Compounding & Extrusion
USEON supplies complete compounding lines as turn-key projects: material handling, dosing, extrusion and pelletizing. Given your material and recipe, we configure the line. Start from what you make.
- Masterbatch
- Engineering & functional compounds
- Reactive & special processes
- Polyolefin finishing
- 01
Material handling
Vacuum loading and premixing.
- 02
Dosing
Loss-in-weight feeders for pellets, powder and liquid; side feeders.
- 03
Extrusion
Twin screw, triple screw, tandem or single screw.
- 04
Pelletizing
Strand, water ring, underwater or air-cooled die face.
Find your application
Each application has its own page with the formula, the line configuration and the lines we have delivered. The columns show how the line is usually built.
Masterbatch
The masterbatch line, station by station
Filler MasterbatchCaCO₃ · talc · BaSO₄ in PP / PE75–85 %typical filler loadingSAT twinSAT-T tripleWater ringUnderwater
Color MasterbatchMono · SPC · tailor-made · fibre grades≤ 1 mmmicro pellets, cut underwaterSAT twinSAT-T tripleUnder water strandUnderwater
Additive MasterbatchFilms · engineering plastics · PET · rigid PVC · pipe coating150–1,000 kg/hSAT40 to SAT75SAT twin—Engineering & functional compounds
Engineering PlasticPA · PBT · PC · PPS + glass fibre · LFT-GHigh torque and high speed: more output with less residence time.U+ twinSAT twinUnder water strand
Cable CompoundingPE · XLPE · semiconductive · PVC · HFFREvery compound in a power or data cable, XLPE for 10 kV and 35 kV.SAT twinSAT-T tripleTandemWater ringUnderwaterAir die face
Thermoplastic Elastomers (TPE)TPV · TPR · SEBS · TPULong L/D, liquid injection and pelletizing for soft, oil-filled materials.SAT twinU+ twinWater ringUnderwater
PVC CompoundingRigid · soft · cable · medicalA twin screw followed by a cooling single screw, because PVC degrades easily at high temperature.TandemSAT twinAir die faceWater ring
Biodegradable PlasticPBAT · PLA · PBS · PVA + starch · mineralsBlends with starch, minerals or cellulose, and direct melt PBAT compounding.SAT twinU+ twinSAT-T tripleTandemUnderwaterAir die faceAir strandReactive & special processes
GraftingPP-g-MAH · PE-g-MAHMaleic anhydride is grafted inside the extruder: liquid dosing, vacuum degassing.U+ twinSAT twinWater strandUnderwater
ThermosetsEpoxy · phenolic · BMI · powder coatingsThe resin has to melt and mix without starting to cure in the barrel.SAT twinCrusher
Hot Melt AdhesiveEVA base · TPU base4,000 cPsbelow: pastilles; above: twin screw and underwater cutSAT twinUnderwaterPastillator
Wood Plastic Composites (WPC)PP · PE · PVC + wood fibreup to 65 %wood fibre, fed after the polymer has meltedSAT twinTandemPelletsDirect sheet
Rotational MouldingColoured PE · PP · PA · PC · crosslinkable PEComplete line from the premixing system to the mill.Single screwSAT twinMillPolyolefin finishing
Petrochemical scale, behind the polymerization reactor.
Polyolefin CompoundingReactor powder is premixed with additives and made into pellets on a large SAT twin screw extruder. Our delivery scope runs from the feeder to the storage silo.Screw diameter130–360 mmThroughputup to 60 t/hUnderwater pelletizer4–25 t/hPolyolefin compounding One supplier, from the recipe to the running line
Consultation from in-house process engineers
Given the material and the recipe, we propose the extruder, the feeding layout and the pelletizing method. You can run a test on our lab machines first.
One-stop: the whole line from one builder
Material handling, dosing, extrusion and pelletizing are designed, built and commissioned together, so the stations match each other.
Options sized to the job
Twin, triple, tandem or single screw and six pelletizing methods: the line is configured for the formula, and not larger than the job needs.
Compounding lines we have delivered
One line from each of six applications. Every application page lists its own projects.
Filler masterbatchPP + CaCO₃ High-Fill Compounding: SAT110 Twin-Screw Underwater Pelletizing Line
2,500–4,000 kg/hSAT110
Engineering plasticHigh-Performance PP + Glass Fiber Compounding
800 kg/hU6
CableHalogen Free Flame Retardant (HFFR) Compounding Line
700 kg/h
TPESAT75 TPV/TPE Reaction Extrusion Pelletizing Line
—SAT75
PVCSoft PVC Compounding Line for Medical Application
2,000 kg/h
Triple screwSAT-T75 Triple Screw Extruder for Filler Masterbatch Compounding
—SAT-T75
Guides by polymer
Formulations, processing windows and extruder solutions, written by our process engineers.
Polypropylene (PP) compounding & extrusion guide
Manufacturing, processing and recycling.
Read the guide PEPE compounding, extrusion & pelletizing
Applications, formulations and extruder solutions.
Read the guide High fillerPP + 80–85% ultra-high filler masterbatch
An engineering deep dive into stable high-throughput compounding.
Read the guideGet a quote
Tell us the polymer, the fillers or additives and their share, and the output you need. We recommend the line and quote it complete.
- 01Polymer, fillers, fibres or additives and their share
- 02Target output and the form of the product
- 03Line configuration and quotation
Souder Chen
Head of Compounding Division
With USEON since 2008. Twin screw compounding, devolatilization and recycling lines.