Extruder 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 Repair Services

Understanding the intricacies of our extruder repair process is essential for recognizing the value we bring to your manufacturing operations. At Screw And Barrel Repair, our procedure begins with a comprehensive assessment of your extruder system, focusing on critical components like the screw, barrel, feed throat, and gearbox. Our diagnostic phase employs advanced techniques such as wear measurement, ultrasonic testing, and pressure flow studies to pinpoint specific areas of concern.

Once we've identified the issues, our skilled technicians deploy precision machining tools to restore dimensions and clearances back to original specifications. For screws, this might involve flight rebuilding or hard-facing with wear-resistant alloys, while barrels might undergo honing or liner replacement to ensure smooth and efficient operation. We also address auxiliary systems, including drive mechanisms and temperature control units, ensuring every part functions in harmony.

For particularly severe damage, we offer a complete overhaul service. This includes disassembling and cleaning all parts, replacing or refurbishing worn components like bearings, seals, and drive chains, and reassembling the system with enhanced components that offer improved performance and durability. Our solutions are tailored to not only repair but also upgrade the efficiency of your extruder, integrating the latest advancements in extrusion technology.

Finally, each repaired extruder is subjected to rigorous testing under operational conditions to ensure it meets all performance criteria. Calibration, pressure testing, and throughput evaluation are all part of this final phase, guaranteeing that your machine returns to you ready for full-scale production. With Screw And Barrel Repair, you receive not just a quick fix, but a comprehensive enhancement of your extruder’s capabilities, ensuring long-term reliability and productivity. 

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