UK Case Study: Increased Productivity in PVC Recycling

The solution implemented is a parallel counter-rotating twin-screw MD-125 series extruder, configured to handle high percentages of regenerated PVC.
The patented Multidrive system distributes torque across multiple motors, reducing mechanical stress on shafts and gears and ensuring uniform power transmission. This aspect is decisive when processing materials with variable behavior.
The induction heating system concentrates heat directly on the barrel, ensuring greater thermal stability compared to traditional resistive systems. Reduced dispersion allows more precise control of plasticization and contributes to production continuity.
The integration of digital control systems enables constant monitoring of process parameters and specific consumption in kWh/kg produced.

The implementation of the Bausano line has allowed Marshall-Tufflex to significantly increase the percentage of recycled PVC used in profile production, while at the same time maintaining dimensional uniformity, structural stability, and consistent surface quality throughout the entire production cycle. The optimization of plasticization and controlled torque management have contributed to reducing scrap linked to process instability, improving flow regularity and the repeatability of the finished product's characteristics.
The extruder's technical configuration has also made it possible to stabilize production parameters over continuous cycles, even with formulations containing a high percentage of regenerated material. This has made the process more controllable, limiting variations linked to the rheological behavior of the recycled material and reducing unplanned interruptions.
The integration of the induction heating system has made it possible to optimize energy consumption, improving the efficiency of heat transfer to the barrel and ensuring greater precision in temperature control. The result is more uniform plasticization and reduced energy dispersion compared to traditional systems.
Today, production is more predictable and structured, with greater control over operating costs, better use of raw material, and more efficient management of energy resources. This has allowed Marshall-Tufflex to combine an increase in recycled material with industrial reliability, maintaining high quality standards over time.