Analyzing and Troubleshooting Single-Screw Extruders

Copyright: 2013
ISBN: 9781569904480
Hardcover: 777 pages/458 figures/87 tables
$249.99 (US)


Single-Screw Extrusion:  Introduction and Troubleshooting. Polymer Materials. Introduction to Polymer Rheology for Extrusion. Resin Physical Properties Related to Processing. Solids Conveying. The Melting Process. Fluid Flow in Metering Channels. Mixing Processes for Single-Screw Extruders. Scaling of Single-Screw Extrusion Processes. Introduction to Troubleshooting the Extrusion Process. Contamination in the Finished Product. Flow Surging. Rate-Limited Extrusion Processes. Barrier and High-Performance Screws. Melt-Fed Extruders.


The book teaches the fundamentals of single-screw extrusion such that fast troubleshooting and process optimization and design are possible. The fundamental processes that are occurring in the machine are developed from the natural reference point of a rotating screw rather the traditional rotating barrel. These fundamentals are then combined with the chemistry of polymers and the physical properties related to processing to troubleshoot and optimize extrusion processes. Many industrial extrusion problem case studies are presented. In each case study, the root cause of the problem is identified along with the solution. A fundamental view of the processes that occur in a single-screw machine from the natural reference frame; i.e., screw rotation. The theory is discussed and compared to experimental data and to a rotating barrel reference frame. Topics include: polymerization chemistry and degradation mechanisms for polymers, physical properties related to processing (e.g., rheology, heat capacity, dynamic friction, bulk density and pellet compaction, melt density), and 30+ case studies for troubleshooting extrusion problems. A detailed description of the problem and the solution is presented so the reader can implement the solution on their own equipment.

Author Info:

Campbell, G.

Gregory A. Campbell is Professor Emeritus at Clarkson University, NY. He formerly directed a research group at GM Research and managed polymer fabrication at Mobil Chemical Research.

  • Treasurer and Vice President at Society of Plastics Engineers
  • Extrusion Board Member at Society of Plastics Engineers
  • President & Chief Technical Officer at Castle Associates  
  • Professor Chemical Engineering at Clarkson University         
  • Manager Process Research and Develoment at Mobile Chemical            
  • Staff Research Engineer at General Motors


Spalding, M.

Mark A. Spalding is currently a Fellow in the Materials & Parts Processing Group (MPP) in Midland. He joined Dow in 1985 after completing a BS degree from The University of Toledo (1979) and a MS and Ph.D. (1985) from Purdue University, all in Chemical Engineering.

Mark has held a number of technical positions in Corporate R&D, Polystyrene R&D, Plastics R&D, and INCLOSIA* Solutions. He is the author of over 100 technical publications. His expertise is in single-screw extrusion and related polymer processing technologies.

He has solved some of the most complicated extrusion problems at Dow customer’s plants by developing and applying sophisticated troubleshooting methods. These solutions have created considerable value to both Dow and to our customers. He has designed extrusion systems for most of Dow’s major customers for virtually every resin that Dow produces.

He is a Fellow and an Honored Service Member (HSM) of the Society of Plastics Engineers (SPE).