Eurotech D22 Twin-Screw Granulator

Overview

The Eurotech D22 Twin-Screw Granulator is an integrated laboratory-scale granulation system engineered for precise, reproducible pellet production from molten polymer streams. Unlike standalone pelletizers, the D22 functions as a complete downstream module within a modular extrusion line—accepting extrudate directly from either Eurotech’s E-lab twin-screw extruder (35 mm barrel diameter) or compatible single-screw units (25 mm or 35 mm). Its core operation relies on controlled melt delivery via a positive-displacement gear pump, followed by calibrated cooling on a temperature-regulated chill roll stack (configurable as 2-roll or 3-roll), and final size-defined granulation through synchronized rotary cutting. Designed for R&D labs and process development centers in polymer compounding, color masterbatch formulation, and reactive extrusion, the D22 delivers granule morphology consistent with industrial-scale strand pelletizing—enabling predictive scale-up without reliance on empirical correlation.

Key Features

• Modular architecture supporting vertical or horizontal installation to match existing lab extrusion layout constraints
• Thermally stabilized chill roll stack with independent zone control (±0.5 °C stability) for uniform solidification of thermosensitive or high-crystallinity polymers
• High-inertia rotary cutter assembly with hardened steel blades and adjustable rotational speed (10–120 rpm), enabling granule length control from 2 mm to 12 mm
• Integrated gear pump (capacity: 0.5–5 L/h) providing pulse-free melt flow and accurate mass throughput monitoring
• Manual melt filtration unit (200 µm nominal rating) upstream of the pump, facilitating rapid screen change during multi-material trials
• Downstream flexibility: configurable winder for continuous roll formation (with tension feedback loop) or guillotine-style cutoff station for sheet-based sample segmentation

Sample Compatibility & Compliance

The D22 accommodates a broad spectrum of thermoplastic materials—including polyolefins (PP, PE), engineering resins (PA6, PC, PBT), thermoplastic elastomers (TPEs), and filled systems (CaCO₃-, talc-, or glass-fiber-reinforced grades). It supports reactive extrusion outputs where residual monomer or condensation byproducts require rapid solidification to prevent post-extrusion crosslinking. All wetted components comply with EU Machinery Directive 2006/42/EC and bear CE marking. Surface finishes meet ISO 8502-3 for non-contaminating contact with food-contact or medical-grade compounds. Documentation includes Factory Acceptance Test (FAT) reports, material traceability certificates for critical rollers and cutter shafts, and conformity declarations aligned with EN 61000-6-2 (EMC immunity) and EN 61000-6-4 (EMC emission).

Software & Data Management

While the D22 operates via local HMI with dedicated PID loops for roll temperature, cutter speed, and pump RPM, it features analog and digital I/O interfaces (4–20 mA, RS485 Modbus RTU) for integration into centralized lab data acquisition systems. Process parameters—including melt pressure (upstream of pump), roll surface temperature (per zone), cutter torque, and cumulative mass throughput—are timestamped and exportable in CSV format. When deployed alongside Eurotech’s E-lab extruder control suite, full batch traceability is enabled, satisfying GLP-compliant record retention requirements per ISO/IEC 17025:2017 Clause 7.5. Audit trails include operator ID, parameter setpoints, deviation alerts, and calibration timestamps—fully compliant with FDA 21 CFR Part 11 when hosted on validated network infrastructure.

Applications

• Rapid formulation screening of polymer blends and additive packages prior to pilot-scale trials
• Granule morphology assessment (aspect ratio, friability, fines content) for correlation with injection molding cycle time and part warpage
• Development of heat-sensitive biopolymer pellets (e.g., PLA, PHA) requiring sub-ambient chill roll temperatures
• Production of reference standards for rheological testing—ensuring homogeneous particle size distribution and minimal thermal history variation
• Process validation of twin-screw compounding lines using identical screw geometry and shear history as production equipment

FAQ

Can the D22 be retrofitted to an existing single-screw extrusion line?
Yes—the system accepts melt feed from any extruder with a 1/2″–3/4″ melt port and operating pressure ≤ 25 MPa; mechanical and electrical interface kits are available upon request.
What is the minimum batch size supported for statistically valid granule analysis?
For morphological consistency, a minimum of 500 g of processed melt is recommended; typical run duration at 2 L/h throughput is ~15 minutes.
Is nitrogen purging capability available for oxygen-sensitive materials?
An optional inert gas manifold (ISO-KF 16 flange) can be installed upstream of the melt filter housing to maintain O₂ < 50 ppm during processing.
Does Eurotech provide IQ/OQ documentation for GMP environments?
Yes—customized Installation Qualification (IQ) and Operational Qualification (OQ) protocols, including sensor calibration records and performance verification tests, are deliverable as add-on services.