Extruder Flight Repair

We work with brands including Milacron, Kraus Maffei, Welex, Maplin, Battenfeld-Cincinnati, Sterling, Werner Pfleiderer, Davis Standard, NRM, Coperion, and many more.

About Our Extruder Flight Repair Services

Extruder flight repair at Screw And Barrel Repair involves a detailed and specialized process that ensures your equipment is restored to its peak operating condition. The first step in our process is a comprehensive evaluation of your extruder screw. This includes precise measurements and analysis of wear patterns, flight depths, and root radii. Using state-of-the-art technology, we accurately assess the level of wear and the structural integrity of the screw flights, which is critical for determining the appropriate repair strategy.

Once the assessment is complete, the repair process begins with the welding of new material onto the worn areas of the flights. We employ advanced welding techniques such as Plasma Transferred Arc (PTA) welding, which provides a highly durable and wear-resistant surface. This method is particularly effective in restoring flights to their original dimensions and extending the lifespan of the equipment. After welding, precision machining is used to reshape the flights to their original specifications, ensuring that they meet stringent industry standards and tolerances.

Next, we undertake a post-repair quality assurance phase, which includes both dimensional and operational testing. Dimensional accuracy is verified using micrometers and gauges to ensure that the flights are within the required specifications. Operational testing often involves running the screw in a controlled environment to observe any discrepancies and fine-tune as necessary. This step ensures that the screw will perform optimally in its working environment, producing consistent product quality.

Finally, we apply specialized coatings to enhance the wear resistance of the extruder flights. Options such as chrome plating or nickel-based coatings are considered based on the operating conditions and the type of material processed by the extruder. These coatings are crucial for reducing future wear and corrosion, thereby extending the operational life of the screw significantly. By integrating rigorous repair processes with advanced material technology, we deliver a repaired extruder flight that offers improved performance, reliability, and longevity in demanding industrial applications.

With nearly five decades of expertise in the field, we stand as pioneers in developing the industry's standard processes for screw rebuilding. When you choose Screw and Barrel Repair, you're not just choosing a service provider; you're partnering with a team of dedicated professionals who are passionate about delivering superior quality and unmatched reliability. Experience the difference with Screw and Barrel Repair - where precision meets perfection, and your satisfaction is our top priority.

Our Extensive Extruder Repair Process

1. Completely clean and strip all chrome or nitride coatings for preparation, inspection, and measurements to evaluate the extent of repair needed for your extruder.
2. Measure the outer diameter (OD) of each flight to assess wear and inspect the root diameter.
3. Precision OD grind to remove all existing hard facing, preparing a new layer of material for your extruder screw repair.
4. Restore the root diameter to perfection, ensuring no pits, zits, or pinholes. We apply an 8RMS finish to the root at this point.
5. Apply coatings such as Hastalloy, C56, or other hard facing materials (5 options available) to the OD of all flights, building beyond the original size.
6. Precision side grinding to remove excess hard facing from flights, essentially trimming the added material from your extruder screw flights.
7. Utilize dye penetrant testing to identify any cracks, pinholes, etc., and perform necessary repairs.
8. Polish the entire screw to a 6RMS mirror finish in preparation for plating or nitriding.
9. Apply hard chrome plating, electroless nickel plating, or nitriding across the entire screw and buff to a 4/5RMS mirror finish. Comply with Military Spec QQC-320B & Military Spec Mil-C-26074B Class A Grade 1. For the most durable exterior coating in harsh environments, we recommend CEB coating: Chrome over Electroless Nickel, baked at 475 degrees for 3 to 5 hours. A 2-year warranty covers all CEB coatings against pitting, chipping, burning, etc.
10. Precision OD grind the flights to your specified size.
11. Inspect all sizes, straightness, root diameter, and prepare for the final buffing and polishing.
12. Complete the final inspection of all sizes and tolerances, and perform final buffing to a mirror finish. Prepare for shipping with crating, foam insulation, and metal banding to your dock.

The final product is an extruder screw repair that surpasses OEM specifications/tolerances and performs like new. Fully guaranteed for one year. Delivery time is half that of our competitors. We surpass OEM specifications for polish finish, hard facing strength, straightness, TIR, plating thickness, etc. Our extruder repairs outperform new extruders, offering better warranties and lower prices.

We rebuild your extruder either to the exact original size or make it oversized to match your current barrel. If built to size, the repair makes your extruder fully interchangeable with any barrel. If built to a specific size, it remains dedicated to that barrel until the next rebuild. If your extrusion barrel is honed oversized to 100% cleanup, we can rebuild your extruder to match. This option saves significant costs over a barrel relining, which is expensive and time-consuming. However, this means the extruder and barrel are fixed to each other until the next repair cycle.

Types of Injection Screws & Other Equipment We Specialize in Rebuilding