Backmixing in screw extruders

Mixing is a critical function in most extrusion operations. One of the most difficult mixing tasks is backmixing. An extrusion operation where good backmixing is very important is when a low percentage color concentrate, CC, is added to a virgin polymer. In this case, the initial distance between the CC pellets may be 100 mm or greater. If the final striation thickness needs to be reduced to the micron level, the reduction of the striation thickness needs to be at least five orders of magnitude this is quite a tough task! This paper will analyze how the velocity profiles, axial mixing, and residence time distribution are related. It will be shown why simple conveying screws have poor axial mixing capability. New mixer geometries that are specifically designed to improve backmixing will be discussed. Results from extrusion experiments will be presented.