The line configuration for Industrie Plastiche La Scala started with a rheological analysis of the customer's specific formulation. Through tests carried out with a plastograph, data was collected on torque, melting time, thermal stability, and the viscous behavior of PVC as a function of temperature and shear rate.
The experimental data obtained was combined with melt flow simulations inside the extrusion head, making it possible to analyze pressure distribution, the radial velocity of the material, and the balance of shear gradients along the distribution channels. This phase makes it possible to predict any thickness inconsistencies, material buildup, or residence time differences that could compromise the pipe's dimensional stability.
The integration of rheological data and flow modeling made it possible to design a screw geometry calibrated to the formulation's actual behavior, defining the compression profile, L/D ratio, and configuration of the plasticization zones based on the material's effective viscosity. The goal is to ensure homogeneous melting, pressure stability, and back-pressure control even at high throughput.
At the same time, the extrusion head design was optimized based on fluid dynamics simulations, balancing the sections of the distribution channels to ensure flow uniformity around the entire pipe circumference. Correct distribution of the melt helps reduce residual stresses, limit thickness variations, and maintain controlled dimensional tolerances.
This integrated approach, combining rheological analysis, instrumental testing, and flow simulations, makes it possible to operate at up to 1,000 kg/h while maintaining the pipe's geometric stability and reducing production scrap.
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