The machine used to extrude materials is very similar to injection molding machine. A motor turns a screw which feeds granules of plastic through a heater. The granules melt into a liquid which is forced through a die , forming a long 'tube like' shape. The shape of the die determines the shape of the tube. The extrusion is then cooled and forms a solid shape. The tube may be printed upon, and cut at equal intervals.

Extrusion Process


Screws are made from nitro alloy steel like 34CrAlNi7, 41CrAlMo7 etc. toughening, tempering, stress relieving, gas nitriding & additional bimetallic coatings can be incorporated on flights depending on the process application. We also do special surface treatment like hard nickel plating, chrome plating & titanium coating depending on the material to be proceed.

Our ability to design and manufacture some of the industry’s most advanced and efficient feed screws is one reason we have been an extrusion leader for more than 15 years. With our R&D facilities and team of experienced polymer process engineers, we offer customers world class screw design and technical capabilities.

Extrusion Molding Screw


KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion screws in India.

Our designs cover all facets of the extrusion industry from thermoplastics to natural and synthetic rubber.

We have a 13 year plus record in this industry from which we have built up significant data, soundly based on experience and results.

Screw construction is hard faced, nitrided or hardened & nitrided, for highly abrasive materials we can supply screws with Tungsten carbide coatings on the flight flanks and core diameters, or in the case of highly corrosive polymers such as Fluoro polymer a Duranickle based screw is offered.

Designs are available for single flight metering screws, single barrier screws, double barrier screws, variable pitch flights, multi start flights and slotted flights.

Two stage screws for vented extruders are also offered. Mixing sections, the more common of which, include Maddock (spiral or straight),

Hoechst, dulmage, pinned, pineapple or combinations of these designs are available. Our capacity ranges from 25mm up to 200mm depending on L/D ratio.

Explanation For Extrusion single Screw


Rubber Extrusion Screw


Extrusion Feed Bush/Grooved Sleeve


Extrusion Static Mixer


Single Screw Extruder

Model(Screw Dia) mm

L/D (Driving Motor)

kw

(Capacity)Kg/h

Ket-32 -32 26-28 5.5 20-25Ket-35 -35 26-28 7.5 30-35Ket-40 -40 26-28 11.20 40-45

Ket-45 -45 26-28 15 50-55Ket-50 -50 28-30 18.75 65-70

Ket-55 -55 28-30 22.4 75-80

Ket-65A -65A 28-32 30 110-120Ket-65B -65B 28-32 37.5 130-140

ket-75 -75 28-32 45 150-170Ket-90 -90 28-32 75 100-270

Ket-100 -100 28-32 75-90 200-350

Ket-120 -120 28-32 90-110 300-450


KAIVANYA EXTRUSION Engineering is the largest and by far the oldest manufacturer of extrusion twin screws in India.

Based on this fact, kaivanya Factory machined the best plasticization satus & blending quality are achieved.

New configured screws, which can be application to process PVC pipes & profiles are developed by kaivanya Factory.

Also anticorrosion & wear resistant material are developed . Polymer material can be sheared & compressed more softly in screw. Extruders with twin-screw and short distance between screws are better than

other types, because of their high capacity and good thermal and mechanical stress.

The powder mixing with chemical additives and melting with thermal and mechanical energy in three zones (feed, compression and metering zone) and because of gear pump and screw's pressure, converting to final product in latest plate.

Explanation For Extrusion Twin Screw



This has enabled production of Twin Barrel with approximately twice to thrice the service life of nitrided barrels at just 20% to 25 % addition cost. This renders the economic efficiency factor irrelevant in purchasing decisions. An additional benefit is the extended service like of twin screw extruders with wear resistant barrels can be operated at normal output for a longer period, without incurring through put losses due to wear. Thus production costs are reduced while competitiveness is improved.

Twin Screw Barrel



PRESENTATION ON

INJECTION MOLDING SCREW & BARREL (Screw & Barrel from Dia. 25 mm to 200mm & Length up to 6000mm)


We manufacture screws for both thermoplastic and thermosets, standard metering design or QLT for improved melt homogeneity and mixing.

These can be hard faced, nitrided or hardened and nitrided with optional hard chrome plating.

Whether you are manufacturing containers for packaging, duct joints for air conditioning or automotive components, we have a screw design available to suit your process for LDPE, HDPE, PP, PVC and more.

INJECTION MOLDING


The feed section establishes solids convey in the same way as a conventional screw. At the beginning of the transition zone , a second flight is started. This flight separates the solids channel from the melt channel. As material progress down the transaction . melting continues as the solids are pressed and sheared against the barrel, forming

a melt film. The barrier flight moves under the melt film and the melt is collected in the solid

pellets and melted polymer are separated and different function are performed on each.

The melt channel is deep , giving low shear and reducing the possibility of overheating the melted polymer.

the solids channel becomes shallower, forcing the unmelted pellets against the barrel for efficient frictional melting.

breakup of solids bed does not occur to stop this frictional melting . the solids bed continues to get shallower and finally disappears into the back side of the primary flight.

Injection Molding Screw



Injection Molding Barrels


Injection Head & Components


Injection Ring Plunger Sets


Tie Bars



PRESENTATION ON

BLOW MOLDING PROCESS(Screw & Barrel from Dia. 25 mm to 200mm &

Length up to 6000mm)


Blow molding is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or preform. The parison is a tube-like piece of plastic with a hole in one end in which compressed air can pass through.

The parison is then clamped into a mold and air is pumped into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected.

Blow Molding Process


Blow Molding Screw


Blow Molding Barrel


Blow Molding Retrofit Spares


The feed section establishes solids convey in the same ways as a conventional screw. At the beginning of the transition (compression) zone, a second flight is started. This

flight separates the solids channel from the melt channel. As material progress down the transition, melting continues as the solids are pressed and

sheared against the barrel, forming a melt film, the barrier flight moves under the melt film and the melt is collected in the solid pellets and melted polymer are separated and different function are performed on each.

The melt channel is deep, giving low shear and reduction the possibility of overheating the melted pellets against the barrel for efficient frictional melting, breakup of solids bed does not occur to stop this frictional melting.

The solids bed continues to get shall over and finally disappears into the back side of the primary flight.

Decompression zone. In this zone, about two-thirds down the screw, the channel suddenly gets deeper, which relieves the pressure and allows any trapped gases (usually moisture or air) to be drawn out by vacuum.

Second metering zone. This zone is like the first metering zone, but with greater channel depth, and repressurizes the melt to get it through the resistance of the screens and the die.

How does the Barrier Screw Works?


PRESENTATION ON

BIMETALLIC SCREW & BARREL (Screw & Barrel from Dia. 25 mm to

200mm & Length up to 6000mm)



BI METALIC BARREL - HVOF THERMAL SPRAY TUNGSTON CARBIDE COATING

1 SURFACE-PREPARATION 2 THERMAL SPARY 3 MIXING ROTORS

4 Rolls 5 As sprayed screw


6 Diamond Polish

7 SMALL SCREW

8 Final Quality


BIMETALIC BARRELS


How does tungsten carbide protect from abrasion wear?


Abrasion Resistance Test Data


PTA WELD OVERLAY BORON CARBIDE COATING


Bimetallic Screw Material

Base Material 1. Nitro alloy2. AISI 4140 3. AISI 43404. Stainless Steels,17-4PH,3165. Special alloy steel

Hard Facing Layer 1. KET183 (Ni/Cr/Boron/WC-35%)2. KET 156 (Nickel- Cr/Boron)3. KET163 (Nickel- Cr/Boron)4. KET188 (Ni/Cr/Boron/WC-19%)5. KET 900 (HOVF) TUGSTEN

88Wc/12 % Co

Root Treatment 1. Nitriding 2. Chrome plating 3. Vapor Deposition 4. HVOF Thermal Spray

Tool Steels 1. D22. H11,H133. V4,V94. CPM9V,CPM-S90V


SCM440(1.7225) High Tensile Strength Full hardening (56 HRc) High Toughness Flame Hardening Chrome Plate Nitride Hard Face

SKD11(1.2379) Full Hardening (60 HRc) Multi Purpose Screw Good Abrasive Resistance Good Corrosive Resistance (11%

Chromium) Glass Fill 20%

SKD61(1.2344) Hot Work Tool Steel Full Hardening (52 HRc) Good Abrasive Resistance High Temp. Hardness Good Abrasive Resistance Nitride Stainless 17-4PH Full Hardening(48HRc) High Toughness High Temp. Excellent Corrosive Resistance Hard face Nitride


Special Alloy High Chemical Resistance Inconel 625 Nickel Base (21%

Chromium9%molybdenum) Hastelloy C276 Nickel Base (15%

chromium ,16% molybdenum

Hard Face Plasma Transfer ARC(PTA) Screw Flight Built up Cobalt (stlelite 12,48 HRc) Nickel(colmonoy56,52 HRc,KET63) Tungsten Carbine KET86,88 70,75

HRc


Alloy Hard Face

Chromium Boride Hardness Tungsten Carbide Hardness

Nickel Based MaterialHardness 49-56HRc

Anti-Abrasive /Corrosive

Nickel Based MaterialHardness 48-59HRc

Anti-Abrasive /Corrosive


Element are Atomization to tiny droplets, mixed to a certain percentage.

Hot Isostatic pressing . Fine & Uniform Micro Structure. Good Toughness. Stainless Steel Grade. Nitride Process can enhance the PM

tool Steel hardness but it is not common practice.

Companies Provided – Bohler,Germany

Powder Metallurgical Tool Steel


Nitride Surface Case Depth :0.2-0.4 mm Hardness : 1000HV

Base Material Hardness 26-32 HRC

NITRIDE

Iron Nitride


Backing Steel High Tensile strength Steel

◦ Chromium /Vanadium◦ 950MPa Tensile Strength◦ 630 Mpa Yield Strength◦ High temp. operating Condition

Bimetallic Barrel/Backing Steel

• Alloy liner • Anti –abrasive • Anti-Corrosive • Base Material • High Tensile Strength


KET 56

Chromium Boride/Carbide •Iron Base Material•Hardness:- 64-69 HRc•Anti- abrasive•Glass Filled Application

KET63

Chromium Boride/Carbide •Iron Base Material•Hardness:- 64-69 HRc•Anti- abrasive•Glass Filled Application

KET 83

Tungsten Carbide •Nickel Base Material•Hardness 56-66 HRc•Anti-abrasive /Corrosive •High Wear application

KET 88

Premium Grade Tungsten Carbide Hardness 60-65 HRcExcellent Anti-abrasive/corrosive



PRESENTATION ON

REBUILDING OF Screw & Barrel(Screw & Barrel from Dia. 25 mm to 200mm &

Length up to 6000mm)


We hard-surface, straighten, machine, grind, and polish to precision tolerances. Special hard-surfacing alloys are made with Nickel, Tungsten-Carbide and Molybdenum.

Screw Modification -- Engineering designed to your specifications. Our expert consultation assures exact results.

Twin Screw Rebuilding -- Straight or Conical Twin Screws. Barrel Manufacturing -- Extrusion and Injection molding barrel with bimetallic

inlays. Barrel Resleeving and Honing -- Partial resleeves up to 24 inches or honing to an

even oversize dimension. Components Building and Repair -- All replaceable components. Chrome-Plating -- On site by our sister company Central Florida Plating. Inspection Certificate -- All incoming and outgoing screws, barrels and components

are inspected and Rockwell tested for hardness and print accuracy.

Rebuilding of Screw & Barrel



Screw Rebuild/Repair Barrel Rebuild/Repair

Rebuild the top of the flight with hard facing (Satellite & Colmonoy)

Repair the internal thread Repair the shank (drive section) Repair the NPT thread Repair the removable nose

Re-sleeve the stroke section or full length of the barrel with standard bimetallic, carbide or corrosion resistant liner

Repair the grooves within the barrel and on the feed housing section

Reline and repair the water jacket for a rubber processing barrels

Pressure testing and acid flushing for rubber processing barrels

Press-out broken screw from barrel


Rebuilding Process

O.D. Rebuilding

Flight Renovation

Screw Re Joint

Special Coating Crack Root

Key Way Spline Repair


Straightening

Nose Resisted

Nose Rethreading

Root Rebuilding

Flight Rebuilding

Crack Fights


THANK YOU VISIT US


Documents

Company is Established in 1998 as a one-man operation, Kaivanya Extrusion Technik Pvt. Ltd. has become world renowned as screw and barrel specialists