Bonnot 6CE Continuous Extrusion Pelletizer System

Overview

The Bonnot 6CE Continuous Extrusion Pelletizer System is an industrial-grade, custom-engineered extrusion platform designed for precise, repeatable shaping of catalytic, pharmaceutical, and advanced ceramic precursors. Operating on the principle of positive-displacement screw extrusion under controlled shear and pressure, the 6CE system delivers consistent cross-sectional geometry across extended production runs. Unlike batch-forming methods, this continuous extrusion architecture enables seamless transition from lab-scale formulation development to pilot- or production-level output—critical for catalyst pellet qualification, tablet core fabrication, and structured sorbent manufacturing. The system integrates modular die tooling, variable-speed drive control, and real-time torque monitoring to ensure process stability and material integrity throughout extrusion.

Key Features

• Modular die assembly supporting rapid changeover between cylindrical, hollow-tube, annular (supported and unsupported), and multi-lobed cross-sections—no retooling downtime required.
• Stainless-steel barrel and hardened alloy screw with optimized compression ratio and helical pitch for uniform densification of low-to-medium plasticity pastes, slurries, and granulated feedstocks.
• Variable-frequency drive (VFD) enabling precise screw speed control from 0.5 to 30 rpm, facilitating adaptation to rheologically diverse formulations including alumina sol-gel precursors, zeolite extrudates, and polymer-bonded metal oxides.
• Integrated torque sensor and temperature monitoring at three axial zones (feed, compression, metering) for closed-loop process validation and deviation detection per ASTM D2369 and ISO 1133-2 protocols.
• CE-compliant electrical architecture with IP54-rated enclosure; compatible with nitrogen-purged or vacuum-assisted hoppers for oxygen-sensitive or volatile binder systems.

Sample Compatibility & Compliance

The 6CE accommodates feed materials with moisture content ranging from 12–35 wt%, plasticity index (PI) between 8–25, and particle size distributions (PSD) up to D90 < 150 µm. It routinely processes alumina, silica, titania, and mixed-metal oxide formulations used in FCC catalysts, automotive exhaust substrates, and CO₂ capture sorbents. All wetted components comply with FDA 21 CFR Part 177 for indirect food contact where applicable. System documentation supports GLP/GMP audit readiness—including full traceability of calibration records, maintenance logs, and operator access controls aligned with Annex 11 requirements.

Software & Data Management

While the 6CE operates via a dedicated HMI interface with local data logging, it supports optional integration with SCADA or MES platforms via Modbus TCP/IP or OPC UA protocols. Process parameters—including screw speed, zone temperatures, torque load, and total extruded mass—are timestamped and exportable in CSV format for statistical process control (SPC) analysis. Audit trails meet FDA 21 CFR Part 11 criteria when paired with validated third-party electronic record systems. Firmware updates are delivered through secure, password-protected channels with SHA-256 integrity verification.

Applications

• Catalyst manufacturing: Production of cylindrical and trilobe extrudates for petrochemical reforming, hydrodesulfurization, and selective catalytic reduction (SCR) systems.
• Pharmaceutical excipient processing: Continuous formation of placebo or API-loaded pellets for fluid-bed coating and modified-release tablet development.
• Advanced ceramics: Shaping of silicon carbide, cordierite, and lithium titanate green bodies prior to sintering—enabling tight tolerances on wall thickness (< ±15 µm) and straightness (≤ 0.2 mm/m).
• Environmental media: Fabrication of activated carbon and biochar monoliths with engineered macroporosity for VOC abatement and water remediation modules.

FAQ

What types of feedstock are compatible with the 6CE extruder?
The system accepts aqueous or solvent-based pastes, slip-cast slurries, and dry granulates with sufficient green strength—commonly used formulations include Boehmite gels, colloidal silica binders, PVA/water mixtures, and methylcellulose-plasticized oxides.
Can the 6CE be integrated into an automated production line?
Yes—standard I/O signals (4–20 mA analog, dry-contact digital) allow synchronization with upstream mixers, downstream cutters, and conveyor-based drying ovens. Custom PLC interfacing is supported upon engineering review.
Is technical support available outside the United States?
Bonnot-certified service engineers operate across EMEA and APAC regions; remote diagnostics and spare-part logistics are coordinated through authorized distribution partners with ISO 9001-certified warehousing.
Does the system require compressed air or external cooling water?
Compressed air (6 bar, oil-free) is required only for optional pneumatic die clamping; water cooling is not mandatory but recommended for sustained operation above 25 rpm or ambient temperatures exceeding 35°C.