Extruder Screw 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 Screw Repair Services

At Screw And Barrel Repair, our extruder screw repair process is a finely tuned operation that blends technical expertise with advanced restoration techniques to ensure your equipment performs optimally. The procedure begins with a thorough assessment of your extruder screw, using precision measurement tools like micrometers and calipers to accurately gauge wear patterns and damage extent. This diagnostic phase is critical for tailoring our approach to your specific needs, whether it's addressing root wear, flight degradation, or drive end damage.

Once we've established the condition of the screw, the actual repair work begins. Our skilled technicians employ a combination of welding and machining processes to restore the screw to its original specifications. Welding techniques such as Metal Inert Gas (MIG) or Tungsten Inert Gas (TIG) are used to add material to worn areas, which is then precisely machined to restore the helical profiles and critical dimensions. This not only improves the physical integrity of the screw but also enhances its performance by ensuring smooth, consistent material flow during operation.

In addition to mechanical restoration, we apply state-of-the-art surface treatments to enhance wear resistance and reduce friction. Techniques such as hardfacing, thermal spraying, or applying specialized coatings like chrome or nickel plating are employed based on the operational demands and the materials processed by the extruder. These treatments are crucial for extending the life of the screw and reducing downtime caused by frequent repairs.

Finally, every repaired extruder screw undergoes a rigorous quality assurance process. This includes detailed inspections and performance testing to ensure that all repaired screws meet stringent industry standards and perform as intended in real-world industrial settings. This comprehensive approach not only restores your equipment but also optimizes its performance, ensuring your production line runs smoothly with minimal interruptions.

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